Vehicle seat and method for producing vehicle seat

Abstract

The present invention provides a vehicle seat in which an air flow generation device is disposed inside a seat back but which suppresses application of an excess load of a seated person to the air flow generation device, thereby preventing a deterioration in the performance of the air flow generation device.　A vehicle seat (S) comprises a headrest (3), and a seat back (2) that supports the headrest (3). The headrest (3) is attached to the seat back (2) so as to protrude forward of a seat surface (S1) of the seat back (2) at an upper end part of the seat back (2). The seat back (2) has a blower device (100) that generates an air flow below the headrest (3). A lower end part of the headrest (3) overlaps with the blower device (100) in a front view.

Description

Vehicle seat and method for manufacturing the vehicle seat

[0001] The present invention relates to a vehicle seat and a method for manufacturing the vehicle seat, and more particularly to a vehicle seat provided with an air flow generating device and a method for manufacturing the vehicle seat.

[0002] Conventionally, a vehicle seat has been proposed that includes a blower and an air outlet that blows the air blown by the blower toward a seated occupant. Specifically, the blower is provided inside a seat cushion (sitting portion) or a seat back (backrest portion) that supports the weight of an occupant, and multiple air outlets that blow air toward the occupant's buttocks or back are formed in the seat cushion and the seat back, and ventilation paths through which air passes between the blower and the air outlets are formed in the seat cushion and the seat back. This allows the occupant seated in the vehicle seat to spend the travel time until they reach their destination comfortably while receiving the blower.

[0003] Patent Literature 1 discloses a vehicle seat in which a blower is positioned above the vertical center of the seat back. A typical seat back is configured to deflect backward to support the weight of the seat occupant when they lean against it. Therefore, by positioning the blower above the vertical center of the seat back, it is possible to prevent the rotation of the blower from being hindered by the weight of the seat occupant when they lean against the seat back.

[0004] JP 2009-291310 A

[0005] The technology described in Patent Document 1 has the effect of suppressing the performance degradation of the air blower caused by the weight of the seated passenger being applied to the air blower. However, in recent years, as seat backs have become lighter and thinner, there has been a demand for further suppression of the load applied to the air blower in order to suppress the performance degradation of the air blower disposed inside the seat back.

[0006] The present invention has been made in consideration of the above-mentioned problems, and its purpose is to provide a vehicle seat that can position an air flow generating device inside the seat back while preventing the seated person from applying excessive load to the air flow generating device, thereby preventing a decrease in the performance of the air flow generating device.

[0007] The above problem is solved by the vehicle seat of the present invention, which is a vehicle seat including a headrest and a seat back that supports the headrest, wherein the headrest is attached to the seat back at an upper end thereof so as to protrude forward from the seating surface of the seat back, and the seat back has an air flow generating device that generates an air flow below the headrest, and the lower end of the headrest overlaps the air flow generating device in a front view.

[0008] According to the above configuration, the headrest is attached to the seat back so as to protrude forward from the seating surface of the seat back and is positioned so as to overlap the airflow generating device in a front view. As a result, the padding of the seat back and the padding of the headrest are located on the seating surface side of the airflow generating device. Therefore, the two paddings can reduce the load of the seated occupant applied to the airflow generating device. Furthermore, because the headrest protrudes forward from the seating surface of the seat back, the weight of the occupant when seated in the vehicle seat can be distributed and supported by the headrest and the seat back. This reduces the load on the seat back relatively, preventing excessive load from being applied by the occupant to the airflow generating device located inside the seat back, thereby preventing a decrease in the performance of the airflow generating device.

[0009] Furthermore, the airflow generating device may have a plurality of rotating blades that rotate around a rotation axis extending in the front-rear direction, and the lower end of the headrest may overlap at least one of the plurality of rotating blades in a front view. According to the above configuration, the headrest is positioned so as to overlap the rotating blades of the airflow generating device in a front view. As a result, the weight of the seated occupant is distributed and supported by the headrest and the seat back, and the rotating blades of the airflow generating device are covered by the headrest. This prevents the occupant from applying excessive weight to the airflow generating device located inside the seat back, and also prevents the rotating blades, which are relatively weak among the components of the airflow generating device, from being damaged by the occupant's weight.

[0010] Furthermore, the lower end of the headrest may be positioned above the rotation axis. According to the above configuration, the lower end of the headrest is positioned above the rotation axis of the airflow generating device. This prevents the rotation axis of the airflow generating device from being covered by the headrest. This prevents the seat occupant from applying excessive load to the airflow generating device located inside the seat back, and also prevents the headrest from covering the front of the airflow generating device, which could lead to a decrease in performance of the airflow generating device.

[0011] Furthermore, the headrest may include a headrest frame that forms the framework of the headrest, a padding that covers the front of the headrest frame, and a cover member that covers the rear of the headrest frame, and the lower end of the headrest frame may be positioned higher than the airflow generating device. With the above configuration, the highly rigid headrest frame covers the front of the airflow generating device, making it possible to prevent a decrease in performance of the airflow generating device due to the load of the seated person's head being applied to the airflow generating device via the headrest frame.

[0012] Furthermore, the lower end of the cover member may be positioned above the airflow generating device. According to the above configuration, the lower end of the cover member that covers the headrest from behind is positioned above the upper end of the airflow generating device. As a result, even if the cover member is made of synthetic resin and is not breathable, the lower end of the cover member is positioned above the upper end of the airflow generating device, making it possible to prevent the cover member from causing a decrease in performance of the airflow generating device.

[0013] The seat back may have a bracket that protrudes forward from the seating surface, and the headrest may be attached to the front surface of the bracket via the headrest frame. According to the above configuration, the headrest frame, which forms the framework of the headrest, is positioned forward of the seating surface of the seat back, allowing the entire headrest to protrude significantly forward of the seating surface. This effectively distributes and supports the weight of the occupant between the headrest and the seat back, thereby reducing the load on the seat back relatively. Furthermore, this prevents the occupant from applying excessive weight to an airflow generating device disposed inside the seat back, thereby preventing a decrease in the performance of the airflow generating device.

[0014] Furthermore, the airflow generating device may be fixed to the seat back by a fixing member that fixes the airflow generating device to the seat back, and a lower end of the headrest may overlap the fixing member in a front view. According to the above configuration, the fixing member that fixes the airflow generating device to the seat back is covered from the front by the headrest. Therefore, even if the fixing member protrudes forward from the airflow generating device, it is possible to prevent an occupant from feeling a foreign body sensation when seated.

[0015] Furthermore, the airflow generating device may have a connector that allows a connection cable electrically connected to the airflow generating device to be inserted or removed, and the lower end of the headrest may be positioned above the connector. With this configuration, the connector is not covered from the front by the headrest. This prevents the headrest from covering the front of the connector, thereby preventing a decrease in workability during inspection of the airflow generating device, which involves inserting or removing the connection cable.

[0016] Furthermore, the above-mentioned problem is solved by a method for manufacturing a vehicle seat of the present invention, which is a method for manufacturing a vehicle seat including a headrest and a seat back that supports the headrest, comprising: attaching an air flow generating device that generates an air flow to the seat back; and attaching the headrest to an upper end of the seat back so that it protrudes forward from the seating surface of the seat back; and wherein, when the headrest is attached to the seat back, the lower end of the headrest overlaps with the air flow generating device in a front view.

