Vehicle seat cushion

Abstract

To provide a vehicle seat cushion that suppresses the occurrence of a submarine phenomenon and allows simplification of the production process.SOLUTION: The rear side of a seat cushion 14 is formed by a main pad rear part 22A made of a soft urethane foam body, making it possible to support the hip 12A of a crew member 12. On the other hand, the front side of the seat cushion 14 is formed by a main pad front part 22B made of a hard urethane foam body, making it possible to support the thighs 12B of the crew member 12. In addition, a split piece part 24 extends, from a skin part 20 of the seat cushion 14, to the side of a boundary part 22C between the main pad rear part 22A and the main pad front part 22B.SELECTED DRAWING: Figure 3

Description

[[Technical Field]]

[0001] The present invention relates to a vehicle seat cushion. [[Background Art]]

[0002] The following Patent Document 1 discloses an invention relating to a seat cushion pad. In this seat cushion pad, a high-hardness member is embedded in the buttocks support region of the seat cushion pad. This high-hardness member uses a urethane foam having a higher hardness than the urethane foam constituting the seat cushion pad. [[Prior Art Documents]] [[Patent Documents]]

[0003] [[Patent Document 1]] Japanese Unexamined Patent Application Publication No. 2013-215476 [[Summary of the Invention]] [[Problems to be Solved by the Invention]]

[0004] By the way, in consideration of the submarine phenomenon, that is, the phenomenon that an occupant slips through the seat belt, slides off the seat, and sinks under the dashboard or the like during a front collision of a vehicle, it is conceivable to apply the prior art described in the above Patent Document 1 to configure the front side of the seat cushion pad with a urethane foam of high hardness, so as to obtain a structure capable of supporting the occupant from the front side of the vehicle during a front collision of the vehicle.

[0005] However, in the prior art described in the above Patent Document 1, the high-hardness member is cut into a predetermined shape from a urethane foam and then embedded in the seat cushion pad, which may complicate the manufacturing process of the seat cushion pad.

[0006] In consideration of the above facts, an object of the present invention is to obtain a vehicle seat cushion that can simplify the manufacturing process while suppressing the occurrence of the submarine phenomenon. [Means for solving the problem]

[0007] The vehicle seat cushion according to claim 1 comprises a first component made of a first foam, capable of supporting the occupant's buttocks and forming the rear side; a second component made of a second foam having a higher hardness than the first foam, positioned adjacent to the first component, capable of supporting the occupant's thighs and forming the front side; and an outer surface portion that forms the upper surface capable of supporting the occupant, extending toward the boundary between the first component and the second component. Ta Divided parts and, The surface portion is composed of a first surface portion covering the first component and a second surface portion covering the second component, and the divided piece portion is composed of a first extension portion that constitutes a part of the first surface portion and extends toward the boundary portion and a second extension portion that constitutes a part of the second surface portion and extends toward the boundary portion. .

[0008] According to the present invention as described in claim 1, the rear side of the vehicle seat cushion is composed of a first component, which is made of a first foam and is capable of supporting the buttocks of the occupant.

[0009] On the other hand, the front part of the vehicle seat cushion is composed of a first component and an adjacent second component. This second component is made of a second foam that is harder than the first foam and is capable of supporting the occupant's thighs.

[0010] Therefore, in this invention, when an occupant sits on the vehicle seat cushion, the first component sinks deeper than the second component. As a result, in the event of a frontal collision, if the occupant attempts to move forward on the vehicle seat cushion due to their inertia, the occupant's movement is restricted by the second component.

[0011] Furthermore, in this invention, a divided piece extends from the surface portion that constitutes the upper surface capable of supporting the occupant of the vehicle seat cushion toward the boundary between the first component and the second component. Therefore, during the manufacturing of the vehicle seat cushion, the foaming liquid of the first foam and the foaming liquid of the second foam, which are poured into the manufacturing mold, can be separated by the divided piece. As a result, in this invention, it is possible to provide parts of the vehicle seat cushion with different hardness without combining the molded foams.

