Cushion body

Abstract

A cushion body (2) for elastically supporting a seated person is configured to be divided into three divided elements which are: a top plate main part (4) that forms the central portion in the seat width direction; and top plate side parts that form both side portions in the seat width direction. The top plate main part (4) has: a base material (4B) that serves as a support base that is joined to a cushion frame (3) from the obverse side of a seat; and a seat cover that directly or indirectly covers the base material (4B) from the obverse side of the seat. The base material (4B) has: a pair of frame side parts (B1) that extend along the inside of respective lower arms (3A) of the cushion frame (3); and a pair of bellows parts (B4) that form portions of the respective frame side parts (B1) into a stretchable undulated shape.

Description

Cushion body

[0001] The present disclosure relates to a cushion body, and more particularly to a cushion body that elastically supports a seated person.

[0002] Japanese Patent Application Laid-Open Publication No. 2024-59200 discloses a seat in which a cushion body consisting of a seat pad and a seat cover that encases the seat pad is divided into three sections in the seat width direction. Specifically, the cushion body is divided into a main top panel that forms the center section in the seat width direction and each of the side top panels that form both side sections in the seat width direction.

[0003] The main and side table tops have seat covers that encase the individual seat pads, and the ends of the seat covers are fastened to a resin base material laid on the back surface of the pads. As a result, the main and side table tops have a configuration in which the individual seat pads are encased between the seat covers and the base material.

[0004] In the configuration described in the above document, the base material has a shape that extends with a substantially constant cross section. Therefore, when a seating load is applied to the cushion body, stress tends to concentrate in a portion of the base material. Therefore, there has been a need for a cushion body that can appropriately distribute the seating load.

[0005] As a means for solving the above problems, the cushion body of the present disclosure takes the following measures.

[0006] One aspect of the present disclosure is a cushion body that elastically supports a seated occupant, the cushion body including three divided elements: a main top plate that forms a central portion in the seat width direction, and side top plate portions that form both side portions in the seat width direction. The main top plate includes a base material that serves as a support base and is attached to a seat frame from the front side of the seat, and a seat cover that directly or indirectly covers the base material from the front side of the seat. The base material includes a pair of frame side portions that extend along the inside of each frame side portion of the seat frame, and a pair of bellows portions that give a portion of the pair of frame side portions an expandable and contractible corrugated shape.

[0007] Therefore, the pair of frame side portions of the base material can be flexed so as to stretch or bend the bellows portion in response to the input of the seating load, thereby distributing the seating load appropriately without concentrating it on one part of the base material.

[0008] According to another aspect of the present disclosure, the cushion body is applied to a seat cushion, and the pair of bellows portions are formed in an area between a front panel bridging between each of the frame side portions and a front pipe bridging between each of the frame side portions on the seat rear side of the front panel.

[0009] Therefore, the pair of frame side portions of the base material can be flexibly bent by the bellows portion in the area in front of the front pipe. Also, the surface rigidity of the pair of frame side portions of the base material can be ensured in the area behind the front pipe. Therefore, the seating load can be appropriately distributed while suppressing the collapse of the support form of the cushion in the area behind the front pipe.

[0010] According to another aspect of the present disclosure, the front panel is a tilt panel that is movable to adjust the tilt angle.

[0011] Therefore, the base material can be bent so as to appropriately follow the tilting movement of the seat frame.

[0012] According to another aspect of the present disclosure, in any one of the first to third inventions, a pair of the bellows portions are formed at a position retracted inward from the outer edges of a corresponding pair of the frame side portions, and the wavy fold lines are oriented to extend in the seat width direction.

[0013] Therefore, it is possible to configure the pair of bellows portions so that they are less likely to interfere with peripheral components arranged outside the corresponding pair of frame side portions.

[0014] Fig. 4 is a perspective view showing a schematic configuration of a cushion body according to a first embodiment; Fig. 5 is an exploded perspective view showing the cushion body removed from a cushion frame; Fig. 6 is an exploded perspective view showing a seat pad of a main top plate removed from a base material; Fig. 7 is a perspective view showing a state in which the base material is assembled to a cushion frame; Fig. 8 is a plan view of Fig. 4; Fig. 9 is an enlarged view of part VI of Fig. 4;

[0015] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings.