[0017] According to the above configuration, the headrest is attached to the seat back so as to protrude forward from the seating surface of the seat back and is positioned so as to overlap the airflow generating device in a front view. As a result, the padding of the seat back and the padding of the headrest are located on the seating surface side of the airflow generating device. Therefore, the two paddings can reduce the load of the seated occupant applied to the airflow generating device. Furthermore, because the headrest protrudes forward from the seating surface of the seat back, the weight of the occupant when seated in the vehicle seat can be distributed and supported by the headrest and the seat back. This reduces the load on the seat back relatively, preventing excessive load from being applied by the occupant to the airflow generating device located inside the seat back, thereby preventing a decrease in the performance of the airflow generating device.

[0018] According to the present invention, while arranging an airflow generating device inside a seat back, it is possible to prevent excessive load from being applied to the airflow generating device by a seat occupant, thereby preventing a deterioration in performance of the airflow generating device. Furthermore, it is possible to prevent the rotor blades, which have a relatively low strength among the components of the airflow generating device, from being damaged by the load of the seat occupant. Furthermore, it is possible to prevent a deterioration in performance of the airflow generating device due to the headrest covering the front of the airflow generating device. Furthermore, it is possible to prevent a deterioration in performance of the airflow generating device due to the load of the seat occupant's head being applied to the airflow generating device via the headrest frame. Furthermore, it is possible to prevent a deterioration in performance of the airflow generating device due to the cover member. Furthermore, even if the fixing member protrudes forward of the airflow generating device, it is possible to prevent a foreign body sensation felt by the occupant when seated. Furthermore, it is possible to prevent a deterioration in operability when inserting and removing a connection cable due to the headrest covering the front of the connector.

[0019] 12. A perspective view of a vehicle seat according to this embodiment, as seen from an obliquely front side. A perspective view of a vehicle seat, as seen from an obliquely rear side. An exploded perspective view of a seat cushion, as seen from an obliquely front side. An exploded perspective view of a seat back, as seen from an obliquely front side. An exploded perspective view of a seat back module, as seen from an obliquely front side. An exploded perspective view of a headrest, as seen from an obliquely front side. A perspective view of a seat back module, as seen from an obliquely rear side. A front view of a first back cover to which a blower device is attached. An enlarged view of a main portion of the first back cover to which a blower device is attached. A diagram for explaining a load applied to the blower device. A side cross-sectional view of a seat back. A rear view of a seat back module according to a second embodiment, as seen from the rear side. A partially enlarged perspective view of the periphery of a back side frame, as seen from an enlarged view. A cross-sectional view taken along line XIV-XIV in FIG. 12, mainly showing a connecting piece. A side view of a back side frame to which a seat back module is assembled. A perspective view showing an enlarged view of a portion of the seat back module. A flow diagram showing a manufacturing method of a vehicle seat.

[0020] An embodiment of the present invention will be described below with reference to Figures 1 to 11. In a vehicle seat S of this embodiment, a headrest 3 is attached to the upper end of a seat back 2 so as to protrude forward (toward the occupant) from a seating surface 2d of the seat back 2. In this case, the lower end of the headrest 3 is positioned so as to overlap with a blower device 100 in a front view. This prevents excessive load from being applied by the occupant to the blower device 100, thereby preventing a deterioration in the performance of the blower device 100.

[0021] The configuration of a vehicle seat S according to one embodiment of the present invention will be described below with reference to the drawings. However, the embodiment described below is intended to facilitate understanding of the present invention and is not intended to limit the present invention. In other words, the present invention may be modified or improved without departing from the spirit thereof, and the present invention naturally includes equivalents thereof. Furthermore, in the following description, descriptions regarding the materials, shapes, and sizes of seat components are merely examples and are not intended to limit the present invention.

[0022] In the following description, the term "seat front-rear direction" refers to the front-rear direction of the vehicle seat S, and is the direction that coincides with the front-rear direction as seen by an occupant seated in the vehicle seat S. The term "seat width direction" refers to the width direction of the vehicle seat S, and is the direction that coincides with the left-right direction as seen by an occupant seated in the vehicle seat S. The term "up-down direction" refers to the up-down direction of the vehicle seat S, and is the direction that coincides with the vertical direction when the vehicle is traveling on a horizontal plane. The term "outside" simply refers to the side closer to the outside in the direction from the center of the vehicle seat S to the outside, and the term "inside" refers to the side closer to the center in the direction from the outside to the center of the vehicle seat S.

[0023] <Overall Configuration of Vehicle Seat S> Fig. 1 is a perspective view of a vehicle seat S seen obliquely from the front, and Fig. 2 is a perspective view of the vehicle seat S seen obliquely from the rear. As shown in Figs. 1 and 2, the vehicle seat S according to this embodiment mainly comprises a seat cushion 1, a seat back 2, a headrest 3, a rail device 4, and a reclining device 5.

[0024] <<Seat Cushion 1>> The seat cushion 1 is a support member that supports the buttocks of a seated occupant and supports the seated occupant from below. The seat cushion 1 mainly includes a seat cushion frame 10 (see FIG. 3 ) that forms the skeleton of the seat cushion 1, and a seat cushion module 1M that is replaceably attached to the seat cushion frame 10.

[0025] The seat cushion frame 10 is a frame body having a rectangular shape in a top view. The seat cushion frame 10 includes left and right side frames 11, a pan frame 12 connecting the front ends of the left and right side frames 11, and a rear connecting frame 13 connecting the rear ends of the left and right side frames 11. The seat cushion frame 10 also includes a support plate 15 connected to the rear connecting frame 13 via elastic springs 14 and supported by the left and right side frames 11. The support plate 15 is a flexible pressure-receiving member that receives the load of a seat occupant applied via a seat cushion module 1M (described later). Cushion module assembly portions 16 are provided on both sides in the seat width direction in front of the pan frame 12. The cushion module assembly portions 16 can be connected to assembly portions 24 formed on a cushion base cover 20 of the seat cushion module 1M (described later). This allows the seat cushion module 1M to be replaceably assembled to the seat cushion frame 10. The seat cushion frame 10 constitutes a seat frame F together with a seat back frame 30 and a headrest frame 70, which will be described later.

[0026] The seat cushion module 1M mainly comprises a cushion base cover 20, a first pad material 1a, a second pad material 1b, and a cover material 1c (see FIG. 1). The seat cushion module 1M is attached to a seat cushion frame 10 to function as a seat portion of the vehicle seat S. Furthermore, the seat cushion module 1M can be removed and replaced, making it easy to change the design and functionality of the vehicle seat S, and enabling the vehicle seat S to be configured to be optimal for each seated occupant.