[0012] The vehicle seat cushion according to claim 2 is, in the invention described in claim 1 ,before The divided parts are ,one The department The aforementioned First extension and The aforementioned The structure includes a plate-like or sheet-like extension member that extends from the first extension and the second extension toward the lower surface opposite to the upper surface, while being in contact with at least one of the second extensions.

[0013] According to the present invention as described in claim 2, the surface portion constituting the upper surface of the vehicle seat cushion is composed of a first surface portion that covers the first component and a second surface portion that covers the second component. Therefore, in the present invention, the shape of the first surface portion can be set to match the shape of the first component, and the shape of the second surface portion can be set to match the shape of the second component.

[0014] Furthermore, in the present invention, the divided piece includes a first extension that constitutes a part of the first skin portion and extends toward the boundary between the first and second components, and a second extension that constitutes a part of the second skin portion and extends toward the said boundary. Therefore, at the boundary between the first and second components, the first skin portion can be brought into close contact with the first component, and the second skin portion can be brought into close contact with the second component.

[0015] By the way, in order to accurately form the boundary between the first component and the second component, it is preferable to extend the divided piece as far as possible towards the underside of the vehicle seat cushion. On the other hand, if the first and second extended portions are made too long, it is possible that the yield of the material constituting the surface portion will decrease.

[0016] In this invention, the divided portion is composed of an extended member, which is a plate-like or sheet-like member that extends toward the lower surface of the vehicle seat cushion from the first extended portion and the second extended portion, with a portion of it in contact with at least one of the first extended portion and the second extended portion. Therefore, in this invention, the boundary between the first component and the second component can be formed with high precision while suppressing a decrease in the yield of the material constituting the surface portion.

[0017] The vehicle seat cushion according to claim 3 is the invention according to claim 1, wherein the surface portion is composed of a main surface portion that covers the first component and the second component, and the divided piece portion is a plate-shaped or sheet-shaped extension member that extends from the main surface portion toward the lower surface opposite to the upper surface while in contact with the main surface portion.

[0018] According to the present invention as described in claim 3, the first component and the second component are covered with a main surface portion. The divided piece is a plate-shaped or sheet-shaped extension member that extends from the main surface portion toward the lower surface of the vehicle seat cushion while in contact with the main surface portion. Therefore, in the present invention, the shape of the main surface portion and the position of the boundary between the first component and the second component can be set independently of each other.

[0019] The vehicle seat cushion according to claim 4 is the invention according to claim 2 or claim 3, wherein the second component is provided with a first inclined surface portion on the side of the first component such that the upper end of the upper surface is located in front of the lower end of the lower surface, and the first component is provided with a second inclined surface portion along the first inclined surface portion on the side of the second component.

[0020] According to the present invention as described in claim 4, a first inclined surface is provided on the side of the second component that is adjacent to the first component, and the upper end of this first inclined surface is located in front of the lower end of the upper surface of the vehicle seat cushion.

[0021] On the other hand, a second inclined surface portion along the first inclined surface portion is provided on the second component side of the first component. Therefore, a boundary surface that slopes downward from the front side toward the rear side of the vehicle seat cushion is formed at the boundary between the first component and the second component of the vehicle seat cushion.

[0022] As a result, in the present invention, compared with a configuration in which a boundary surface where an upper end portion and a lower end portion are at the same position in the front-rear direction of the vehicle seat cushion is formed at the boundary between the first component and the second component, a larger area capable of receiving an occupant during a vehicle front collision can be secured in the vehicle seat cushion.

Effects of the Invention

[0023] As described above, the vehicle seat cushion according to the present invention has an excellent effect that the manufacturing process can be simplified while suppressing the occurrence of the submarine phenomenon.

