Vehicle seating system

Abstract

To provide a vehicle seat device in which a headrest can effectively absorb the external force transmitted to the headrest from an object due to a collision when the rear part of the headrest collides with the object located immediately behind the headrest.SOLUTION: A vehicle seat device comprises: a first metal frame 21 which is a skeleton member of a headrest 20 and has a pair of left and right side part constitution parts 23 and a first support part 22 which connects upper ends of the pair of side part constitution parts to each other; a first foaming material 25 which is attached to the first metal frame and is formed of EPP; and a second foaming material 45 which is attached to the first foaming material so as to cover at least the front surface of the first foaming material and is softer than the first foaming material. When assuming a virtual surface PL brought into contact with the rear ends of the pair of side part constitution parts and the rear end of the first support part, at least a portion of a rearward protruding part 39 being a portion of the first foaming material is located on the rear side with respect to the virtual surface.SELECTED DRAWING: Figure 8

Description

Technical Field

[0001] The present invention relates to a vehicle seat device.

Background Art

[0002] Patent Documents 1 and 2 below disclose vehicle seat devices provided with headrests.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] Assume that the vehicle seat devices of Patent Documents 1 and 2 above are installed in the cab of a truck, for example. Usually, a vehicle seat device is provided immediately in front of the wall that forms the rear of the cab of the truck. Therefore, when a rear-end collision occurs in the truck, the rear part of the headrest of the vehicle seat device may collide with the above wall.

[0005] There is room for improvement in the headrests of Patent Documents 1 and 2 above with regard to shock absorption in such cases.

[0006] In consideration of the above facts, an object of the present invention is to obtain a vehicle seat device in which when the rear part of a headrest collides with an object located immediately behind the headrest, the headrest can effectively absorb the external force transmitted from the object to the headrest due to the collision.

Means for Solving the Problems

[0007] The vehicle seat device according to claim 1 is a skeletal member of a headrest and comprises a first metal frame having a pair of left and right side components and a first support portion connecting the upper ends of the pair of side components; a first foam material attached to the first metal frame and made of EPP; and a second foam material attached to the first foam material so as to cover at least the front surface of the first foam material and being softer than the first foam material, wherein, when a virtual surface is assumed to be in contact with the rear ends of the pair of side components and the rear ends of the first support portion, at least a portion of the rear projection which is part of the first foam material is behind the virtual surface. The first foam material is positioned such that its rear surface is not covered by the second foam material, and the first foam material has an uncovered portion. .

[0008] For example, if a vehicle equipped with the vehicle seat device described in claim 1 is involved in a rear-end collision, the rear of the headrest may collide with an object located directly behind the headrest. In this case, at least a portion of the rear projection, which is located behind a virtual plane that contacts the rear ends of the pair of side components of the first metal frame and the rear end of the first support, absorbs the external force transmitted from the object to the headrest as a result of the collision. The cushioning properties of the first foam material, which is made of EPP (expanded polypropylene), are superior to those of the second foam material. Therefore, when the rear of the headrest of the vehicle seat device described in claim 1 collides with an object located directly behind the headrest, the headrest can effectively absorb the external force transmitted from the object to the headrest as a result of the collision.

[0010] Claim 1 In the vehicle device described above, when the rear of the headrest collides with an object located directly behind the headrest, the first foam material (uncovered portion) readily absorbs the external force transmitted from the object to the headrest as a result of the collision.

[0011] Claim 2The vehicle seat device according to the invention described herein is a skeletal member of a headrest and comprises a first metal frame having a pair of left and right side components and a first support portion connecting the upper ends of the pair of side components, a first foam material attached to the first metal frame and made of EPP, and a second foam material attached to the first foam material so as to cover at least the front surface of the first foam material and being softer than the first foam material, and assuming a virtual surface that contacts the rear ends of the pair of side components and the rear end of the first support portion, at least a part of the rear projection which is part of the first foam material is behind the virtual surface The first metal frame is located and is a skeletal member of the seat back, and comprises a second metal frame having a second support portion extending in the vehicle width direction at its upper end, the first metal frame being fixed to the second metal frame, and the first foam material having a first cover portion covering the rear surface of the second support portion. .