[0027] The cushion base cover 20 has a rectangular shape in top view and includes left and right cover side portions 21, a cover front portion 22, and a cover rear portion 23. The cover front portion 22 is provided with an assembly portion 24 for fixing the cushion base cover 20 to the pan frame 12, and the cover rear portion 23 is provided with a frame detachment portion 25 that detachably engages with the rear connecting frame 13. Therefore, the cushion base cover 20 can be attached to the seat cushion frame 10 by engaging the frame detachment portion 25 with the rear connecting frame 13 and assembling the assembly portion 24 to the pan frame 12.

[0028] A control device 90 that controls the vehicle seat S is attached via a bracket 91 below the cushion base cover 20. The control device 90 is an ECU (Electronic Control Unit) that acquires output signals from detection sensors (such as temperature sensors) built into the vehicle, and controls a blower device 100 and a seat heater 110 (described later) based on the output signals to improve the comfort of an occupant sitting in the vehicle seat S.

[0029] The first padding 1a and the second padding 1b are cushioning materials that are placed on the cushion base cover 20 and cover the cushion base cover 20. The first padding 1a and the second padding 1b are foamed resin molded bodies with different properties (breathability and flexibility). By stacking multiple foamed resin molded bodies with different properties in this way, it is possible to reduce manufacturing costs while improving seating comfort and comfort. The cover material 1c is made of a stretchable synthetic leather material and covers the first padding 1a and the second padding 1b.

[0030] <<Seat Back 2>> The seat back 2 is a support member that supports the back of a seated occupant and supports the seated occupant from behind. The seat back 2 has a seat back frame 30 (see FIG. 4 ) that forms a skeleton, a seat back module 2M that is replaceably attached to the seat back frame 30 from the front, and a second back cover 50 that covers the seat back 2 from the rear.

[0031] The seatback frame 30 is a frame body having a generally rectangular shape in a front view. The seatback frame 30 includes left and right backside frames 31, an upper frame 32 connecting the upper ends of the left and right backside frames 31, and a lower frame 33 connecting the lower ends of the left and right backside frames 31.

[0032] The backside frames 31 are elongated frame members extending vertically and arranged spaced apart from each other in the seat width direction. Each backside frame 31 is an angled bar formed by bending a plate vertically, and the front edge is bent outward to improve the strength of the backside frame 31. A reclining body 5a, a back rotation shaft 5b, and a spiral spring 5c ​​(see FIG. 1) of the reclining device 5 (described later) are attached to the lower end of the backside frame 31.

[0033] The upper frame 32 is a frame having a generally inverted U shape and connects the upper ends of the left and right back side frames 31. The upper frame 32 is made of round pipe material. The upper frame 32 is provided with four module assembly portions 34 arranged at generally equal intervals from one another. The module assembly portions 34 protrude outward from the upper frame 32 and are assembled to a cover assembly portion 45 (see FIG. 7 ) provided on the first back cover 40 (described later) and an assembly portion 55 provided on the second back cover 50 by being connected and fixed thereto.

[0034] The lower frame 33 is a long frame member extending laterally and connecting the lower ends of the left and right back side frames 31. The lower frame 33 has a recess formed by bending a plate-like body so as to be recessed downward. The back rotation shaft 5b of the reclining device 5, which will be described later, is housed inside the recess.

[0035] FIG. 5 shows an exploded perspective view of the seatback module 2M. As shown in FIG. 5, the seatback module 2M mainly comprises a first back cover 40, first and second padding materials 2a and 2b, a seat heater 110, and an upholstery material 2c (see FIG. 1). The seatback module 2M is attached to the seatback frame 30 to function as the backrest of the vehicle seat S. The seatback module 2M can be easily removed and replaced to easily change the design and functionality of the vehicle seat S, enabling the vehicle seat S to be optimized for each occupant. In recent years, technology for thinning the seatback 2 has been attracting attention in order to reduce the weight of the seatback 2. The seatback module 2M of this embodiment incorporates a blower device 100, which improves the comfort of the occupant seated in the seatback 2 while achieving a thinner seat back compared to conventional seatbacks. The blower device 100 will be described later.

[0036] The first back cover 40 is a cover member that supports the electrical components housed in the seat back module 2M and protects the electrical components by covering the seat back module 2M from the rear. Specifically, the seat back module 2M supports a blower device 100 (described later), an electric motor 108 (see FIG. 7 ), and a seat heater 110. The first back cover 40 has a synthetic resin cover main body 40a and a first opening 44 formed in the approximate center of the cover main body 40a. The cover main body 40a has an outer dimension slightly larger than the seat back frame 30, and is provided on its rear side with a rear reinforcing rib 40b that improves the strength of the cover main body 40a and a cover assembly portion 45 that is fixed to the module assembly portion 34 of the seat back frame 30.

[0037] The first opening 44 is formed in a position facing a pressure-receiving plate 60 attached to the front side of the first back cover 40. Therefore, when the weight of a seated occupant is applied to the pressure-receiving plate 60, the pressure-receiving plate 60 can deform rearward in accordance with the posture of the seated occupant's back and waist. The cover main body 40a has left and right cover side portions 41 on the outer sides of the first opening 44 in the seat width direction, an upper cover portion 42 above, and a lower cover portion 43 below.

[0038] The left and right cover side portions 41 extend in the vertical direction and are recessed rearward on the inside. The left and right cover side portions 41 are connected to the plate mounting portion 61 of the pressure plate 60 to support the left and right side edges of the pressure plate 60. An electric motor 108 is attached to and supported on the back side of the cover side portion 41 located on the right side when viewed from the front.

[0039] As shown in Fig. 5, the cover upper portion 42 has a generally triangular shape that protrudes upward, and its ends in the seat width direction connect the upper ends of the left and right cover side portions 41. A bracket 46 to which the headrest 3 is attached is fixed to the upper end of the cover upper portion 42. As will be described later with reference to Fig. 11, the bracket 46 protrudes forward from the cover upper portion 42, and the headrest 3 can be fixed to the upper end of the seat back 2 so that it protrudes forward (toward the occupant) from the seating surface 2d.

[0040] A blower device 100 is attached below the bracket 46. The blower device 100 generates an airflow that draws air in from the front of the seat back 2 and blows the air downward at the rear (back side). As will be described later, the front of the blower device 100 is covered by the first padding 2a and the second padding 2b of the seat back 2 and the padding 3a of the headrest 3. This prevents the weight of the seated occupant from being applied to the blower device 100 while the blower device 100 is built into the seat back 2. Details of the weight of the seated occupant applied to the headrest 3 and the blower device 100 will be described later. The blower device 100 corresponds to an airflow generating device.

[0041] The cover lower portion 43 extends in the seat width direction and connects the lower ends of the left and right cover side portions 41 at both ends in the seat width direction. The cover lower portion 43 supports the lower end of the pressure-receiving plate 60. Front reinforcing ribs 40c that improve the strength of the first back cover 40 are provided on the front sides of the cover side portions 41, the cover upper portion 42, and the cover lower portion 43.

[0042] The first pad material 2a and the second pad material 2b are cushion materials that are placed on the first back cover 40 and cover the first back cover 40. The first pad material 2a and the second pad material 2b are foamed resin molded bodies that have different properties (breathability and flexibility). The first pad material 2a is formed with a blower covering portion 2aa that faces the blower device 100, and a space that can supply air to an area facing an intake port 102 of the blower device 100 (described later) is provided.