Brief Description of Drawings

[0024] [Figure 1] It is a side view seen from the seat width direction that schematically shows the configuration of the vehicle seat according to the first embodiment. [Figure 2] It is a perspective view that schematically shows the configuration of the vehicle seat cushion according to the first embodiment. [Figure 3] It is an enlarged cross-sectional view that schematically shows the configuration of the main part of the vehicle seat cushion according to the first embodiment (a cross-sectional view showing a state cut along line 3-3 in FIG. 2). [Figure 4] It shows each step of the manufacturing process of the vehicle seat cushion according to the first embodiment, where (A) shows the first step, (B) shows the second step, (C) shows the third step, and (D) shows the fourth step. [Figure 5] It is an enlarged cross-sectional view that schematically shows the configuration of the main part of the vehicle seat cushion according to the second embodiment (a cross-sectional view corresponding to FIG. 3).

Mode for Carrying Out the Invention

[0025] <First Embodiment> A first embodiment of the vehicle seat 10 according to the present invention will be described below with reference to Figures 1 to 4. The arrows FR, UP, and LH shown in each figure as appropriate indicate the forward, upward, and leftward directions of the vehicle seat 10, respectively. In this embodiment, the forward, upward, and leftward directions of the vehicle seat 10 coincide with the forward, upward, and leftward directions of the vehicle on which the vehicle seat 10 is mounted.

[0026] As shown in Figure 1, the vehicle seat 10 is a front seat mounted on the front side of the vehicle's interior. This vehicle seat 10 includes a "seat cushion 14" which serves as a vehicle seat cushion to support the buttocks 12A and thighs 12B of the occupant 12, a seat back 16 which supports the back 12C of the occupant 12, and a headrest (not shown) which supports the head (not shown) of the occupant 12.

[0027] The seat cushion 14 has a cushion pan (not shown) attached to its lower side, and this cushion pan is supported to the vehicle floor (not shown) via guide rails (not shown), etc.

[0028] In this embodiment, as shown in Figures 2 and 3, the seat cushion 14 is characterized in that the "surface portion 20" that constitutes its "upper surface 14A" and the cushion pad 22 that constitutes the main part of the seat cushion 14 are integrally molded, and the cushion pad 22 is composed of multiple types of foam with different hardness. Herein, hardness refers to Shore hardness. The configuration of the seat cushion 14, which is the main part of this embodiment, will be described in detail below.

[0029] The cushion pad 22 is roughly shaped like a rectangular plate with its thickness direction aligned with the vertical direction of the seat and its longitudinal direction aligned with the front-to-back direction of the seat when viewed from the vertical direction of the seat. The cushion pad 22 is composed of a first component, the "main pad rear section 22A", a second component, the "main pad front section 22B", and a pair of side pad sections (not shown).

[0030] The main pad rear section 22A is composed of a "soft urethane foam" as the first foam and constitutes the rear portion of the seat in the center of the cushion pad 22 in the seat width direction. Furthermore, on the front side of the main pad rear section 22A, there is an "inclined surface section 22A1" which is a second inclined surface section where the upper end of the upper surface 14A side of the seat cushion 14 is located further forward than the lower end of the lower surface 14C side of the seat cushion 14. When the occupant 12 is seated on the seat cushion 14, the main pad rear section 22A mainly supports the occupant 12's buttocks 12A.

[0031] On the other hand, the main pad front portion 22B is made of a "rigid urethane foam" as a second foam with higher hardness than the soft urethane foam, and constitutes the front part of the seat in the center of the cushion pad 22 in the seat width direction. Furthermore, on the rear side of the seat of the main pad front portion 22B, there is an "inclined surface portion 22B1" as a first inclined surface portion, where the upper end of the upper surface 14A side of the seat cushion 14 is located further forward of the seat than the lower end of the lower surface 14C side of the seat cushion 14. In other words, the inclined surface portion 22A1 and the inclined surface portion 22B1 extend along each other. When the occupant 12 is seated on the seat cushion 14, the main pad front portion 22B mainly supports the thighs 12B of the occupant 12.

