Vehicle seat and vehicle seat manufacturing method

Abstract

This vehicle seat (10) comprises a seat back frame (22) and a headrest (40) attached to an upper part of the seat back frame (22). The headrest (40) has a frame member (41) supported by the seat back frame (22), and a cover member (44) that covers the frame member (41) and has a front wall part (441a) facing forward in a seat front-rear direction. The cover member (44) has a through-hole (443) in the front wall part (441a). When viewed from the seat front-rear direction, the frame member (41) is disposed at a position overlapping the through-hole (443).

Description

Vehicle seat and method for manufacturing a vehicle seat

[0001] The present disclosure relates to a vehicle seat on which an occupant sits and a method for manufacturing the vehicle seat.

[0002] The vehicle seat includes a seat back and a seat cushion. A headrest for supporting the occupant's head is attached to the upper part of the seat back. The headrest has a frame member constituting the skeleton of the headrest, a cover member covering the frame member, and a cushion and a skin material covering the surface of the cover member. The frame member is made of a high-strength member such as metal and is connected to the seat back frame. Further, the cover member is formed of a resin material that is more flexible than the frame member. The cover member covers the edge of the frame member and protects the occupant from the frame member and its edge. For example, Japanese Patent Application Laid-Open No. 2016-078625 describes an example of a headrest.

[0003] In a conventional headrest, in the front-rear direction of the seat, the front of the frame member is covered with a cover member, and there is a gap in the front-rear direction of the seat between the frame member and the cover member. Therefore, for example, when a large acceleration is applied to the vehicle, the cover member receives the load of the occupant's head and greatly deform. In this case, there is a problem that the position supporting the occupant's head shifts rearward from the assumed support position.

[0004] An object of the present disclosure is to solve the above-described problems.

[0005] A first aspect of the present disclosure is a vehicle seat including a seat back frame and a headrest attached to the upper part of the seat back frame, wherein the headrest has a frame member supported by the seat back frame and a cover member covering the frame member and having a front wall portion facing forward in the front-rear direction of the seat, and the cover member has a through hole in the front wall portion, and the frame member is disposed at a position overlapping the through hole when viewed from the front-rear direction of the seat.

[0006] A second aspect of the present disclosure is a method for manufacturing a vehicle seat, comprising: a seat back frame; and a headrest attached to the upper part of the seat back frame, wherein the headrest comprises: a frame member supported by the seat back frame; and a cover member covering the frame member and having a front wall portion facing forward in the seat front-rear direction, wherein the cover member has a through hole in the front wall portion, and the frame member is positioned to overlap the through hole when viewed from the seat front-rear direction, the method for manufacturing a vehicle seat comprising: a first step of attaching the cover member to the frame member; and a second step of attaching the headrest to the seat back frame after the first step.

[0007] According to this disclosure, the frame member can support the occupant's head through the through-hole in the cover member, so that the occupant's head can be held in a favorable position even when a large acceleration is applied.

[0008] Figure 1 is a schematic perspective view of a vehicle seat according to the first embodiment of the present disclosure. Figure 2 is a perspective view of the frame structure of the vehicle seat. Figure 3 is a partially omitted cross-sectional view showing the positional relationship between the protruding surface of the frame member and the blower and duct as viewed from the seat width direction. Figure 4A is a perspective view of the connection structure connecting the headrest pillar and the frame assembly, and Figure 4B is an exploded perspective view showing the connection structure of Figure 4A in an unconnected state. Figure 5 is an exploded perspective view of the headrest of Figure 1. Figure 6 is an exploded perspective view of the frame assembly of Figure 4A as viewed from the rear at an oblique angle after disassembly. Figure 7 is a cross-sectional view of the area near the lower end of the frame assembly. Figure 8 is a front view of the cover member, frame member and headrest pillar of Figure 2. Figure 9 is a partially omitted perspective view of the first surface of the rear wall. Figure 10 is a cut cross-sectional view of the engagement portion between the frame member and the second cover member as viewed from above. Figure 11 is a perspective view of the frame assembly of the headrest of Figure 1. Figure 12 is a partially omitted cross-sectional view showing the connection portion between the headrest and the headrest pillar and its surrounding area. Figure 13 is a partially abbreviated front view of the arrangement relationship between the frame assembly and the connecting structure in Figure 4A, viewed from the front. Figure 14 is a partially abbreviated side view showing the positional relationship between the airbag and the protruding surface of the headrest in Figure 1, viewed from the seat width direction. Figure 15 is a flowchart illustrating a method for manufacturing a vehicle seat according to the first embodiment. Figure 16 is a schematic front perspective view of a vehicle seat according to the second embodiment of this disclosure, viewed from the left front. Figure 17 is a partially abbreviated rear perspective view of a vehicle seat viewed from the left rear. Figure 18 is a partially cross-sectional side view of the pillar cover and its surroundings of the vehicle seat. Figure 19 is an exploded perspective view of the main parts showing the pillar cover in an exploded state. Figure 20 is a schematic perspective view of the main parts showing the state in which the outside of the headrest pillar of the vehicle seat is covered with the pillar cover. Figure 21 is an enlarged cross-sectional view of the main parts showing the engagement point between the cover support and the pillar cover of the vehicle seat. Figure 22 is an enlarged cross-sectional view of the main parts when the tab portion of the front cover member and the engagement recess of the rear cover member of the pillar cover are engaged. Figure 23 is a schematic bottom view showing the positional relationship between the engaging claw of the pillar cover and the headrest pillar in the seat-forward direction. Figure 24 is a schematic side view showing the positional relationship between the engaging claw and the airbag module in the seat-forward direction.Figure 25 is a schematic rear perspective view showing the front cover member assembled to the headrest pillar. Figure 26 is a schematic rear perspective view showing the rear cover member being attached to the front cover member after the display has been mounted to the seat back.