[0016] First Embodiment The configuration of a cushion body 2 according to a first embodiment will be described with reference to Figures 1 to 6. In the following description, when referring to front, back, up, down, left, and right directions, these refer to the directions shown in the respective figures.

[0017] Furthermore, when a direction is indicated with the word "seat," it refers to a direction based on the seat cushion 1 described below. In the following description, when a specific reference drawing is not shown or when there is no reference symbol corresponding to the reference drawing, any of Figures 1 to 6 will be referred to as appropriate.

[0018] As shown in Fig. 1, a cushion body 2 according to this embodiment is applied to a seat cushion 1 that forms the seating portion of an automobile seat. As shown in Fig. 2, the seat cushion 1 includes the cushion body 2 that elastically supports the buttocks of a seated occupant, and a cushion frame 3 that supports the cushion body 2 from the back side (underside) of the seat.

[0019] The cushion body 2 is divided into three separate elements: a main top plate 4 that forms the center portion in the seat width direction, and left and right side top plate portions 5 that form both side portions in the seat width direction. The cushion frame 3 is made of metal members assembled into a frame shape in a plan view. Here, the cushion frame 3 corresponds to the "seat frame" in this disclosure.

[0020] Specifically, the cushion frame 3 has a pair of left and right lower arms 3A that form a framework along the left and right sides of the seat cushion 1. The cushion frame 3 has a front pipe 3B that is integrally bridging between the front portions of the lower arms 3A. The cushion frame 3 has a rear pipe 3C that is integrally bridging between the rear portions of the lower arms 3A. Here, each lower arm 3A corresponds to a "frame side" in this disclosure.

[0021] The cushion frame 3 has a tilt panel 3D that forms a framework along the front portion of the seat cushion 1. The cushion frame 3 has a pair of left and right tilt arms 3E that extend from the left and right sides of the tilt panel 3D toward the rear of the seat and are rotatably connected to the corresponding lower arms 3A. Here, the tilt panel 3D corresponds to the "front panel" in this disclosure.

[0022] The rear end of each tilt arm 3E is connected to the corresponding lower arm 3A so as to be rotatable about an axis (rotation center 3R) extending in the seat width direction. Each tilt arm 3E rotates about the rotation center 3R by a rotational driving force transmitted from a drive unit (not shown). This adjusts the inclination angle (tilt angle) of the tilt panel 3D relative to each lower arm 3A.

[0023] As described above, the cushion body 2 is divided into the main top plate 4 and each side top plate 5, so that parts can be replaced according to the specifications of each divided element. The main top plate 4 and each side top plate 5 are individually assembled to the cushion frame 3 after their respective components are assembled into one divided element.

[0024] Specifically, each of the top side panels 5 is integrally fixed to the cushion frame 3 by fitting with clips (not shown) or fastening with bolts. After each of the top side panels 5 is assembled to the cushion frame 3, the main top panel 4 is snap-fitted between them from above the seat.

[0025] The main top plate 4 and each side top plate 5 have a common basic structure. The main top plate 4 and each side top plate 5 are configured to be flexible so as to appropriately follow the tilting operation that adjusts the tilt angle of the cushion frame 3. The configuration of each divided element of the cushion body 2 will be described in detail below, taking the configuration of the main top plate 4 as an example.

[0026] 3, the main table top 4 has a urethane foam seat pad 4A and a resin base material 4B laid on the back surface of the seat pad 4A. The main table top 4 also has a fabric seat cover 4C that covers the front surface of the seat pad 4A. The peripheral edge of the seat cover 4C is pulled into and fastened to the back surface of the base material 4B.

[0027] As a result, the seat cover 4C is integrated with the base material 4B so as to enclose the seat pad 4A between the base material 4B and the seat cover 4C. As a result, the main top plate 4 is assembled into one module.

[0028] 4 and 5, the base material 4B of the top panel main 4 is formed in a frame shape in a plan view that extends along the frame shape of the cushion frame 3. Specifically, the base material 4B has a pair of left and right frame side portions B1 that extend in the front-to-rear direction of the seat along the inner regions of the lower arms 3A.

[0029] The base material 4B also has a frame front portion B2 that extends in the seat width direction along the upper surface of the tilt panel 3D. The frame front portion B2 is bent downward toward the front so as to overlap the upper surface and front face of the tilt panel 3D.