[0032] The side pad portion, like the main pad front portion 22B, is made of rigid urethane foam. This side pad portion extends in the front-to-back direction of the seat and bulges outwards towards the top of the seat, forming part of the side support portion 14B of the seat cushion 14.

[0033] On the other hand, the surface portion 20 is made of, for example, fabric, leather, or synthetic leather. This surface portion 20 includes a "first surface portion 20A" that covers the main pad rear portion 22A from above the seat, a "second surface portion 20B" that covers the main pad front portion 22B from above the seat, and a third surface portion 20C that covers the side pad portion from above the seat.

[0034] In this embodiment, the main pad rear portion 22A and the main pad front portion 22B are separated by a "divided piece portion 24" which includes a part of the surface portion 20.

[0035] More specifically, the divided piece 24 is composed of a "first extension 20A1" which constitutes the front part of the first surface part 20A, a "second extension 20B1" which constitutes the rear part of the second surface part 20B, and an "extension member 26".

[0036] The first extension portion 20A1 extends from the portion of the first surface portion 20A that is bonded to the upper surface of the main pad rear portion 22A toward the "boundary portion 22C" between the main pad rear portion 22A and the main pad front portion 22B, and is also bonded to the inclined surface portion 22A1.

[0037] On the other hand, the second extension portion 20B1 extends from the portion of the second surface portion 20B that is bonded to the upper surface of the main pad front portion 22B toward the boundary portion 22C, and is also bonded to the inclined surface portion 22B1.

[0038] The extension member 26 is made of, for example, a plate-shaped soft urethane foam or a sheet-shaped pressed felt. This extension member 26 extends from the first extension portion 20A1 and the second extension portion 20B1 to the lower surface 14C of the seat cushion 14, with a portion of it in close contact with at least one of the first extension portion 20A1 and the second extension portion 20B1. A divided piece portion (not shown) with a similar configuration to the divided piece portion 24 is also provided at the boundary between the main pad rear portion 22A and the side pad portion.

[0039] Next, an example of the manufacturing process for the seat cushion 14 according to this embodiment will be described using Figure 4. Note that the process for the side support portion 14B will be omitted.

[0040] First, in the first step shown in Figure 4(A), the first surface portion 20A is placed in the first cavity portion 28A of the lower mold 28 in the manufacturing mold 27, and the second surface portion 20B is placed in the second cavity portion 28B of the lower mold 28 in the manufacturing mold 27. At this time, the first extension portion 20A1 and the second extension portion 20B1 are placed along the guide projection portion 28C provided on the lower mold 28 that divides the first cavity portion 28A and the second cavity portion 28B, and these are positioned so that they are raised relative to the lower mold 28.

[0041] Next, in the second step shown in Figure 4(B), the foaming concentrate L1 of the flexible urethane foam is injected into the first cavity 28A, and the foaming concentrate L2 of the rigid urethane foam is injected into the second cavity 28B.

[0042] Next, in the third step shown in Figure 4(C), the extension member 26 is placed on the molding surface 30A of the upper mold 30, which is positioned in a predetermined location. At this time, the inclination angle of the extension member 26 with respect to the molding surface 30A is set according to the shape of the inclined surface portion 22A1 of the main pad rear portion 22A and the inclined surface portion 22B1 of the main pad front portion 22B. Then, the first extension portion 20A1 and the second extension portion 20B1 are positioned along the extension member 26, and at least one of the first extension portion 20A1 and the second extension portion 20B1 is joined to the extension member 26 via adhesive or the like, if necessary.

[0043] Then, in the fourth step shown in Figure 4(D), the foaming liquid is demolded after it has foamed and hardened, and the molded seat cushion 14 is removed. At this time, any burrs formed along the parting line between the lower mold 28 and the upper mold 30, as well as burrs formed on the lower surface 14C of the seat cushion 14, are removed.