[0043] The seat heater 110 is an electric heating wire heater that receives electrical energy via a heater connection cable 130 and heats the back and waist of an occupant seated in the vehicle seat S. The cover material 2c is made of a stretchable synthetic leather material and covers the first pad material 2a and the second pad material 2b.

[0044] Returning to FIG. 4 , the second back cover 50 covers the entire seat back 2 from the rear. More specifically, the seat back 2 is assembled by fastening the second back cover 50 and the seat back module 2M while sandwiching the seat back frame 30 in the front-rear direction. The second back cover 50 has a synthetic resin cover main body 50a and a second opening 54 formed in approximately the center of the cover main body 50a. The cover main body 50a protects the seat back module 2M by covering the first back cover 40 from the rear and serves to improve the strength of the seat back 2. An assembly portion 55 that is fixed to the module assembly portion 34 of the seat back frame 30 is provided on the front side of the second back cover 50.

[0045] The second opening 54 is formed at approximately the same position and with approximately the same dimensions as the first opening 44 of the first back cover 40, allowing the pressure plate 60 to deform rearward in accordance with the posture of the seat occupant's back and waist when the weight of the seat occupant is applied to the pressure plate 60. The cover main body 50a has left and right cover side portions 51 on both sides of the second opening 54 in the seat width direction, an upper cover portion 52 above, and a lower cover portion 53 below. The left and right cover side portions 51, upper cover portion 52, and lower cover portion 53 of the second back cover 50 respectively cover the left and right cover side portions 41, upper cover portion 42, and lower cover portion 43 of the first back cover 40 from behind.

[0046] <<Headrest 3>> The headrest 3 is a support member that supports the head of a seated occupant and supports the seated occupant from behind. As shown in Fig. 6 , the headrest 3 mainly comprises a headrest frame 70 that forms the skeleton of the headrest 3, a padding material 3a, a skin material 3b (see Fig. 1 ), and a headrest cover 80.

[0047] The headrest frame 70 is a plate-like body having a substantially rectangular shape in a front view, and includes a frame main body 71 and an outer edge flange 72 that is bent rearward relative to the frame main body 71 at the outer edge of the frame main body 71. A bracket assembly portion 73 is provided in the center of the frame main body 71 and is attached to a bracket 46 fixed to the seat back 2. A fastener (screw) is inserted through the bracket assembly portion 73 to fix the frame main body 71 to a front surface 46a of the bracket 46. In addition, cover assembly portions 74 are provided at the four corners (upper right, upper left, lower right, and lower left) of the frame main body 71, to which a headrest cover 80 that covers the rear of the headrest frame 70 is attached. The headrest frame 70 and the headrest cover 80 are assembled by engaging the cover assembly portion 74 with an assembly portion 84 provided on the headrest cover 80.

[0048] The headrest cover 80 covers the headrest frame 70 from behind, and forms the outer shell of the headrest 3 by being attached to the headrest frame 70. The headrest cover 80 has approximately the same outer dimensions as the headrest frame 70, and includes a cover body 81 and an outer edge flange 82 that is bent forward relative to the cover body 81 at the outer edge of the cover body 81.

[0049] An attachment opening 83 that allows the bracket 46 to pass through is formed in approximately the center of the headrest cover 80. This allows the bracket 46 and the bracket assembly portion 73 to be joined and connected, making it possible to attach the headrest 3 to the first back cover 40 of the seat back 2. In addition, assembly portions 84 that allow the headrest cover 80 and the headrest frame 70 to engage with each other are provided at the four corners (upper right, upper left, lower right, and lower left) of the headrest cover 80. The assembly portions 84 protrude forward and can engage with the cover assembly portion 74 of the headrest 3.

[0050] The padding 3a is a cushioning material that covers the front of the headrest frame 70. The padding 3a is a flexible foamed resin molding. The skin material 3b (see FIG. 1) is made of a stretchable synthetic leather material and covers the entire headrest 3.

[0051] <<Rail Device 4>> Returning to Fig. 1 , the rail device 4 connects the vehicle seat S to the floor of the vehicle so that the seat S can slide in the front-rear direction. The rail device 4 has a known structure (the structure of a general slide rail mechanism). In detail, the rail device 4 has a lower rail 4a fixed to the floor and an upper rail 4b that can slide in the front-rear direction relative to the lower rail 4a.

[0052] The rail device 4 also includes a locking member 4c that locks the upper rail 4b against sliding movement relative to the lower rail 4a. The upper rail 4b is normally locked by the locking member 4c so that it cannot slide relative to the lower rail 4a. When the occupant performs a predetermined operation, the upper rail 4b transitions to an unlocked state in which it can slide relative to the lower rail 4a. The locking member 4c has a known locking mechanism.

[0053] <<Reclining Device 5>> The reclining device 5 rotatably connects the seat back 2 to the seat cushion 1. More specifically, the seat back 2 can be displaced between an upright position in which the seat back 2 is upright, a forward-tilting position in which the seat back 2 is tilted forward, and a rearward-tilting position in which the seat back 2 is tilted backward.

[0054] The reclining device 5 has a known reclining mechanism. Specifically, the reclining device 5 has a reclining main body 5a that is driven to rotate the seat back 2, a back rotation shaft 5b, and a spiral spring 5c ​​that biases the seat back frame 30 forward around the back rotation shaft 5b.

[0055] <Blower Device 100> Next, the blower device 100 will be described in detail with reference to Figures 8 to 11. The blower device 100 includes a blower body 101, an inlet 102 formed in front of the blower body 101, and an outlet 103 formed on the lower side with an opening toward the right. In other words, by rotating the blower body 101, the blower device 100 draws air from the front (from the seating surface 2d toward the inlet 102) and generates an airflow that flows downward (from the cover upper portion 42 toward the first opening 44). This allows the blower device 100 to draw in warm air warmed by the body temperature of the seated occupant and deliver it downward from the vehicle seat S, thereby improving the comfort of the occupant sitting in the vehicle seat S.

[0056] Fig. 9 is an enlarged view of the main part of Fig. 8. The blower body 101 is a propeller fan having a rotary shaft 101a extending in the front-rear direction and a plurality of rotary blades 101b that rotate around the rotary shaft 101a. However, the blower body 101 is not limited to this, and may also be a sirocco fan.

[0057] Furthermore, the blower device 100 is electrically connected to a blower connection cable 120 that supplies electrical energy to the blower device 100 via a blower connection connector 121. Therefore, when inspecting the blower device 100, the inspection can be easily performed by pulling out the blower connection cable 120 from the blower device 100 and connecting an inspection cable.

[0058] Next, we will explain the mounting structure of the blower device 100. As described above, the blower device 100 is supported by the first back cover 40 of the seat back module 2M. More specifically, the blower device 100 is mounted to the cover upper portion 42 of the first back cover 40.

[0059] The cover upper portion 42 has a flat plate portion 42 a and a blower device accommodating recess 42 b located below the flat plate portion 42 a. The flat plate portion 42 a has an umbrella shape that protrudes upward and has a flat surface that is flat in the sheet thickness direction.