[0012] Claim 2 The first foam material of the vehicle seat device described herein has a first cover portion that covers the rear surface of the second support portion of the second metal frame. Therefore, when the rear of the seat back collides with an object located directly behind the seat back, the first cover portion of the first foam material absorbs the external force transmitted from the object to the seat back as a result of the collision.

[0013] The vehicle seat device according to claim 3 is a skeletal member of a headrest and comprises a first metal frame having a pair of left and right side components and a first support portion connecting the upper ends of the pair of side components; a first foam material attached to the first metal frame and made of EPP; and a second foam material attached to the first foam material so as to cover at least the front surface of the first foam material and being softer than the first foam material, wherein, when a virtual surface is assumed to be in contact with the rear ends of the pair of side components and the rear ends of the first support portion, at least a portion of the rear projection which is part of the first foam material is located behind the virtual surface, and the first foam material has a front contact portion which is in contact with the front surface of the first metal frame, While facing from the rear with respect to the portion of the first support of the first metal frame that contacts the virtual surface, It has a projection that contacts the rear surface of the first metal frame.

[0014] Claim 3 In the vehicle seat device described above, the front contact portion and protrusions of the first foam material sandwich the first metal frame in the front-to-back direction. Therefore, the first foam material is less likely to fall off the first metal frame.

[0015] The vehicle seat device according to claim 5 is a vehicle seat device according to any one of claims 1 to 3, wherein the rear surface of the first foam material both sides to , away from the first metal frame A recess is formed, and the second foam material has a second cover portion located in the recess.

[0016] A recess is formed on the rear surface of the first foam material of the vehicle seat device according to claim 5. Therefore, the total amount of EPP constituting the first foam material can be reduced compared to the case where no recess is formed.

[0017] The vehicle seat device according to claim 4 is a skeletal member of a headrest and comprises a first metal frame having a pair of left and right side components and a first support portion connecting the upper ends of the pair of side components, a first foam material attached to the first metal frame and made of EPP, and a second foam material attached to the first foam material so as to cover at least the front surface of the first foam material and being softer than the first foam material, wherein, when a virtual surface is assumed to be in contact with the rear ends of the pair of side components and the rear end of the first support portion, at least a part of the rear projection which is part of the first foam material is located behind the virtual surface, and the first foam material is in contact with the first component which is in contact with the front surface of the first metal frame and the rear surface of the first support portion, It is separate from the first component, Furthermore, it comprises a second component fixed to the first component.

[0018] Claim 4 The first foam material of the vehicle seat device described herein has a second component that contacts the rear surface of the first support and is fixed to the first component. Therefore, when the rear of the headrest collides with an object located directly behind the seat back, the second component of the first foam material can make it difficult for the external force transmitted from the object to the headrest as a result of the collision to be transmitted to the first support. [Effects of the Invention]

[0019] As described above, according to the vehicle seat device of the present invention, when the rear part of the headrest collides with an object located immediately behind the headrest, the headrest can effectively absorb the external force transmitted from the object to the headrest due to the collision.

Brief Description of Drawings

[0020] [Figure 1] It is a perspective view seen from the front of the vehicle seat device according to an embodiment of the present invention. [Figure 2] It is a perspective view seen from the rear of the seat back when the cover of the vehicle seat device shown in FIG. 1 is removed. [Figure 3] It is a perspective view seen from the front of the seat back frame and the headrest frame shown in FIG. 2. [Figure 4] It is a perspective view seen from the rear of the seat back frame, the headrest frame, and the first foam material fixed to the headrest frame shown in FIG. 3. [Figure 5] It is a perspective view seen from the front of the first foam material shown in FIG. 4. [Figure 6] It is a perspective view seen from the rear of the first foam material shown in FIG. 4. [Figure 7] It is a cross-sectional view taken along the arrow line 7-7 in FIG. 2. [Figure 8] It is a cross-sectional view taken along the arrow line 8-8 in FIG. 2. [Figure 9] It is a perspective view similar to FIG. 2 of the vehicle seat device according to the first modification of the present invention. [Figure 10] It is a perspective view seen from the rear of the first foam material of the first modification. [Figure 11] It is a cross-sectional view taken along the arrow line 11-11 in FIG. 9. [Figure 12] It is a perspective view similar to FIG. 2 of the vehicle seat device according to the second modification of the present invention. [Figure 13] It is a schematic exploded perspective view of the first foam material and the headrest frame of the second modification. [Figure 14] It is a cross-sectional view taken along the arrow line 14-14 in FIG. 12. [Modes for carrying out the invention]