[0044] <Operation and Effects of This Embodiment> Next, the operation and effects of this embodiment will be described.

[0045] In this embodiment, as shown in Figures 1 and 3, the rear side of the seat cushion 14 is composed of a main pad rear portion 22A, which is made of soft urethane foam and is capable of supporting the buttocks 12A of the occupant 12.

[0046] On the other hand, the front part of the seat cushion 14 consists of the main pad rear part 22A and the adjacent main pad front part 22B. This main pad front part 22B is made of rigid urethane foam, which has a higher hardness than the soft urethane foam, and is capable of supporting the thighs 12B of the occupant 12.

[0047] Therefore, in this embodiment, when an occupant 12 sits on the seat cushion 14, the rear portion 22A of the main pad sinks deeper than the front portion 22B of the main pad. As a result, in the event of a frontal collision, if the occupant 12 attempts to move forward on the seat cushion 14 due to its inertia, the displacement of the occupant 12 will be limited by the front portion 22B of the main pad.

[0048] Furthermore, in this embodiment, the divided piece 24 extends from the surface portion 20 that constitutes the upper surface 14A of the seat cushion 14 capable of supporting the occupant 12 toward the boundary portion 22C between the main pad rear portion 22A and the main pad front portion 22B. Therefore, during the manufacturing of the seat cushion 14, the foaming liquid of the soft urethane foam and the foaming liquid of the hard urethane foam poured into the manufacturing mold 27 can be separated by the divided piece 24 (see Figure 4(D)). As a result, in this embodiment, parts with different hardness can be provided in the seat cushion 14 without combining the molded foams.

[0049] Furthermore, in this embodiment, the surface portion 20 constituting the upper surface 14A of the seat cushion 14 includes a first surface portion 20A that covers the main pad rear portion 22A and a second surface portion 20B that covers the main pad front portion 22B. Therefore, in this embodiment, the shape of the first surface portion 20A can be set to match the shape of the main pad rear portion 22A, and the shape of the second surface portion 20B can be set to match the shape of the main pad rear portion 22A.

[0050] Furthermore, in this embodiment, the divided piece 24 is configured to include a first extension 20A1 which constitutes a part of the first surface portion 20A and extends toward the boundary portion 22C between the main pad rear portion 22A and the main pad front portion 22B, and a second extension 20B1 which constitutes a part of the second surface portion 20B and extends toward the boundary portion 22C. Therefore, at the boundary portion 22C, the first surface portion 20A can be brought into close contact with the main pad rear portion 22A, and the second surface portion 20B can be brought into close contact with the main pad front portion 22B.

[0051] By the way, in order to accurately form the boundary portion 22C, it is preferable to extend the divided piece portion 24 as far as possible toward the lower surface 14C side of the seat cushion 14. On the other hand, if the first extended portion 20A1 and the second extended portion 20B1 are made too long, it is conceivable that the yield of the material constituting the surface portion 20 will be poor.

[0052] In this embodiment, the divided piece portion 24 is configured to include an extension member 26, and this extension member 26 is plate-shaped or sheet-shaped, extending from the first extension portion 20A1 and the second extension portion 20B1 toward the lower surface 14A of the seat cushion 14, with a portion of it in contact with at least one of the first extension portion 20A1 and the second extension portion 20B1. Therefore, in this embodiment, the boundary portion 22C between the main pad rear portion 22A and the main pad front portion 22B can be molded with high precision while suppressing a decrease in the yield of the material constituting the surface portion 20.

[0053] Furthermore, in this embodiment, an inclined surface portion 22B1 is provided on the main pad rear portion 22A side of the main pad front portion 22B, and the upper end of this inclined surface portion 22B1 on the upper surface 14A side of the seat cushion 14 is located further forward of the seat than the lower end on the lower surface 14C side of the seat cushion 14.