[0009] In the following description, the terms front, rear, right, left, up, and down are used. Front and rear refer to the relative positional relationship in the front-rear direction of the seat as shown in Figure 1. Note that the front-rear direction of the seat may be the same as the front-rear direction of the vehicle (e.g., automobile). Right and left refer to the relative positional relationship in the width direction of the seat as shown in Figure 1. The width direction of the seat is perpendicular to the front-rear direction of the seat and may be the same as the width direction of the vehicle. Up and down refer to the relative positional relationship in the up and down direction, perpendicular to the front-rear direction and the width direction of the seat, as shown in Figure 1. Note that the term "up and down direction of the seat" is also used in this specification. The up and down direction of the seat is the direction along the longitudinal direction of the seat back 20.

[0010] The vehicle seat 10 according to the first embodiment shown in Figure 1 is, for example, the passenger seat of a right-hand drive four-wheeled vehicle (not shown). However, the vehicle seat 10 may be a seat other than the passenger seat. Furthermore, the vehicle seat 10 is not limited to an automobile seat installed in a right-hand drive four-wheeled vehicle. The vehicle seat 10 may be an aircraft seat or a railway vehicle seat.

[0011] As shown in Figure 1, the vehicle seat 10 includes a seat back 20, a seat cushion 30, a headrest 40, and an airbag 50.

[0012] The seat cushion 30 comprises a cushion frame 32 and a seat cushion 34. The cushion frame 32 is supported by seat rails S1 and S2 so as to be movable in the seat's front-to-back direction. The vehicle seat 10 moves in the seat's front-to-back direction along the two seat rails S1 and S2 by operation by the occupant. The seat cushion 34 is formed of, for example, a urethane cushioning material and a surface sheet covering the cushioning material, and is supported by the cushion frame 32.

[0013] As shown in Figures 1 and 2, the seat back 20 includes a seat back frame 22, a seat back cushion 24, a blower unit 26, and a headrest pillar 28. The seat back frame 22 is formed in a substantially rectangular shape, with its length in the vertical direction of the seat being greater than its length in the width direction of the seat. The seat back frame 22 includes a pair of left and right frame bodies 221 and a connecting frame 222 that connects the upper parts of the pair of frame bodies 221. The seat back frame 22 is connected to the cushion frame 32 via a reclining mechanism 29. The reclining mechanism 29 rotatably connects the seat back 20 to the seat cushion 30.

[0014] In the following, the vertical positional relationship of the seat back 20, headrest 40, headrest pillar 28, and their components will be explained based on the state in which the seat back 20 is not tilted in the front-to-back direction relative to the seat cushion 30 (reclining angle is 0°), as shown in Figure 1. The state in which the seat back 20 is not tilted in the front-to-back direction means that the headrest 40 is positioned above the seat back 20 in the vertical direction.

[0015] The seat back cushion 24 is supported by the seat back frame 22. The seat back cushion 24 has a cushioning material, such as urethane foam, and a surface covering material that covers the surface of the cushioning material. The seat back cushion 24 covers the front of the blower unit 26.