[0060] The blower device-accommodating recess 42b forms a recess recessed rearward from the flat plate portion 42a (see FIGS. 10 and 11 ), and the blower device 100 is accommodated inside the recess and fixedly supported therein. As a result, the blower device 100 is positioned rearward from the flat surface of the flat plate portion 42a. The blower device-accommodating recess 42b is also located below the bracket 46 to which the headrest 3 is attached and above the pressure-receiving plate 60. In other words, the blower device 100 is located away from the bracket 46 and the pressure-receiving plate 60, to which a large load is applied when an occupant sits in the vehicle seat S.

[0061] Additionally, an upper reinforcement rib 42c is provided behind the blower device accommodating recess 42b to improve the strength of the cover upper portion 42. The upper reinforcement rib 42c is an orthogonal rib consisting of a vertical reinforcement rib 42c1 extending vertically through the cover upper portion 42 and a horizontal reinforcement rib 42c2 extending widthwise of the seat, which intersect at right angles. The blower device 100 is fixed at the intersection where the vertical reinforcement rib 42c1 and the horizontal reinforcement rib 42c2 intersect at right angles. More specifically, the blower device 100 is fixed to the upper reinforcement rib 42c by a blower device fixing portion 104. The blower device fixing portion 104 includes a first blower device fixing portion 104a, a second blower device fixing portion 104b, and a third blower device fixing portion 104c that protrude upward, downward, and leftward from the blower device 100, and is fixed to the intersection of the upper reinforcement ribs 42c by fasteners (screws). This makes it possible to improve the strength of the cover upper portion 42 while realizing a reduction in the weight and thickness of the seat back 2, and further makes it possible to stably fix the blower device 100 to the cover upper portion 42. The blower device fixing portion 104 corresponds to a fixing member.

[0062] Next, the positional relationship between the blower device 100 and the headrest 3 and the reduction in the load of the seated occupant applied to the blower device 100 will be described. As shown in FIGS. 8 and 9 , the lower end of the headrest 3 is positioned so as to overlap the blower device 100 in a front view. This will be described in more detail below with reference to FIG. 10 . FIG. 10 is a side cross-sectional view of the seat back 2 and the headrest 3. As shown in FIG. 10 , the headrest 3 is attached to a bracket 46 of the seat back 2 at the upper end thereof so as to protrude forward (toward the occupant) from the seating surface 2d of the seat back 2. Specifically, the headrest 3 is attached to a front surface 46a of the bracket 46 via a headrest frame 70. The lower end of the headrest 3 is positioned so as to overlap the blower device 100 in a front view. In other words, the lower end of the headrest 3 is positioned lower than the upper end of the blower device 100.

[0063] Conventionally, the headrest 3 has been attached via a headrest peeler so as to extend above the seat back 2, as shown by the two-dot chain line in Figure 10. In this case, the load applied from the seat occupant's back (mainly the shoulders) is supported at the back support point Pb, and the load applied from the head is supported at the head support point Ph1. Therefore, as the seat back 2 has become thinner, if the seat occupant applies a large load toward the rear in the direction indicated by arrow A, the load may reach the blower device 100 via the first pad material 2a and the second pad material 2b, resulting in a deterioration in the performance of the blower device 100.

[0064] In contrast, in the vehicle seat S according to this embodiment, the headrest 3 is attached to the seat back 2 so as to protrude forward (toward the occupant), and the lower end of the headrest 3 is positioned so as to overlap the blower device 100 in a front view. As a result, the head support point Ph2 is displaced forward (toward the occupant) compared to the conventional head support point Ph1, and the load applied by the occupant is effectively distributed between the back support point Pb and the head support point Ph2, thereby reducing the load applied to the blower device 100 compared to conventional seat backs. Furthermore, since the front of the blower device 100 is covered by the headrest 3, the load applied to the blower device 100 can be absorbed by the first and second padding materials 2a and 2b of the seat back 2 and the padding material 3a of the headrest 3. Therefore, even if the seat back 2 is made thinner, excessive load from the occupant is prevented from being applied to the blower device 100, thereby preventing a decrease in the performance of the blower device 100.

[0065] To further explain the positional relationship between the headrest 3 and the blower device 100, the lower end of the headrest 3 is positioned so as to overlap at least one of the multiple rotary blades 101b when viewed from the front. This allows the weight of the seated occupant to be absorbed by the first pad material 2a and the second pad material 2b of the seat back 2 and the pad material 3a of the headrest 3, making it possible to prevent damage to the rotary blades 101b, which have relatively low strength among the components of the blower device 100.

[0066] Furthermore, the lower end of the headrest 3 overlaps with the first blower device fixing portion 104a in a front view (see FIG. 9 ). Therefore, even if the fastening member (screw) that fixes the first blower device fixing portion 104a protrudes forward (toward the seat occupant), the fastening member is covered by the padding material 3a of the headrest 3, which prevents the occupant from feeling a foreign body sensation when seated.

[0067] The blower device 100 also has a blower connector 121 that allows the insertion and removal of a connection cable 105 electrically connected to the blower device 100. The lower end of the headrest 3 is located above the blower connector 121. Therefore, the headrest 3 covers the front of the blower connector 121, preventing a decrease in workability when inspecting the blower device 100 by inserting and removing the blower cable 120. The blower cable 120 electrically connects the above-mentioned control device 90 and the blower device 100, and transmits a control signal output by the control device 90 to the blower device 100.

[0068] In addition, the lower end of the headrest frame 70 is positioned higher than the upper end of the blower device 100. This allows the highly rigid headrest frame 70 to cover the front of the blower device 100, preventing a decrease in performance of the blower device 100 due to the weight of the seated occupant's head being applied to the blower device 100 via the headrest frame 70. In Figure 11, the position of the lower end of the headrest frame 70 in the vertical direction is indicated by L1, and the position of the upper end of the blower device 100 is indicated by L3, with L1 being positioned higher than L3.

[0069] In addition, the lower end of the headrest cover 80, which covers the rear of the headrest 3, is located above the upper end of the blower device 100. Here, the headrest cover 80 is a molded body made of synthetic resin and is not breathable. Therefore, by locating the lower end of the headrest cover 80 above the blower device 100, it is possible to suppress a decrease in intake performance due to the headrest cover 80 covering the intake port 102 of the blower device 100, thereby preventing a decrease in performance of the blower device 100. In Figure 11, the position of the lower end of the headrest cover 80 in the vertical direction is indicated by L2, and the position of the upper end of the blower device 100 is indicated by L3, with L2 located above L3.

[0070] In addition, the lower end of the headrest 3 is located above the rotation axis 101a of the blower body 101. This prevents the headrest 3 from covering the front of the blower body 101, which would otherwise cause a deterioration in the performance of the blower device 100. In Figure 11, the position of the lower end of the headrest 3 in the up-down direction is indicated by L4.

[0071] <Method of Manufacturing Vehicle Seat> Next, a method of manufacturing the vehicle seat S will be described. First, the seat back module 2M is assembled. Specifically, electrical components including the blower device 100 and the electric motor 108 are attached to the first back cover 40. Next, the front of the first back cover 40 is covered with the first pad material 2a, the seat heater 110, and the second pad material 2b, and is then covered with the upholstery material 2c. This completes the assembly of the seat back module 2M.