[0021] Hereinafter, a vehicle seat device 10 (hereinafter referred to as "seat device 10") according to an embodiment of the present invention will be described with reference to Figures 1 to 8. In each figure, arrows FR indicate the front direction of the vehicle, arrows UP indicate the upward direction of the vehicle, and arrows LH indicate the left side in the left-right direction (vehicle width direction). Hereafter, when simply referring to the front-rear, left-right, and up-down directions, these refer to the front-rear direction of the vehicle, the left-right direction in the left-right direction (vehicle width direction), and the up-down direction of the vehicle.

[0022] The seat device 10 shown in Figure 1 is installed in the passenger compartment 100 of a truck, which is an example of a vehicle (not shown). The seat device 10 comprises a seat cushion 11, a seat back 15 whose lower end is connected to the rear end of the seat cushion 11, and a headrest 20 fixed to the upper end of the seat back 15. The seat cushion 11 is fixed to the floor surface (not shown) of the passenger compartment 100.

[0023] The seat back 15 comprises a seat back frame (second metal frame) 16, press felt 18, a portion of the first foam material 25, a portion of the second foam material 45, and the lower part 13 of the cover (trim) 12, which will be described later. The seat back frame 16 shown in Figure 3 is made of metal pipes. The front shape of the seat back frame 16 is approximately rectangular. The left and right ends of a pair of upper and lower reinforcing members 15A are connected to the left and right sides of the seat back frame 16, respectively. The upper end (second support part) 17 of the seat back frame 16 extends in the left and right direction. Press felt 18 made of metal plates is attached to the front of the upper and lower reinforcing members 15A (see Figure 2; not shown in Figures 3 and 4).

[0024] The headrest 20 includes a headrest frame (first metal frame) 21, a part of the first foam material 25, a part of the second foam material 45, and the upper part 14 of the cover 12, which will be described later.

[0025] A headrest frame 21, as shown in Figure 3, is provided inside the headrest 20. The headrest frame 21 is made of metal pipes. The front shape of the headrest frame 21 is roughly U-shaped. The central part of the upper end (first support part) 22 of the headrest frame 21 extends in the left-right direction. The left and right side components 23 of the headrest frame 21 extend in the up-down direction. The upper end 22 connects the upper ends of the left and right side components 23. The lower ends of the left and right side components 23 are fixed to the upper end 17 of the seat back frame 16.

[0026] The first foam material 25 shown in Figures 4 to 8 is an integrally molded product made of EPP (expanded polypropylene). The first foam material 25 (EPP) is softer than the seat back frame 16 and the headrest frame 21, and harder than the second foam material 45 (urethane). The first foam material 25 is manufactured separately from the seat back frame 16, the headrest frame 21, and the second foam material 45 using a mold (not shown). The first foam material 25 has a front contact portion 26, an outer peripheral wall 30, and a rear projection portion 39.

[0027] In this specification, "the first foam material 25 is composed of EPP" means both that the constituent materials of the first foam material 25 do not contain any materials other than EPP, and that the constituent materials of the first foam material 25 contain EPP and trace amounts of materials other than EPP. That is, the first foam material 25 may be composed of EPP alone, or it may be composed of EPP and trace amounts of materials other than EPP. The same applies to the first foam materials 25A and 25B described later.

[0028] The front shape of the front contact portion 26 is approximately rectangular. However, the upper end surface of the front contact portion 26 is approximately arc-shaped. The front contact portion 26 is approximately thin plate-shaped. Three through holes 27 are formed near the upper end of the front contact portion 26.

[0029] A roughly U-shaped outer peripheral wall 30 is provided on the outer peripheral edge of the rear surface of the front contact portion 26, excluding the lower edge. That is, the rear surface of the outer peripheral wall 30 is located behind the rear surface of the front contact portion 26.