[0016] As shown in Figure 2, the blower unit 26 is attached to the seat back frame 22. The blower unit 26 is located in the center of the seat back 20 in the seat width direction and is attached to the connecting frame 222 of the seat back frame 22. The blower unit 26 comprises a blower 261 with a built-in fan and a duct 262 connected to the blower 261. The blower 261 blows air into the seat back cushion 24 through the duct 262. The blower 261 may also be configured to draw air from the seat back cushion 24 through the duct 262.

[0017] The blower 261 protrudes downward from the connecting frame 222. The duct 262 is attached to the lower part of the blower 261. The duct 262 is bent forward and opens forward. A bracket 263 is provided on the side of the blower unit 26. The bracket 263 is a plate-shaped member that extends vertically and is attached so as to protrude downward from the connecting frame 222. The bracket 263 is equipped with a clip 265 to hold the harness 264 that supplies power to the blower 261. The clip 265 is a member fitted into the bracket 263 and has a holding part (not shown) on the rear side of Figure 2 that holds the harness 264.

[0018] As shown in Figure 3, the blower 261 and duct 262 are positioned behind the protruding surface 415 of the protruding portion 413 of the headrest 40, which will be described later, in the front-rear direction of the seat. With the blower unit 26 positioned in this way, protrusion onto the seat back cushion 24 can be suppressed, thus preventing excessive seating load from being applied to the blower unit 26 when an occupant is seated.

[0019] As shown in Figures 1 and 2, the headrest pillar 28 is joined to the connecting frame 222 of the seat back frame 22 by welding or the like. The headrest pillar 28 is formed from, for example, a metal pipe such as iron. The headrest pillar 28 has an inverted U shape when viewed from the front-rear direction of the seat. The headrest pillar 28 has two legs 281 spaced apart in the seat width direction and a pillar upper part 282 that connects the upper parts of the legs 281. The legs 281 extend in the vertical direction. The lower ends of the legs 281 are joined to the seat back frame 22. The headrest 40 is connected to the pillar upper part 282 via a connecting structure 280 shown in Figure 4A.

[0020] As shown in Figures 4A and 4B, the upper part 282 of the pillar extends in the seat width direction and is integrally connected to the two leg portions 281. A connecting structure 280 is attached to the upper part 282 of the pillar. The connecting structure 280 has a mounting stay 283. The mounting stay 283 is joined to the upper part 282 of the pillar by welding or the like. The mounting stay 283 has a front wall 284 facing forward. A pair of connecting holes 285 for fixing the headrest 40 are formed in the front wall 284. Bolts 432 extending from the headrest 40 pass through the connecting holes 285. The headrest pillar 28 configured as described above is covered by a pillar cover 286 made of, for example, resin, as shown in Figure 1.

[0021] As shown in Figure 1, the headrest 40 is attached to the top of the seat back 20. The headrest 40 is connected to the seat back frame 22 via the headrest pillar 28.

[0022] As shown in Figure 5, the headrest 40 comprises a frame member 41, a connecting portion 43, a cover member 44, a headrest pad 45, a slab 46, a headrest surface 47, a back panel 48, and a support pipe 49.

[0023] The cover member 44 is made of a material that is less rigid than the frame member 41, such as resin. The cover member 44 protects the occupants from the edges of the frame member 41 by covering the perimeter of the frame member 41.

[0024] As shown in Figures 5 and 6, the cover member 44 includes a first cover member 441 that covers the front of the frame member 41 and a second cover member 442 that covers the rear of the frame member 41. The first cover member 441 has a front wall portion 441a that faces forward in the front-rear direction of the seat. The second cover member 442 has a rear wall portion 442a that faces rearward in the front-rear direction of the seat. A through hole 443 is formed in the front wall portion 441a. The through hole 443 is formed in a substantially rectangular shape when viewed from the front-rear direction of the seat and penetrates the first cover member 441 in the front-rear direction of the seat. When viewed from the front-rear direction of the seat, the frame member 41 is positioned to overlap with the through hole 443. Three mounting holes 411 for attaching screws 440 are formed at predetermined locations in the first cover member 441.

[0025] As shown in Figure 7, a short, forward-projecting front projection 444 is formed at the lower part of the first cover member 441. The front projection 444 protrudes further forward than the projection surface 415 of the frame member 41, which will be described later. This front projection 444 improves the support force for the occupant's head at the lower part of the headrest 40 when a large forward acceleration occurs. The portion of the first cover member 441 from below the lower end of the through hole 443 to the front projection 444 forms a first lower edge 455 that slopes to gradually protrude forward as it goes downward. The first lower edge 455 has a curved portion, but as a whole it slopes along the support pipe 49, as shown in Figure 12. The first lower edge 455 is formed to be parallel to the second lower edge 456, which will be described later.