[0030] The base material 4B also has a frame rear portion B3 that extends in the seat width direction along the upper surface of the rear pipe 3C. The frame rear portion B3 is bent downward toward the rear so as to cover the area from the upper surface to the rear surface of the rear pipe 3C.

[0031] The base material 4B is assembled to the cushion frame 3 as follows: First, the rear frame portion B3 of the base material 4B is set so as to cover the upper portion of the rear pipe 3C. Next, the front frame portion B2 of the base material 4B is set so as to cover the upper portion of the tilt panel 3D. Then, at the same time, a claw (not shown) formed on the lower edge of the front frame portion B2 is snap-fitted to the underside of the front edge of the tilt panel 3D.

[0032] 1, the rear portion of the main top panel 4 is positioned below the seat back (not shown) and supported by the rear pipe 3C. Also, the front portion of the main top panel 4 is integrally joined to the tilt panel 3D.

[0033] 4 and 5, a wave-shaped bellows portion B4 that enables expansion and contraction in the seat front-rear direction is formed in the middle of each frame side portion B1 of the base material 4B in the seat front-rear direction. As shown in Fig. 5, each bellows portion B4 is formed in the area between the tilt panel 3D and the front pipe 3B located behind it in a plan view.

[0034] 6, each bellows portion B4 is formed at a position retracted inward in the seat width direction from the outer edge of the corresponding frame side portion B1, thereby making it unlikely for each bellows portion B4 to interfere with peripheral components (not shown) arranged outside each frame side portion B1.

[0035] Each bellows portion B4 has a bellows shape in which the wavy fold lines extend in the width direction of the seat. Also, each bellows portion B4 has a shape that tapers upward in the seat due to a draft angle set during resin molding of the base material 4B.

[0036] 4 and 5, because the bellows portions B4 are formed on each frame side portion B1, the base material 4B is able to flex so as to appropriately follow the tilting movement of the cushion frame 3. Specifically, the base material 4B flexes in a manner that stretches and bends each bellows portion B4 in accordance with the movement of the tilt panel 3D being pulled up around the rotation center 3R.

[0037] Furthermore, as the tilt panel 3D is lowered from the raised position, the base material 4B is restored so that the extension and bending of each bellows portion B4 is returned to its original shape. By being able to bend in this manner, the base material 4B can appropriately follow the tilting movement of the cushion frame 3 without interfering with the tilting movement.

[0038] The base material 4B is elastically supported from the back side (underside) of the seat by a cushion spring (not shown) that is stretched between the front pipe 3B and the rear pipe 3C. With respect to the base material 4B, each bellows portion B4 is formed in an area forward of the front pipe 3B, so that each bellows portion B4 can be deflected in an area forward of the front pipe 3B.

[0039] This ensures the surface rigidity of each frame side portion B1 of the base material 4B in the region rearward of the front pipe 3B, thereby preventing the support form of the base material 4B from being lost due to the cushion spring (not shown).

[0040] That is, if each bellows portion B4 were formed in a region of each frame side portion B1 that was rearward of the front pipe 3B, there would be a risk that the bellows portion B4 would bend too much due to the bending caused by the input of seating load, causing a difference in circumferential length between the frame side portion B1 and the cushion spring (not shown). However, by forming each bellows portion B4 in a region that is forward of the front pipe 3B, it is possible to bend each frame side portion B1 together with the cushion spring without causing a large difference in circumferential length between them.

[0041] Because the base material 4B has the bellows portions B4 formed thereon, the base material 4B can bend while stretching the bellows portions B4 even when a seating load is applied, thereby distributing the seating load appropriately without concentrating it on a part of the base material 4B.

[0042] To summarize the above, the cushion body 2 according to this embodiment has the following configuration: Note that the reference numerals in parentheses below correspond to the respective components shown in the above embodiment.

[0043] That is, the cushion body (2) that elastically supports the seat occupant is configured to be divided into three divided elements: a main top plate (4) that forms the center portion in the seat width direction, and each side top plate (5) that forms both side portions in the seat width direction. The main top plate (4) has a base material (4B) that serves as a support base that is assembled to the seat frame (3) from the seat surface side, and a seat cover (4C) that directly or indirectly covers the base material (4B) from the seat surface side.