[0030] Three retaining protrusions (projections) 35 are provided on the upper part of the inner surface of the outer peripheral wall 30. The front surface of each retaining protrusion 35 is located behind the rear surface of the front contact portion 26. When the first foam material 25 is in a free state, the distance between the front surface of the retaining protrusion 35 and the rear surface of the front contact portion 26 is slightly greater than the diameter of the headrest frame 21.

[0031] Furthermore, a rear projection 39 is provided on the rear surface of the front contact portion 26. As shown in Figure 6, the rear projection 39 is located on the inner side of the outer peripheral wall 30. A roughly U-shaped mounting groove 38 is formed between the inner surface of the front part of the outer peripheral wall 30 and the outer peripheral surface of the front part of the rear projection 39. The front shape of the mounting groove 38 is roughly the same as the front shape of the headrest frame 21 excluding the lower end. The amount of rearward projection of the rear projection 39 from the front contact portion 26 is roughly the same as the amount of rearward projection of the outer peripheral wall 30 from the front contact portion 26. Furthermore, roughly straight ridges (projections) 41 are provided on both the left and right sides of the outer peripheral surface 40 of the rear projection 39. The front surface of the ridges 41 is located behind the rear surface of the front contact portion 26. When the first foam material 25 is in a free state, the distance between the front surface of the ridges 41 and the rear surface of the front contact portion 26 is slightly smaller than the diameter of the headrest frame 21.

[0032] Furthermore, the lower end of the rear projection 39 is provided with an extension (first cover portion) 42 that has less thickness in the front-rear direction than the portion of the rear projection 39 excluding the lower end, and extends below the lower end of the outer peripheral wall 30. In addition, as shown in Figures 5, 6, and 8, the front surface of the front contact portion 26 and the lower end of the rear projection 39 constitute an inclined surface 43 that is inclined in the vertical and front-rear directions when viewed from the side.

[0033] The first foam material 25 is attached to the headrest frame 21 by the following procedure. First, the first foam material 25 is positioned directly in front of the headrest frame 21, with the headrest frame 21 and the mounting groove 38 facing each other in the front-rear direction. Next, the extension 42 is positioned directly behind the upper end 17 of the seat back frame 16 via the lower end of the inner circumferential space of the headrest frame 21, and the inclined surface 43 is brought into contact with the rear surface of the upper end 17. Subsequently, the first foam material 25 is rotated backward using the contact point between the inclined surface 43 and the upper end 17 as the pivot point, and the upper part of the headrest frame 21 is inserted into the mounting groove 38 through the gap between the upper part of the outer circumferential surface of the rear projection 39 and the lower surface of each retaining projection 35. At this time, the left and right side components 23 of the headrest frame 21 move into the mounting groove 38, while elastically deforming each protrusion 41. Finally, the first foam material 25 is moved downward relative to the seat back frame 16 and the headrest frame 21, so that each retaining projection 35 is positioned directly above the top of the headrest frame 21.

[0034] When the headrest frame 21 is inserted into the mounting groove 38, as shown in Figure 8, the upper surface of the upper part of the mounting groove 38 comes into contact with the upper end 22 of the headrest frame 21 while undergoing elastic deformation. Furthermore, the lower end of the inclined surface 43 comes into contact with the upper end 17 of the seat back frame 16 while undergoing elastic deformation. As a result, the relative downward movement of the first foam material 25 with respect to the headrest frame 21 is restricted.

[0035] Furthermore, as shown in Figure 7, the left and right protrusions 41 of the first foam material 25 elastically deform and contact the rear surfaces of the left and right side components 23 of the headrest frame 21, respectively, and the bottom surfaces of both the left and right sides of the mounting groove 38 (rear surfaces of the front contact portions 26) contact the front surfaces of the left and right side components 23, respectively. In other words, the left and right side components 23 are sandwiched in the front-rear direction by the protrusions 41 and the bottom surfaces of the mounting groove 38. Furthermore, as shown in Figure 8, each retaining projection 35 of the first foam material 25 elastically deforms and contacts the rear surface of the upper end portion 22 of the headrest frame 21, respectively, and the top bottom surface of the mounting groove 38 (rear surfaces of the front contact portions 26) contacts the front surface of the upper end portion 22. In other words, the upper end portion 22 is sandwiched in the front-rear direction by each retaining projection 35 and the bottom surfaces of the mounting groove 38. As a result, the relative movement of the first foam material 25 with respect to the headrest frame 21 in the front-rear direction is restricted.