[0026] As shown in Figures 5 and 6, the second cover member 442 has the same external shape as the first cover member 441 when viewed from the front-rear direction of the sheet. The second cover member 442 is positioned at the rear of the frame member 41 and accommodates the peripheral wall portion 42 of the periphery of the frame member 41. The second cover member 442 (rear wall portion 442a) has a first surface 446 facing forward and a second surface 447 formed on the opposite side of the first surface 446 and facing rear.

[0027] As shown in Figure 9, a receiving portion 448 and an insert bush 449 are formed on the first surface 446 of the second cover member 442. The receiving portion 448 is located near the lower end of the second cover member 442 and protrudes forward from the first surface 446. The receiving portion 448 extends in the sheet width direction. As shown in Figure 7, the receiving portion 448 engages with the protrusion 421 of the frame member 41 to prevent misalignment between the frame member 41 and the second cover member 442. As shown in Figure 5, the insert bush 449 protrudes forward from the first surface 446. The insert bush 449 is provided in the portion corresponding to the mounting hole 411 of the first cover member 441. A screw 440 is tightened into the insert bush 449.

[0028] As shown in Figure 6, a protrusion 450 is formed on the second surface 447 of the second cover member 442. The protrusion 450 extends in the sheet width direction. As shown in Figure 7, the protrusion 450 protrudes rearward, in the opposite direction to the protrusion direction of the receiving portion 448. The protrusion 450 is located behind the receiving portion 448. The protrusion 450 is positioned so as to overlap with the receiving portion 448 when viewed from the front-rear direction of the sheet. The protrusion 450 prevents misalignment between the frame member 41 and the second cover member 442 by increasing the rigidity of the receiving portion 448.

[0029] As shown in Figure 6, an insertion hole 451 is formed in the center of the second cover member 442 in the width direction and vertical direction of the seat. The insertion hole 451 is a rectangular hole that penetrates the second cover member 442 in the front-rear direction of the seat and has dimensions that allow the connecting portion 43 to pass through. As shown in Figure 6, the vertical length L2 of the insertion hole 451 of the second cover member 442 is smaller than the vertical length L1 of the through hole 443 of the first cover member 441. By making the vertical length L2 of the insertion hole 451 smaller than the vertical length L1 of the through hole 443 in this way, a decrease in the rigidity of the second cover member 442 can be prevented, and a decrease in the overall rigidity of the headrest 40 can be suppressed.

[0030] The insertion hole 451 is positioned so as to overlap with the through hole 443 when viewed from the front-to-rear direction of the seat. This arrangement increases the rigidity of the headrest 40 compared to the case where the through hole 443 and the insertion hole 451 do not overlap, allowing for more reliable support of the occupant's head load.

[0031] As shown in Figure 6, the second cover member 442 has a plurality of hooks 452 and two engaging portions 453 on its second surface 447. The hooks 452 are arranged in a plurality along the outer circumference of the second cover member 442. The hooks 452 hold the trim cords 471 of the headrest upholstery 47, which will be described later (see Figure 12). The engaging portions 453 are groove-shaped portions that extend downward from the lower edge of the insertion hole 451, and two are provided spaced apart in the seat width direction. The engaging portions 453 are formed to protrude rearward from the second surface 447. The hook portions 472 provided on the edge of the headrest upholstery 47 are hooked onto the engaging portions 453 (see Figure 12).

[0032] As shown in Figures 3, 4, 7, and 12, a second lower edge 456 is formed on the lower end of the second cover member 442 in the vertical direction. The second lower edge 456 slopes forward as it goes downward. The second lower edge 456 is parallel to the first lower edge 455 and is also formed parallel to the upper inclined portion 200a of the outer shape 200 of the seat back 20. When the load of the seated person's head is applied and the lower part of the headrest 40 flexes, the first lower edge 455 and the second lower edge 456 of the first cover member 441 and the second cover member 442 come into contact with the upper part of the seat back 20. As a result, the first cover member 441 and the second cover member 442 can appropriately transmit the load to the upper inclined portion 200a of the seat back 20.

[0033] As shown in Figure 5, the frame member 41 is formed in the shape of a thin plate that is thin and spread out in the width direction and vertical direction of the sheet. The frame member 41 is made of a material with excellent strength, such as steel plate. When viewed from the front, the frame member 41 is formed in the shape of a trapezoid where the top side is narrower than the bottom side.

[0034] As shown in Figure 8, in a front view, the right edge 41r and left edge 41l of the frame member 41 are located inward in the width direction relative to the right edge 441r and left edge 441l of the first cover member 441. This configuration allows for a wide surface area on which the first cover member 441 supports the head of the seated person, while suppressing an increase in the width of the frame member 41.