[0072] Next, the headrest 3 is attached to the upper end of the seat back module 2M so as to protrude forward (toward the seat occupant) from the seating surface 2d. Specifically, the headrest 3 is attached via the headrest frame 70 to the front surface 46a of the bracket 46 that protrudes forward from the seating surface 2d of the seat back module 2M. This allows the headrest 3 to be attached to the seat back module 2M while being positioned forward (toward the seat occupant) from the seating surface 2d of the seat back module 2M.

[0073] Next, the seat back module 2M to which the headrest 3 is attached and the second back cover 50 are assembled to the seat back frame 30. Specifically, the seat back module 2M and the second back cover 50 are assembled to the module assembly portion 34 of the seat back frame 30 so as to sandwich the seat back frame 30 from the front and rear.

[0074] Similarly, the seat cushion module 1M is assembled, and then the seat cushion module 1M is attached to the seat cushion frame 10. Finally, the cables connected to the electrical components (blower connection cable 120, heater connection cable 130, etc.) are connected to the control device 90 or an on-board device. In this manner, the vehicle seat S is manufactured.

[0075] While the vehicle seat S according to one embodiment of the present invention has been described above, the above-described embodiment is merely an example for facilitating understanding of the present invention and is not intended to limit the present invention. In other words, the present invention may be modified or improved without departing from the spirit and scope of the present invention, and of course, equivalents thereof are also included in the present invention.

[0076] The vehicle seat S in the above-described embodiment has been described as having a seat cushion module 1M replaceably attached to the seat cushion frame 10, but is not limited to this. The present invention may also be applied to a vehicle seat S in which the seat cushion 1 has a seat cushion frame 10 and a cushion pad material, but does not have a replaceable seat cushion module 1M. Similarly, the vehicle seat S has been described as having a seat back module 2M replaceably attached to the seat back frame 30, but is not limited to this. The present invention may also be applied to a vehicle seat S in which the seat back 2 has a seat back frame 30 and a back pad material, but does not have a replaceable seat back module 2M.

[0077] In the above embodiment, the blower device 100 is described as drawing in air from the front and generating an airflow that flows downward behind the first back cover 40, but this is not limited to this. The blower device 100 may also draw in air from below and generate an airflow that flows forward. In addition, the blower device 100 is described as drawing in air through the suction port 102 of the blower body 101, but this is not limited to this. The first pad material 2a and the second pad material 2b may have the air suction port 102 and a ventilation duct through which the drawn air passes, and the air may be drawn in through the ventilation duct.

[0078] In the above-described embodiment, the first back cover 40 has the first opening 44, and the second back cover 50 has the second opening 54. However, the present invention is not limited to this. The entire seat back 2 may be covered with the upholstery material 2c, and the first opening 44 or the second opening 54 may be closed.

[0079] Second Embodiment Next, a second embodiment will be described. Patent document (U.S. Patent No. 10,046,682) discloses a method for assembling a seat back assembly in which a pre-assembled front seat back module and a pre-assembled rear seat back module are interconnected around a seat back frame. In this method for assembling the seat back assembly, the front seat cushion module and the pre-assembled rear seat back module are joined to the seat cushion frame, and then a headrest is joined to the upper part of the seat back assembly.

[0080] However, in the vehicle seat assembly described in the above-mentioned patent document, the headrest is attached to the seatback frame after the front seat cushion module and the rear seatback module are combined. Therefore, for example, when replacing the front seat cushion module with another module, the headrest must be removed from the seatback frame once, which reduces workability. Therefore, we provide a vehicle seat and a method for manufacturing a vehicle seat that improves workability when installing or replacing the seatback 2.

[0081] As shown in Figures 6 to 8, the headrest 3 is attached to the first back cover 40 of the seatback module 2M via a bracket 46 provided on the seatback module 2M. This makes it possible to replace the seatback module 2M without removing the headrest 3. Conventionally, the headrest 3 was attached to the seatback frame 30, but replacing the seatback module 2M required removing the headrest 3 once. By providing the headrest 3 on the seatback module 2M, it is no longer necessary to remove the headrest 3, improving the ease of replacing the seatback module 2M. In other words, the seatback module 2M can be replaced together with the headrest 3, improving the ease of replacing the seatback module 2M.

[0082] As shown in Fig. 6, the bracket 46 has a protruding portion 46c that protrudes forward from the cover upper portion 42, and is configured to fix the headrest 3 at the upper end of the seat back 2 in a state where it protrudes forward from the seating surface 2d of the seat back 2 (see Fig. 10). In addition, a front surface 46a of the bracket 46 abuts against the bracket assembly portion 73. A through hole for passing a fastener 75 is formed in the front surface 46a.

[0083] Furthermore, a bracket through-hole 46b is formed at the rear of the bracket 46 (see FIGS. 7 and 12). For example, a bolt of a fastener 75 (fastening member) inserted from the headrest side can be tightened through the bracket through-hole 46b. That is, the headrest frame 70 of the headrest 3 is fastened and fixed to the bracket 46 by the fastener 75, and the fastener 75 is disposed at a position overlapping with the bracket through-hole 46b in the front-rear direction.

[0084] By forming the bracket through-hole 46b in this manner, a fastener 75 can be inserted from the rear of the seat back module 2M to attach the headrest 3 to the seat back module 2M. The bracket through-hole 46b is configured to be covered from the rear by the second back cover 50 (rear back cover) when the seat back module 2M and the second back cover 50 are assembled, thereby making it possible to hide the fastener 75 and bracket 46 that attach the headrest.

[0085] Furthermore, the bracket through-holes 46b are provided above the seat back frame 30 (see FIG. 12). By providing the bracket through-holes 46b, the fasteners 75 can be easily seen through the bracket through-holes 46b even after the seat back module 2M is attached to the seat back frame 30.

[0086] <Cover Mounting Portion 49> The cover mounting portion 49 that mounts the seat back module 2M to the seat back frame 30 will now be described with reference to the drawings. A plurality of cover mounting portions 49 are provided on the back surface (rear surface) of the first back cover 40 that constitutes the seat back module 2M, as shown in Fig. 7. Each cover mounting portion 49 is composed of an engaging portion 49a, a connecting piece 49b, a fixing piece 49c, and a guide piece 49d.

[0087] As shown in Fig. 7, the engaging portion 49a is provided on the cover upper portion 42 and is disposed below the bracket through-hole 46b. The engaging portion 49a is formed in a hook shape so as to hook onto the horizontal frame 32a of the upper frame 32 (see Figs. 7 and 15). When attaching the seat back module 2M to the seat back frame 30, the worker first hooks the engaging portion 49a onto the horizontal frame 32a, and then rotates it downward to attach the other cover mounting portion 49 to the seat back frame 30.

[0088] As shown in Fig. 7, the connecting piece 49b is provided on the lower portion of the cover side portion 41. As shown in Fig. 14, the connecting piece 49b is an L-shaped member formed by bending a plate-like member, and is composed of an attachment portion 49ba and a base portion 49bb. The attachment portion 49ba extends rearward from the side of the base portion 49bb and is configured to be attached to the back side frame 31. The base portion 49bb is inserted into the first back cover 40.