[0054] On the other hand, on the main pad rear portion 22A, an inclined surface portion 22A1 is provided on the main pad front portion 22B side, which is aligned with the inclined surface portion 22B1. As a result, at the boundary portion 22C between the main pad front portion 22B and the main pad rear portion 22A of the seat cushion 14, a boundary surface is formed that slopes downward from the front side of the seat to the rear side of the seat.

[0055] As a result, in this embodiment, compared to a configuration in which an interface surface is formed at the boundary portion 22C where the upper end and lower end of the seat cushion 14 are in the same position in the front-rear direction, a wider surface area can be secured on the seat cushion 14 that can receive the occupant 12 during a frontal collision of the vehicle.

[0056] Thus, in this embodiment, it is possible to simplify the manufacturing process while suppressing the occurrence of the submarine phenomenon.

[0057] <Second Embodiment> Next, the configuration of the "seat cushion 40" as a vehicle seat cushion according to the second embodiment of the present invention will be described with reference to Figure 5. Note that components identical to those in the first embodiment described above will be given the same numbers and their descriptions will be omitted.

[0058] In this second embodiment, the "surface portion 42" that constitutes the "upper surface 40A" of the seat cushion 40 includes a "main surface portion 42A" that covers the upper surfaces of the main pad rear portion 22A and the main pad front portion 22B. The extension member 26 is attached to the main surface portion 42A via a joint (not shown) formed by sewing or adhesive.

[0059] With this configuration, the shape of the main surface portion 42A and the position of the boundary portion 22C between the main pad rear portion 22A and the main pad front portion 22B can be set independently of each other.

[0060] In the first embodiment described above, the divided piece 24 was configured to include an extension member 26, but the configuration of the divided piece is not limited to this. For example, depending on the specifications of the seat cushion 14, a configuration in which the divided piece does not include an extension member 26 may be adopted, that is, a configuration in which the divided piece is composed of at least one of the first extension portion 20A1 and the second extension portion 20B1. [Explanation of symbols]

[0061] 14. Seat cushion (vehicle seat cushion) 14A Top 20 Epidermis 20A 1st epidermis 20A1 1st extension part 20B 2nd epidermis 20B1 2nd extension part 22A Main pad rear section (first component) 22A1 Inclined surface section (second inclined surface section) 22B Main pad front section (second component) 22B1 Inclined surface section (first inclined surface section) 24 Split piece 26. Extended member 40 Seat Cushions (Vehicle Seat Cushions) 40A top 42 Epidermis 42A Main epidermis

Claims

1. A first component, composed of a first foam material, capable of supporting the occupant's buttocks and forming the rear side, The second component is made of a second foam with higher hardness than the first foam, is positioned adjacent to the first component, is capable of supporting the occupant's thigh, and constitutes the front side, A divided piece extending from the surface portion that constitutes the upper surface capable of supporting the occupant toward the boundary portion between the first component and the second component, It has, The skin portion is composed of a first skin portion covering the first component and a second skin portion covering the second component, The divided portion includes a first extension that constitutes a part of the first skin portion and extends toward the boundary portion, and a second extension that constitutes a part of the second skin portion and extends toward the boundary portion. Vehicle seat cushion.

2. The divided piece comprises a plate-like or sheet-like extension member that extends from the first extension and the second extension toward the lower surface opposite to the upper surface, with a portion of the extension in contact with at least one of the first extension and the second extension. A vehicle seat cushion according to claim 1.

3. The aforementioned skin portion is composed of a main skin portion that covers the first component and the second component, The divided portion is a plate-like or sheet-like extension member that extends from the main surface portion toward the lower surface opposite to the upper surface while in contact with the main surface portion. A vehicle seat cushion according to claim 1.

4. The second component is provided with a first inclined surface portion on the side of the first component, wherein the upper end of the upper surface is located in front of the lower end of the lower surface. The second component side of the first component is provided with a second inclined surface portion that is aligned with the first inclined surface portion. A vehicle seat cushion according to claim 2 or claim 3.

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