[0035] The frame member 41 has a projection 413 in the center in the width direction of the sheet. The projection 413 is a portion that protrudes forward from the peripheral edge 414 of the frame member 41 and is integrally connected to the peripheral edge 414 via a step. When viewed from the front-rear direction of the sheet, the projection 413 is formed in a rectangular shape with rounded corners. The projection 413 has a forward-facing projection surface 415. Although not particularly limited, the projection 413 may have a plurality of punching holes 413a formed therein.

[0036] As shown in Figure 11, the protrusion 413 of the frame member 41 has dimensions slightly smaller than the through hole 443 formed in the first cover member 441. The protrusion 413 passes through the through hole 443 and protrudes forward of the first cover member 441. As shown in Figure 12, the protrusion 413 is not covered by the cover member 44 and is in direct contact with the headrest pad 45. Such a protrusion 413 can support the load of the occupant's head with high rigidity by receiving the load of the occupant's head without going through the first cover member 441. As shown in Figures 5 and 6, the protrusion 413 occupies more than half of the dimensions of the headrest 40 in the seat width direction and vertical direction. As shown in Figure 10, the dimension W1 of the protrusion 413 in the seat width direction is larger than the dimension W2 of the receiving portion 448 of the second cover member 442 in the seat width direction. Such a protrusion 413 has excellent load-bearing capacity for the occupant's head.

[0037] As shown in Figure 5, the peripheral edge 414 is positioned to surround both sides and the top of the protruding portion 413 in the sheet width direction. The front and outer sides of the peripheral edge 414 are covered by the first cover member 441 of the cover member 44. Three mounting holes 416 are formed in the peripheral edge 414 through which three screws 440 are inserted. The three mounting holes 416 are positioned to overlap with the mounting holes 411 of the first cover member 441.

[0038] As shown in Figure 6, a peripheral wall portion 42 is formed at the outer peripheral end of the frame member 41, including the protruding portion 413 and the peripheral edge portion 414, and extends in a curve toward the rear. The peripheral wall portion 42 is formed to surround the outer circumference of the frame member 41.

[0039] As shown in Figures 7 and 10, a projection 421 is formed on the peripheral wall portion 42 at the lower end of the frame member 41, projecting backward. The projection 421 has two convex portions 422 and a concave portion 423. The convex portions 422 are portions that project further backward than the other parts of the peripheral wall portion 42. The two convex portions 422 are spaced apart in the sheet width direction. The concave portion 423 is formed between the two convex portions 422. The concave portion 423 has a smaller rearward projection length than the convex portions 422 and is formed in a concave shape when viewed from above. The projection 421 engages with the receiving portion 448 of the second cover member 442 at the concave portion 423. By engaging with the second cover member 442, the concave portion 423 prevents the cover member 44 from shifting relative to the frame member 41 in the sheet front-rear direction and the sheet width direction.

[0040] As shown in Figures 5 and 6, the frame member 41 is joined to a connecting portion 43 and a support pipe 49. The connecting portion 43 is joined to the rear surface of the protruding portion 413 of the frame member 41 by welding or the like. The connecting portion 43 is formed in a U-shape when viewed from above. As shown in Figure 6, the connecting portion 43 has a rearward-facing connecting wall 431 at its rear end. Two bolts 432 are joined to the connecting wall 431 by welding. The bolts 432 pass through the bolt holes 433 of the connecting wall 431 and protrude to the rear of the connecting wall 431. As shown in Figure 4B, the connecting portion 43 protrudes rearward through the insertion hole 451 of the second cover member 442. The connecting portion 43 is attached to the headrest pillar 28 via the connecting wall 431 and the bolts 432.

[0041] As shown in Figure 6, the support pipe 49 is joined to the lower end of the frame member 41. The support pipe 49 extends long in the width direction of the seat and is formed in a U shape when viewed from the front-rear direction of the seat. The upper end of the support pipe 49 is welded to the frame member 41. As shown in Figure 7, the support pipe 49 extends shortly diagonally downward in the front. The support pipe 49 is positioned inside the front projection 444 of the first cover member 441 and supports the front projection 444 and the first lower edge 455.

[0042] As shown in Figure 11, the frame member 41, the connecting part 43, the cover member 44, and the support pipe 49 are assembled together to form a frame assembly 410. As shown in Figure 6, the frame member 41 is positioned inside the cover member 44, sandwiched between the first cover member 441 and the second cover member 442 of the cover member 44 from the front-rear direction of the seat. As shown in Figure 11, the frame member 41, the first cover member 441, and the second cover member 442 are connected by fastening together with three screws 440.