[0036] Furthermore, as shown in Figure 7, the left and right side components 23 of the headrest frame 21 are sandwiched between the left and right inner surfaces of the left and right sides of the mounting groove 38. As a result, the relative movement of the first foam material 25 with respect to the headrest frame 21 in the left-right direction is restricted.

[0037] Furthermore, the rear of the rear projection 39 passes through the inner circumferential space of the headrest frame 21 to the rear. Furthermore, as shown in Figure 8, the extension 42 of the first foam material 25 contacts the rear surface of the upper end 17 of the seat back frame 16. Furthermore, as shown in Figures 7 and 8, a virtual surface PL is assumed that contacts the rear end of the upper end 22 of the headrest frame 21 and the rear ends of the left and right side components 23. In this case, the rear of the outer peripheral wall 30, the retaining projection 35, and the rear of the rear projection 39 (including the extension 42) are located behind the virtual surface PL.

[0038] The second foam material 45 shown in Figures 2, 7, and 8 is a one-piece molded product made of urethane. The second foam material 45 is manufactured separately from the seat back frame 16, headrest frame 21, and first foam material 25 using a mold (not shown). The second foam material 45 has a lower component 46 and an upper component 50.

[0039] In this specification, "the second foam material 45 is composed of urethane" means both that the constituent materials of the second foam material 45 do not contain any materials other than urethane, and that the constituent materials of the second foam material 45 contain urethane and trace amounts of materials other than urethane. That is, the second foam material 45 may be composed of urethane alone, or it may be composed of urethane and trace amounts of materials other than urethane. The same applies to the second foam materials 45A and 45B described later.

[0040] The lower component 46 can cover the front of the seat back frame 16 and the press felt 18, both left and right sides of the seat back frame 16, both left and right sides of the top surface of the seat back frame 16, and the rear surface of the seat back frame 16.

[0041] The left-right dimension of the upper component 50 is smaller than that of the lower component 46. The upper component 50 comprises a front portion 51, a pair of left and right side portions 52, and an upper portion 53. Furthermore, the second foam material 45 has an opening 47 that spans the rear surface of the lower component 46 and the rear surface of the upper component 50.

[0042] As shown in Figures 2, 7, and 8, the second foam material 45 is attached to the seat back frame 16, the press felt 18, and the first foam material 25. The front surface of the first foam material 25 is covered by the front part 51 of the upper component 50, both the left and right sides of the first foam material 25 are covered by the left and right side parts 52, and the top surface of the first foam material 25 is covered by the upper part 53. In this way, the upper part 53 of the second foam material 45 is in contact with the top surface of the first foam material 25, so that the relative upward movement of the first foam material 25 with respect to the headrest frame 21 is restricted. As shown in Figure 2, most of the press felt 18 is exposed to the rear of the seat device 10 through the opening 47. Also, the entire rear surface of the first foam material 25 is exposed to the rear through the opening 47. That is, the entire rear surface of the first foam material 25 is an uncovered portion 44 that is not covered by the second foam material 45. As shown in Figures 2, 7, and 8, the upper rear surface of the lower component 46 and the upper 53 and side 52 rear surfaces of the upper component 50 are substantially continuous with the rear surface of the first foam material 25.

[0043] Furthermore, as shown in Figure 1, a cover 12 made of a flexible material is attached to the entire outer surface of the seat back frame 16, press felt 18, first foam material 25, and second foam material 45, which are thus integrated. The cover 12 is a bag-shaped member with an open lower end. The cover 12 has a lower part 13 and an upper part 14 connected to the upper end of the lower part 13. The upper part 14 covers the outer surface of the first foam material 25 and the upper component 50, and the lower part 13 covers the outer surface of the seat back frame 16, press felt 18, and lower component 46.

[0044] (Mechanism of Action and Effects) Next, the operation and effects of this embodiment will be described.