[0089] The length L2 of the base portion 49bb is longer than the length L1 of the attachment portion 49ba. That is, the surface area of ​​the base portion 49bb is larger than the surface area of ​​the attachment portion 49ba. This allows the connecting piece 49b to be fixed to the first back cover 40 more firmly.

[0090] 13, when the seatback module 2M is attached to the seatback frame 30, the connecting pieces 49b overlap the sides of the backside frames 31, and can be fastened to fixing portions provided on the backside frames 31 with fasteners 49g. More specifically, the through-holes into which the fasteners 49g are inserted are configured to overlap with fixing portions of the backside frames 31. In this way, providing the connecting pieces 49b makes it possible to easily attach the seatback module 2M to the seatback frame 30.

[0091] 15 , when the seat back module 2M is attached to the seat back frame 30, the connecting piece 49b is preferably located below the lower end 32ba of the vertical frame 32b of the upper frame 32. By positioning the connecting piece 49b in this manner, it is possible to prevent the connecting piece 49b from interfering with the upper frame 32 when attaching the seat back module 2M to the seat back frame 30.

[0092] As shown in FIG. 7 , the fixing piece 49c and the guide piece 49d are provided on the upper portion of the cover side portion 41. The fixing piece 49c and the guide piece 49d are formed to protrude rearward from the rear surface of the first back cover 40. As shown in FIG. 16 , the fixing piece 49c fixes the vertical frame 32b from the outside via a fixing member 49f. The guide piece 49d abuts against the inside of the vertical frame 32b. The vertical frame 32b is sandwiched and fixed between the fixing piece 49c and the guide piece 49d. By providing the fixing piece 49c and the guide piece 49d in this manner, the seat back module 2M can be guided and fixed to an appropriate position when assembling the seat back module 2M to the seat back frame 30.

[0093] 7 and 16, a plurality of rear reinforcement ribs 41a (ribs) are formed on the rear surface of the cover side portion 41 of the first back cover 40. The rear reinforcement rib 41a is part of the rear reinforcement rib 40b of the cover main body 40a. The rear reinforcement rib 41a has a recess 49e formed to match the outer shape of the vertical frame 32b at the portion where it abuts against the vertical frame 32b of the upper frame 32. When the seatback module 2M is attached to the seatback frame 30, the vertical frame 32b fits into the recess 49e, thereby preventing misalignment in the seat width direction. Furthermore, when the seatback module 2M is fixed by the fixing member 49f, lateral movement of the seatback frame 30 is prevented.

[0094] <Method of Manufacturing Vehicle Seat S> A method of manufacturing the vehicle seat S, particularly the method of manufacturing the seat back 2, will be described using the flow diagram shown in Fig. 17. First, the components constituting the seat back frame 30, the seat back module 2M, the second back cover 50, and the headrest 3 are prepared. At this time, it is preferable that the seat back frame 30 is assembled to the completed seat cushion 1.

[0095] Next, the seat back module 2M is assembled. Specifically, the pressure-receiving plate 60, the first pad material 2a, the second pad material 2b, etc. are attached to the first back cover 40 (step S101).

[0096] Next, the headrest 3 is assembled. Specifically, the headrest cover 80, the padding 3a, and the covering material 3b of the headrest 3 are attached to the headrest frame 70 (step S102). Next, the assembled headrest 3 is attached to the seatback module 2M. Specifically, the bracket 46 of the seatback module 2M is inserted into the attachment opening 83 of the headrest cover 80 and fastened and fixed with the fasteners 75 (step S103).

[0097] Next, the seat back module 2M is attached to the seat back frame 30, and the second back cover 50 is assembled to the seat back module 2M and the seat back frame 30 from behind the seat (step S104). When attaching the seat back module 2M to the seat back frame 30, the engaging portion 49a is hooked onto the lateral frame 32a, and then the seat back module 2M is rotated to fix the connecting piece 49b to the back side frame 31. This completes the vehicle seat S.

[0098] When replacing the seat back module 2M, the second back cover 50 is removed from the seat back frame 30, and then the seat back module 2M is removed from the seat back frame 30 together with the headrest 3. Thereafter, another seat back module 2M with the headrest 3 attached thereto is attached to the seat back frame 30, and after being fixed to the seat back frame 30, the second back cover 50 is attached.

[0099] Since the seat back module 2M provided with the headrest 3 can be replaced without attaching or detaching the headrest 3 to or from the seat back frame 30, workability when attaching or replacing the seat back 2 is improved.

[0100] In the above-described embodiment, a vehicle seat S mounted on a vehicle has been given as an example of a vehicle seat, and an example of the configuration thereof has been described. However, the present invention is not limited to seats mounted on ground vehicles having wheels such as automobiles and trains, and may also be applied to seats mounted on aircraft, ships, and other vehicles that move on non-ground surfaces, for example.

[0101] The following additional notes are provided regarding the second embodiment described with reference to Figures 12 to 17. The vehicle seat of the present invention solves the above problems by providing a vehicle seat including a seat back and a headrest, wherein the seat back includes a seat back frame and a seat back module provided in front of the seat back frame, and the headrest is attached to the seat back module. This configuration allows the seat back module to be replaced without removing the headrest, thereby improving the ease of installation or replacement of the seat back compared to, for example, a case where the headrest is attached to the seat back frame.

[0102] According to the manufacturing method of the present invention, the problems are solved by a manufacturing method of a vehicle seat including a seat back frame, a seat back module provided in front of the seat back frame, a rear back cover provided behind the seat back frame, and a headrest attached to the seat back module, the manufacturing method including attaching the headrest to the seat back module, and attaching the seat back module with the attached headrest to the seat back frame. With the above configuration, the seat back module can be replaced without removing the headrest, which improves the workability when installing or replacing the seat back compared to, for example, a case where the headrest is attached to the seat back frame.

[0103] In the above configuration, the headrest has a headrest frame that forms the skeleton of the headrest, a mounting bracket for fixing the headrest frame is provided on an upper portion of the seatback module, and a through-hole is formed behind the mounting bracket, the headrest frame is fixed to the mounting bracket with a fastening member, and the fastening member is positioned so as to overlap with the through-hole in the front-rear direction. With the above configuration, the headrest can be attached to the seatback module by inserting the fastening member from behind the seatback module.

[0104] In the above configuration, a rear back cover may be provided behind the seat back frame, and the through hole formed in the seat back module may be covered from behind by the rear back cover. With the above configuration, fastening members and mounting brackets for attaching a headrest can be hidden.

[0105] In the above configuration, the through-hole of the seatback module may be provided above the seatback frame, and with the above configuration, the fastening member can be easily seen through the through-hole even after the seatback module is attached to the seatback frame.

[0106] In the above configuration, the seat back module may have an engagement portion below the through hole that engages with the seat back frame. With this configuration, the seat back module can be easily attached to the seat back frame, even after a headrest has been attached, for example.