[0043] As shown in FIG. 12, the headrest pad 45 is made of, for example, urethane sponge or the like, and is attached so as to cover the front of the frame assembly 410. A recess 454 is formed on the front surface of the front of the headrest pad 45. A slab 46 is fitted into the recess 454 and joined by an adhesive or the like. The slab 46 is, for example, a flexible plate-like member formed of a foamed resin material, and by giving the headrest 40 an appropriate hardness, the holding feeling of the head is improved. The vertical length L3 of the slab 46 is larger than the vertical length L4 of the protrusion 413. Thus, by increasing the vertical length L3 of the slab 46, the supporting force on the head of the occupant increases.

[0044] The headrest skin 47 is attached so as to cover the outside of the headrest pad 45 and the slab 46. The edge of the headrest skin 47 is arranged so as to wrap around the rear part of the frame assembly 410 and is attached to the rear part of the second cover member 442.

[0045] A trim cord 471 is provided at the edge of the headrest skin 47. The trim cord 471 is hooked and held by the hook 452 of the second cover member 442. Also, a pair of hook portions 472 are attached to other parts of the edge of the headrest skin 47. The hook portion 472 is formed with a J-shaped cross section. The hook portion 472 is hooked and held by the engaging portion 453 of the second cover member 442. In this way, the headrest skin 47 is fixed to the second cover member 442.

[0046] The back panel 48 is attached to the rear part of the second cover member 442 of the cover member 44. The back panel 48 covers the connection portion between the second cover member 442 and the headrest skin 47. An opening 481 is formed in the back panel 48 to expose the coupling portion 43 rearward. The opening 481 passes through the mounting stay 283. The headrest 40 is fixed to the mounting stay 283 of the headrest pillar 28 through the coupling portion 43 exposed in the opening 481. The bolt 432 passes through the connecting hole 285 of the mounting stay 283. The nut 287 is tightened onto the bolt 432 from the rear part of the mounting stay 283 to fix the headrest 40 and the headrest pillar 28.

[0047] As shown in FIG. 13, when viewed in the front-rear direction of the seat, the bolt 432 that fixes the headrest 40 to the headrest pillar 28 is disposed inside the virtual triangular region T formed by the three screws 440 that connect the frame assembly 410. By disposing the bolt 432 in this way, the load in the front-rear direction of the seat can be effectively transmitted to the headrest pillar 28, and the headrest 40 is more firmly fixed to the headrest pillar 28.

[0048] As shown in FIG. 1, in the vehicle seat 10, the airbag 50 is provided on the left side portion of the seat back 20. The airbag 50 is housed in the airbag housing portion 52 provided in the seat back 20. The airbag 50 is deployed when an unexpected situation occurs and protects the occupant from side impacts. When the vehicle seat 10 is for the right seat, the airbag 50 is provided on the right side portion of the seat back 20.

[0049] As shown in FIG. 14, a part (rear end) of the airbag 50 is located behind the protruding surface 415. The airbag 50 arranged in this way is deployed when the vehicle detects a large impact. At that time, the headrest 40 can support the occupant's head near the deployment area of the airbag 50. Thereby, the vehicle seat 10 can more effectively protect the occupant's head.

[0050] The vehicle seat 10 configured as described above is manufactured by the following steps.

[0051] As shown in Figure 15, the seat back 20 and the seat cushion 30 are assembled (S10).

[0052] Next, the cover member 44 is attached to the frame member 41 to assemble the frame assembly 410 (S20, first step). Specifically, the joint 43 and support pipe 49 are joined to the frame member 41 by welding. Then, the first cover member 441 is attached to the frame member 41 from the front, and the second cover member 442 is attached from the rear. After that, the first cover member 441, the frame member 41, and the second cover member 442 are fixed together with screws 440 to complete the frame assembly 410.

[0053] Next, the headrest pad 45, slab 46, and headrest upholstery 47 are attached to the frame assembly 410 (S30). The headrest 40 is completed through the above steps.

[0054] Next, the headrest 40 is attached to the headrest pillar 28 (seat back frame 22) (S40, second step). Through these steps, the vehicle seat 10 is completed. A vehicle seat 10 manufactured by this method can directly support the occupant's head with the frame member 41 when the occupant is seated, and has excellent support for the occupant's head.

[0055] The first embodiment provides the following effects.