[0045] For example, if a rear-end collision occurs in a vehicle equipped with the seat device 10, the rear of the headrest 20 may collide with the wall 101 located directly behind the headrest 20. In this embodiment, the rear of the outer peripheral wall 30, the retaining projection 35, and the rear of the rear projection 39 (including the extension 42) are located behind the virtual plane PL. Moreover, the entire rear surface of the first foam material 25 is an uncovered portion 44 that is not covered by the second foam material 45. Therefore, the outer peripheral wall 30, retaining projection 35, and rear projection 39 of the first foam material 25 absorb the external force transmitted from the wall 101 to the headrest 20 as a result of the headrest 20 colliding with the wall 101. The EPP (expanded polypropylene), which is the constituent material of the first foam material 25, is harder than the urethane, which is the constituent material of the second foam material 45. Therefore, when an external force is transmitted from the wall 101 to the first foam material 25, the deformation speed of the first foam material 25 is lower than the deformation speed of the second foam material 45 when an external force is transmitted from the wall 101 to the second foam material 45. In other words, the first foam material 25 deforms more slowly than the second foam material 45. Therefore, the cushioning properties of the first foam material 25 are superior to those of the second foam material 45. As a result, the first foam material 25 can effectively absorb the external force transmitted from the wall 101 to the headrest 20 due to the collision. In other words, compared to the case where the entire rear surface of the first foam material 25 is covered by the second foam material 45, the external force transmitted from the wall 101 to the headrest 20 due to the collision is effectively absorbed by the headrest 20.

[0046] Furthermore, if a rear-end collision occurs in a vehicle equipped with the seat device 10, the rear of the upper end of the seat back 15 may collide with the wall 101 located directly behind the seat back 15. In this embodiment, the extension 42 of the first foam material 25 covers the rear surface of the upper end 17 of the seat back frame 16. Therefore, the extension 42 of the first foam material 25 can effectively absorb the external force transmitted from the wall 101 to the upper end of the seat back 15 due to the collision.

[0047] Furthermore, the left and right side components 23 are sandwiched in the front-to-back direction by the protrusions 41 and the bottom surface of the mounting groove 38 (the rear surface of the front contact portion 26), and the upper end portion 22 is sandwiched in the front-to-back direction by the retaining projection 35 and the bottom surface of the mounting groove 38 (the rear surface of the front contact portion 26). Therefore, even if the seat device 10 collides with the wall 101, the first foam material 25 is unlikely to fall forward from the headrest frame 21.

[0048] Although embodiments of the present invention have been described above, the present invention is not limited to these embodiments.

[0049] For example, the present invention may be implemented in the form of the first modified example shown in Figures 9 to 11. In the following description of the first modified example, the same reference numerals are used for the same components (parts) as in the above embodiment, and their detailed descriptions are omitted.

[0050] The first foam material 25A of the sheet device 10A of the first modified example is an integrally molded product made of EPP. The first foam material 25A has a front contact portion 26, an outer peripheral wall 30A, and a rear projection portion 39.

[0051] Recesses 30B are formed on the rear surfaces of both the left and right sides of the outer peripheral wall 30A. Therefore, the thickness of the left and right sides of the outer peripheral wall 30A in the front-to-back direction is smaller than the thickness of the top of the outer peripheral wall 30A.

[0052] The second foam material 45A in the first modified example is an integrally molded product made of urethane. The second foam material 45A has a lower component 46 and an upper component 50A.

[0053] The upper component 50A includes a front portion 51 that covers the front surface of the first foam material 25A, a pair of left and right side portions 52 that cover both the left and right sides of the first foam material 25A, an upper portion 53 that covers the top surface of the first foam material 25A, and a pair of left and right rear portions (second cover portions) 54 connected to the rear of the left and right side portions 52. Furthermore, the second foam material 45A has an opening 47A that spans the rear surface of the lower component 46 and the rear surface of the upper component 50A.