[0107] In the above configuration, the headrest may include a headrest cover provided behind the headrest frame, the mounting bracket may have a protrusion that protrudes forward, and the headrest cover may have a mounting opening through which the protrusion of the mounting bracket is inserted. With the above configuration, the headrest can be more firmly attached to the seat back module.

[0108] In the above configuration, the seatback frame may have side frames disposed on both sides and an upper frame connecting upper ends of the side frames, the seatback module may have a front back cover attached to the seatback frame, the front back cover having an engagement portion that engages with the upper frame and a connecting piece that protrudes rearward and connects to the side frame, and the side frame may have a fixing portion that fixes the connecting piece. With the above configuration, the seatback module can be easily attached to the seatback frame.

[0109] In the above configuration, the connecting piece is insert-molded into the front back cover, and the connecting piece comprises a base portion disposed within the front back cover and a mounting portion extending rearward from a side portion of the base portion and attached to the side frame, the base portion being larger than the mounting portion. With the above configuration, the connecting piece can be more firmly fixed to the front back cover.

[0110] In the above configuration, the seatback frame may have side frames disposed on both sides and an upper frame connecting upper ends of the side frames, and the seatback module may have a front back cover attached to the seatback frame, the front back cover having connecting pieces protruding rearward and connecting to the side frames, the connecting pieces being positioned below the lower ends of the upper frame. With the above configuration, it is possible to prevent the connecting pieces from interfering with the upper frame when assembling the seatback module to the back frame.

[0111] In the above configuration, the seatback frame may have side frames arranged on both sides and an upper frame connecting upper ends of the side frames, the upper frame being composed of horizontal frames extending in the seat width direction and vertical frames extending downward from both ends of the horizontal frames, the seatback module having a front back cover attached to the seatback frame, the front back cover having guide pieces protruding rearward and abutting against the inside of the vertical frames and fixing pieces protruding rearward and fixing the vertical frames from the outside, the vertical frames being sandwiched between the guide pieces and the fixing pieces. With the above configuration, the seatback module can be guided to an appropriate position when assembled to the seatback frame.

[0112] In the above configuration, a rib may be formed on the rear surface of the front back cover, and the rib may have a recess formed in the portion of the upper frame that abuts against the vertical frame, the recess conforming to the outer shape of the vertical frame. With this configuration, when the seatback module is assembled to the seatback frame, the seatback module can be guided to an appropriate position. Furthermore, movement of the vertical frame in the seat width direction can be suppressed.

[0113] DESCRIPTION OF SYMBOLS S Vehicle seat F Seat frame 1 Seat cushion 1a First pad material 1b Second pad material 1c Cover material 1M Seat cushion module 2 Seat back 2a First pad material 2aa Blower covering portion 2b Second pad material 2c Cover material 2d Seating surface 2M Seat back module 3 Headrest 3a Pad material 3b Cover material 4 Rail device 4a Lower rail 4b Upper rail 4c Locking member 5 Reclining device 5a Reclining main body 5b Back rotation shaft 5c Spiral spring 10 Seat cushion frame 11 Side frame 12 Pan frame 13 Rear connecting frame 14 Elastic spring (elastic member) 15 Support plate 16 Cushion module assembly portion 20 Cushion base cover 21 Cover side portion 22 Cover front portion 23 Cover rear portion 24 Assembly portion 25 Frame attachment / detachment portion 30 Seat back frame 31 Back side frame 32 Upper frame 32a Horizontal frame 32b Vertical frame 32ba Lower end 33 Lower frame 34 Module assembly portion 40 First back cover 40a Cover main body 40b Back reinforcement rib 40c Front reinforcement rib 41 Cover side portion 41a Back reinforcement rib 42 Cover upper portion 42a Flat plate portion 42b Blower device accommodating recess 42c Upper reinforcement rib 42c1 Vertical reinforcement rib 42c2 Horizontal reinforcement rib 43 Cover lower portion 44 First opening 45 Cover assembly portion 46 Bracket 46a Front surface 46b Bracket through hole 46c Protrusion 49 Cover attachment portion 49a Engagement portion 49b Connecting piece 49ba Attachment portion 49bb Base portion 49c Fixing piece 49d Guide piece 49e Recess 49f Fixing member 49g Fastener 50 Second back cover 50a Cover main body 51 Cover side portion 52 Cover upper portion 53 Cover lower portion 54 Second opening 55 Assembly portion 60 Pressure receiving plate 61 Plate mounting portion 70 Headrest frame 71 Frame main body 72 Outer edge flange 73 Bracket assembly portion 74 Cover assembly portion 75 Fastener 80 Headrest coverDESCRIPTION OF SYMBOLS 81 Cover body 82 Outer edge flange 83 Mounting opening 84 Assembly portion 90 Control device 91 Bracket 100 Blower device (air flow generating device) 101 Blower body 101a Rotating shaft 101b Rotating blades 102 Intake port 103 Outlet port 104 Blower device fixing portion (fixing member) 104a First blower device fixing portion 104b Second blower device fixing portion 104c Third blower device fixing portion 108 Electric motor 110 Seat heater 120 Blower connection cable 121 Blower connection connector 130 Heater connection cable Ph1 Conventional head support point Ph2 Head support point Pb Back support point

Claims

1. A vehicle seat comprising a headrest and a seat back supporting the headrest, wherein the headrest is attached to the seat back at an upper end thereof so as to protrude forward from the seating surface of the seat back, the seat back has an airflow generating device that generates an airflow below the headrest, and the lower end of the headrest overlaps with the airflow generating device in a front view.

2. The vehicle seat described in claim 1, characterized in that the air flow generating device has multiple rotating blades that rotate around a rotation axis extending in the front-to-rear direction, and the lower end of the headrest overlaps with at least one of the multiple rotating blades when viewed from the front.

3. The vehicle seat according to claim 2, wherein the lower end of the headrest is positioned above the rotation axis.

4. The vehicle seat described in claim 1, characterized in that the headrest has a headrest frame that forms the skeleton of the headrest, a padding material that covers the front of the headrest frame, and a cover member that covers the headrest frame from the rear, and the lower end of the headrest frame is located higher than the upper end of the air flow generating device.

5. The vehicle seat according to claim 4, wherein the lower end of the cover member is positioned above the upper end of the air flow generating device.

6. The vehicle seat according to claim 4, wherein the seat back has a bracket that protrudes forward from the seating surface, and the headrest is attached to a front surface of the bracket via the headrest frame.

7. A vehicle seat as described in claim 1, characterized in that the air flow generating device is fixed to the seat back by a fixing member that fixes the air flow generating device to the seat back, and the lower end of the headrest overlaps with the fixing member in a front view.

8. The vehicle seat according to claim 1, characterized in that the air flow generating device has a connection connector that allows the insertion and removal of a connection cable electrically connected to the air flow generating device, and the lower end of the headrest is located above the connection connector.

9. A method for manufacturing a vehicle seat having a headrest and a seat back supporting the headrest, comprising: attaching an air flow generating device that generates an air flow to the seat back; and attaching the headrest to an upper end of the seat back so that it protrudes forward from the seating surface of the seat back, wherein the air flow generating device overlaps with the lower end of the headrest when viewed from the front when the headrest is attached to the seat back.

Images