[0056] As shown in Figure 2, the headrest 40 of the vehicle seat 10 has a frame member 41 supported by the seat back frame 22 and a cover member 44 that covers the frame member 41. The cover member 44 has a through hole 443 in its front wall portion 441a. When viewed from the front-rear direction of the seat, the frame member 41 is positioned to overlap with the through hole 443.

[0057] With this configuration, the frame member 41 directly supports the headrest pad 45 without being covered by the cover member 44, thus suppressing the rearward movement of the occupant's head even when a large acceleration is applied.

[0058] As shown in Figure 3, the frame member 41 has a projection 413 that passes through the through hole 443 and protrudes forward from the front wall portion 441a of the cover member 44.

[0059] With this configuration, the frame member 41 can receive the load of the occupant's head at a position that protrudes forward from the front wall portion 441a of the cover member 44, thus further improving the occupant's head support performance.

[0060] As shown in Figure 3, the headrest 40 further has a connecting portion 43 for supporting the frame member 41 to the seat back frame 22. The cover member 44 also has a rear wall portion 442a facing rearward in the seat front-rear direction. The frame member 41 is positioned between the front wall portion 441a and the rear wall portion 442a. An insertion hole 451 for the connecting portion 43 is formed in the rear wall portion 442a, and when viewed from the seat front-rear direction, the insertion hole 451 is positioned to overlap with the through hole 443.

[0061] With this configuration, the load from the occupant's head, received by the protruding portion 413, is efficiently transmitted to the seat back frame 22 via the connecting portion 43, thereby ensuring reliable support for the head.

[0062] As shown in Figure 6, the vertical length L2 of the insertion hole 451 is smaller than the vertical length L1 of the through hole 443.

[0063] This configuration suppresses the overall reduction in rigidity of the cover member 44, thereby improving the strength of the headrest 40.

[0064] As shown in Figure 10, the frame member 41 has a projection 421 that protrudes toward the rear wall portion 442a. The rear wall portion 442a is provided with a receiving portion 448 that engages with the projection 421.

[0065] With this configuration, the frame member 41 and the cover member 44 are securely fixed together, and misalignment between the frame member 41 and the cover member 44 can be prevented.

[0066] The protrusion 421 has a plurality of convex portions 422 and concave portions 423 formed between the convex portions 422. The protrusion 421 engages with the receiving portion 448 at the concave portions 423.

[0067] This configuration makes it possible to more effectively prevent misalignment of the frame member 41 and the cover member 44 in the sheet width direction.

[0068] The dimension W1 of the protruding portion 413 in the sheet width direction is greater than the dimension W2 of the receiving portion 448 in the sheet width direction.

[0069] With this configuration, the larger dimensions of the protrusion 413 in the seat width direction improve the support performance for the occupant's head.

[0070] As shown in Figure 7, the second cover member 442 has a first surface 446 on which a receiving portion 448 is provided, and a second surface 447 opposite to the first surface 446. The receiving portion 448 protrudes from the first surface 446. The second surface 447 has a convex portion 450 that protrudes in the opposite direction to the protrusion direction of the receiving portion 448.

[0071] With this configuration, the receiving portion 448 and the protruding portion 450 are formed to overlap, thereby improving the rigidity of the receiving portion 448 of the second cover member 442.

[0072] As shown in Figure 14, the protruding portion 413 of the frame member 41 has a protruding surface 415 that supports the occupant's head. The rear end of the airbag 50 is located behind the protruding surface 415 in the seat-forward direction.

[0073] With this configuration, the headrest 40 can support the occupant's head near the deployment area of ​​the airbag 50. This allows the vehicle seat 10 to protect the occupant's head more effectively.

[0074] As shown in Figure 15, the manufacturing method of the vehicle seat 10 includes a first step (S20) of attaching a cover member 44 to a frame member 41, and a second step (S40) of attaching a headrest 40 to a seat back frame 22 after the first step.

[0075] This method makes it possible to manufacture a vehicle seat 10 that offers excellent protection for the occupant's head.

[0076] Next, a second embodiment relating to this disclosure will be described.

[0077] A vehicle seat includes a headrest that supports the occupant's head. The headrest is attached to the seatback via a headrest pillar. U.S. Patent No. 1,0427,575 discloses a configuration in which a headrest pillar supported by a seatback frame is covered with a pillar cover.

[0078] It is anticipated that a significant load will be applied to the headrest from the occupant's head, etc. In the above configuration, if such a situation occurs, there is a concern that the pillar cover may deform significantly.

[0079] The second embodiment aims to solve the problems described above.