[0044] The base material (4B) has a pair of frame side portions (B1) extending along the inside of each frame side portion (3A) of the seat frame (3), and a pair of bellows portions (B4) that form a portion of the pair of frame side portions (B1) into an expandable and contractible wave-like shape. According to the above configuration, the pair of frame side portions (B1) of the base material (4B) can bend so as to stretch or bend the bellows portions (B4) in response to the input of a seating load. This allows the seating load to be appropriately distributed without concentrating on a portion of the base material (4B).

[0045] The cushion body (2) is applied to the seat cushion (1). A pair of bellows portions (B4) are formed in a region between a front panel (3D) bridging between the frame side portions (3A) and a front pipe (3B) bridging between the frame side portions (3A) on the seat rear side of the front panel (3D).

[0046] According to the above-described configuration, the pair of frame side portions (B1) of the base material (4B) can be flexibly bent by the bellows portion (B4) in the region in front of the seat from the front pipe (3B). Furthermore, the surface rigidity of the pair of frame side portions (B1) of the base material (4B) can be ensured in the region behind the seat from the front pipe (3B). Therefore, the seating load can be appropriately distributed while suppressing the collapse of the support form of the cushion body (2) in the region behind the seat from the front pipe (3B).

[0047] In addition, the front panel (3D) is a tilt panel (3D) that is moved to adjust the tilt angle. According to the above configuration, the base material (4B) can be deflected so as to appropriately follow the tilt movement of the seat frame (3).

[0048] In addition, the pair of bellows portions (B4) are formed at positions retracted inward from the outer edges of the corresponding pair of frame side portions (B1). Moreover, the pair of bellows portions (B4) are oriented such that the wavy folding lines extend in the seat width direction. According to the above configuration, the pair of bellows portions (B4) can be configured to be less likely to interfere with peripheral components arranged outside the corresponding pair of frame side portions (B1).

[0049] Other Embodiments Although one embodiment of the present disclosure has been described above, the present disclosure can be embodied in various forms in addition to the above embodiment.

[0050] The cushion body of the present disclosure can also be applied to seats in vehicles other than automobiles, such as trains, airplanes, ships, etc. In addition to vehicles, the cushion body can also be applied to non-vehicle seats installed in various facilities, such as sports facilities, theaters, concert venues, and event venues.

[0051] The cushion body can also be applied to seat structures other than seat cushions, such as seat backs, headrests, ottomans, and armrests. The cushion body may not include a seat pad, and the base material may be directly covered with a seat cover. The cushion body may also be configured such that a thin sub-skin cushion made of elastomer or urethane is provided on the surface of the base material instead of the seat pad.

[0052] The cushion body may be applied to a seat cushion that does not have a mechanism for adjusting the tilt angle. Even in such a configuration, by forming bellows portions on each frame side of the base material, each frame side can bend while stretching the bellows portions in response to the input of seating load. This allows the seating load to be appropriately distributed without concentrating on one part of the base material.

[0053] When the cushion body is applied to a seat back with an adjustable folding angle, the formation of bellows portions on each frame side of the base material allows the base material to bend so as to appropriately follow the folding movement. When the cushion body is applied to a seat cushion, the bellows portions formed on each frame side of the base material may be formed in an area behind the seat from the front pipe.

Claims

1. A cushion body that elastically supports a seated occupant, the cushion body comprising three divided elements: a main top plate that forms the central portion in the seat width direction, and each side top plate that forms both side portions in the seat width direction; the main top plate having a base material that serves as a support base attached to the seat frame from the front side of the seat, and a seat cover that covers the base material directly or indirectly from the front side of the seat; and the base material having a pair of frame side portions that extend along the inside of each frame side portion of the seat frame, and a pair of bellows portions that make part of the pair of frame side portions into an expandable and contractible wave-shaped form.

2. A cushion body as claimed in claim 1, wherein the cushion body is applied to a seat cushion, and the pair of bellows portions are formed in the region between a front panel bridging between the frame side portions and a front pipe bridging between the frame side portions on the seat rear side of the front panel.

3. The cushion body according to claim 2, wherein the front panel is a tilt panel that can be moved to adjust the tilt angle.

4. A cushion body as set forth in any one of claims 1 to 3, wherein a pair of the bellows portions are formed at positions retracted inward from the outer edges of a corresponding pair of the frame side portions, and the wavy fold lines are oriented to extend in the seat width direction.

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