[0054] As shown in Figures 9 and 11, the left and right rear portions 54 of the upper component 50A fit into the left and right recesses 30B of the first foam material 25A, and the inner ends of the left and right rear portions 54 contact the left and right sides of the rear projection 39. That is, the rear surfaces of both the left and right sides of the outer peripheral wall 30A are covered by the rear portions 54. As shown in Figures 9 and 11, the rear surface of the rear projection 39 of the first foam material 25A and the upper rear surface of the outer peripheral wall 30A are uncovered portions 44A that are not covered by the second foam material 45A. The upper rear surface of the lower component 46 and the upper 53 and rear rear surfaces of the rear portion 54 of the upper component 50 are substantially continuous with the rear surface of the first foam material 25A. Furthermore, although not shown, a cover 12 is attached to the entire outer surface of the seat back frame 16, press felt 18, first foam material 25A and second foam material 45A.

[0055] Since a recess 30B is formed in the outer peripheral wall 30A of the first modified example, the total amount of EPP constituting the outer peripheral wall 30A is less than the total amount of EPP constituting the outer peripheral wall 30 of the embodiment. Generally, EPP is expensive, so the first foam material 25A of the first modified example can be manufactured at a lower cost than the first foam material 25 of the embodiment. Therefore, the sheet device 10A of the first modified example can be manufactured at a lower cost than the sheet device 10 of the embodiment.

[0056] The present invention may also be implemented in the form of the second modified example shown in Figures 12 to 14. In the following description of the second modified example, the same reference numerals are used for the same components (parts) as in the above embodiment, and their detailed descriptions are omitted.

[0057] The first foam material 25B of the sheet device 10B of the second modified example has a first component 25-1 and a second component 25-2. The first component 25-1 and the second component 25-2 are integrally molded products made of EPP. The first component 25-1 and the second component 25-2 are manufactured separately from each other using a mold (not shown).

[0058] The first component 25-1 has a front contact portion 26 and an outer peripheral wall 25-1a, which is roughly U-shaped in front view and connected to the outer peripheral portion of the rear surface of the front contact portion 26, excluding the lower end.

[0059] The second component 25-2 has a base portion 25-2a whose front shape is substantially the same as that of the front contact portion 26, and an extension portion 42 connected to the lower end of the base portion 25-2a. As shown in Figure 14, a concave surface 42a extending in the left-right direction is formed on the front surface of the extension portion 42.

[0060] The first component 25-1, which is separated from the second component 25-2, is attached to the headrest frame 21. That is, the inner surface of the outer peripheral wall 25-1a contacts the outer peripheral surface of the headrest frame 21, and the outer peripheral edge of the rear surface of the front contact portion 26 contacts the front surface of the headrest frame 21. Furthermore, as shown in Figure 14, the second component 25-2 covers the rear surface of the headrest frame 21. Furthermore, the concave surface 42a of the base portion 25-2a contacts the upper and rear surfaces of the upper end portion 17. Furthermore, the rear surface of the outer peripheral wall 25-1a of the first component 25-1 and the outer peripheral edge of the front surface of the base portion 25-2a are bonded together. As shown in Figure 14, the second component 25-2 is positioned behind the virtual plane PL.

[0061] The second foam material 45B in the second modified example is an integrally molded product made of urethane. The second foam material 45B has a lower component 46 and an upper component 50B.

[0062] The upper component 50B includes a front portion 51B that covers the front surface of the first foam material 25B, a pair of left and right side portions 52B that cover both left and right sides of the first foam material 25B, and an upper portion 53B that covers the top surface of the first foam material 25B. Furthermore, the second foam material 45B has an opening 47B that spans the rear surface of the lower component 46 and the rear surface of the upper component 50B.

[0063] As shown in Figures 12 and 14, the second foam material 45B is attached to the seat back frame 16, the press felt 18, and the first foam material 25B. The entire rear surface of the first foam material 25B is exposed to the rear through the opening 47B. That is, the entire rear surface of the first foam material 25B (second component 25-2) is an uncovered portion 44B that is not covered by the second foam material 45B. The upper rear surface of the lower component 46 and the upper 53B and side 52B rear surfaces of the upper component 50B are substantially continuous with the rear surface of the first foam material 25B. Furthermore, although not shown in the figures, a cover 12 is attached to the entire outer surface of the seat back frame 16, the press felt 18, the first foam material 25B, and the second foam material 45B.

[0064] In the second modified example, the base 25-2a of the first foam material 25B covers the rear surfaces of the headrest frame 21 and the upper end 17. Therefore, the base 25-2a of the first foam material 25B can effectively absorb the external force transmitted from the wall 101 to the upper end of the headrest 20 and seat back 15 due to the collision.

[0065] The second foam materials 45, 45A, and 45B may be composed of materials other than urethane. However, the constituent materials of the second foam materials 45, 45A, and 45B must be softer than EPP.

[0066] The seat devices 10, 10A, and 10B may be configured such that the headrest 20 can move up and down relative to the seat back 15. [Explanation of Symbols]

[0067] 10 10A 10B Vehicle seat device (seat device) 15 Seatback 16. Seat back frame (second metal frame) 17 Upper end (second support part) 20 headrests 21. Headrest frame (first metal frame) 22 Upper end (first support part) 23 Side component 25 25A 25B First foaming material 25-1 First component 25-2 Second component 26 Front contact part 35 Retaining protrusion (protrusion) 39 Rear protrusion 41 Projection (protrusion) 42 Extension section (first cover section) 44 44A 44B Uncoated section 45 45A 45B Second foaming agent 54 Rear section (second cover section) PL Virtual Face

Claims

1. A headrest skeletal member comprising a first metal frame having a pair of left and right side components and a first support portion connecting the upper ends of the pair of side components, A first foam material made of EPP is attached to the first metal frame, A second foam material is attached to the first foam material so as to cover at least the front surface of the first foam material, and is softer than the first foam material, Equipped with, When a virtual surface is assumed that contacts the rear ends of the pair of side components and the rear end of the first support, at least a portion of the rear projection, which is part of the first foam material, is located behind the virtual surface. A vehicle seat device having an uncovered portion of the first foam material that is not covered on its rear surface by the second foam material.

2. A headrest skeletal member comprising a first metal frame having a pair of left and right side components and a first support portion connecting the upper ends of the pair of side components, A first foam material made of EPP is attached to the first metal frame, A second foam material is attached to the first foam material so as to cover at least the front surface of the first foam material, and is softer than the first foam material, Equipped with, When a virtual surface is assumed that contacts the rear ends of the pair of side components and the rear end of the first support, at least a portion of the rear projection, which is part of the first foam material, is located behind the virtual surface. It is a skeletal member of the seat back, and comprises a second metal frame having a second support portion extending in the vehicle width direction at its upper end, The first metal frame is fixed to the second metal frame, A vehicle seat device having a first cover portion that covers the rear surface of the second support portion, wherein the first foam material is a first cover portion.

3. A headrest skeletal member comprising a first metal frame having a pair of left and right side components and a first support portion connecting the upper ends of the pair of side components, A first foam material made of EPP is attached to the first metal frame, A second foam material is attached to the first foam material so as to cover at least the front surface of the first foam material, and is softer than the first foam material, Equipped with, When a virtual surface is assumed that contacts the rear ends of the pair of side components and the rear end of the first support, at least a portion of the rear projection, which is part of the first foam material, is located behind the virtual surface. The first foaming material is A front contact portion that contacts the front surface of the first metal frame, A projection that contacts the rear surface of the first metal frame, while facing from the rear with respect to the portion of the first support of the first metal frame that contacts the virtual surface, A vehicle seat device having the following features.

4. A headrest skeletal member comprising a first metal frame having a pair of left and right side components and a first support portion connecting the upper ends of the pair of side components, A first foam material made of EPP is attached to the first metal frame, A second foam material is attached to the first foam material so as to cover at least the front surface of the first foam material, and is softer than the first foam material, Equipped with, When a virtual surface is assumed that contacts the rear ends of the pair of side components and the rear end of the first support, at least a portion of the rear projection, which is part of the first foam material, is located behind the virtual surface. The first foaming material is A first component that contacts the front surface of the first metal frame, A second component that contacts the rear surface of the first support portion, is separate from the first component, and is fixed to the first component, A vehicle seat device equipped with the following features.

5. Recesses are formed on both the left and right sides of the rear surface of the first foam material, away from the first metal frame. The vehicle seat device according to any one of claims 1 to 3, wherein the second foam material has a second cover portion located in the recess.

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