[0080] In the second embodiment, "front" and "rear" represent the relative positional relationship in the front-rear direction of the seat. "Left" and "right" represent the relative positional relationship in the seat width direction. Note that the "front-rear direction of the seat" is the same direction as the front-rear direction of the vehicle (e.g., a four-wheeled automobile), and the "seat width direction" is the same direction as the left-right direction of the vehicle. "Up" and "down" represent the relative positional relationship in the vertical direction.

[0081] Figure 16 is a schematic front perspective view of the vehicle seat 1010 according to the second embodiment, viewed from the left front. In the illustrated example, the vehicle seat 1010 constitutes the left seat of a four-wheeled vehicle (not shown). If the four-wheeled vehicle is a so-called right-hand drive vehicle, the vehicle seat 1010 is, for example, a passenger seat. If the four-wheeled vehicle is a so-called left-hand drive vehicle, the vehicle seat 1010 is, for example, a driver's seat. Note that the vehicle seat 1010 is not limited to an automobile seat installed in a four-wheeled vehicle. The vehicle seat 1010 may be an aircraft seat, a railway vehicle seat, or a ship seat.

[0082] The vehicle seat 1010 comprises a seat cushion 1020, a seat back 1030, and a headrest 1040. The seat cushion 1020 supports the buttocks of an occupant (not shown). The seat cushion 1020 has cushion frames 1022L and 1022R. The cushion frames 1022L and 1022R are movably supported by seat rails S1 and S2 provided on the floor FL of a four-wheeled vehicle. The vehicle seat 1010 moves in the front-rear direction along the seat rails S1 and S2 based on the operation of the occupant.

[0083] The seat back 1030 supports the occupant's back. As shown in Figure 17, a display 1050 is provided on the rear surface of the seat back 1030. The display 1050 is, for example, a monitor that constitutes a car navigation system and displays a map. The display 1050 may also be a monitor that displays video input from an external source. The display 1050 is mounted on the bracket 1052 shown in Figure 19.

[0084] As shown in Figure 16, the vehicle seat 1010 includes an airbag module 1060. The airbag module 1060 is supported on the left side of the frame body 1302 that constitutes the seat back frame 1300. The airbag module 1060 has a casing 1062 and an airbag 1064. In its initial state, the airbag 1064 is housed in the casing 1062 and deploys in the event of an unforeseen incident as shown by the dashed line in Figure 17. If the vehicle seat 1010 is the right-hand seat of a four-wheeled vehicle, the airbag module 1060 is provided on the right side of the seat back 1030.

[0085] The headrest 1040 supports the occupant's head. As can be seen from Figure 18, the headrest 1040 is supported by the headrest pillar 1400. As shown in Figure 19, the headrest pillar 1400 is attached to the seat back frame 1300. This configuration will be explained below. In the following, the vertical and longitudinal positional relationships of the seat back 1030, headrest 1040, headrest pillar 1400 and their components will be explained based on the state in which the seat back 1030 is not tilted in the longitudinal direction relative to the seat cushion 1020 (reclining angle is 0°), as shown in Figure 16. The state in which the seat back 1030 is not tilted in the longitudinal direction means that the headrest 1040 is positioned approximately vertically above the seat back 1030.

[0086] As shown in Figure 16, the seat back 1030 has a seat back frame 1300. The seat back frame 1300 is roughly inverted U-shape. Specifically, the seat back frame 1300 has a pair of left and right frame bodies 1302 and a connecting frame 1304 that connects the upper parts of the pair of frame bodies 1302. The material of the frame bodies 1302 and the connecting frame 1304 is, for example, metal.

[0087] As can be seen from Figures 19 and 20, the headrest pillar 1400 has a roughly inverted U-shape. Specifically, the headrest pillar 1400 has two legs 1402 and a pillar upper part 1410 (see Figure 19). Hereinafter, the leg 1402 located on the left side in the seat width direction will be referred to as the left leg 1402L, and the leg 1402 located on the right side in the seat width direction will be referred to as the right leg 1402R. The pillar upper part 1410 extends in the seat width direction and connects the left leg 1402L and the right leg 1402R. The left leg 1402L extends downward from the left end of the pillar upper part 1410. The right leg 1402R extends downward from the right end of the pillar upper part 1410. Each of the left leg 1402L and the right leg 1402R is bent at multiple points. As a result, as shown in Figure 20, the left leg portion 1402L has a first left extension portion 1404L extending from the rear to the front, and a second left extension portion 1406L extending downward from the front end of the first left extension portion 1404L. Similarly, the right leg portion 1402R has a first right extension portion 1404R extending from the rear to the front, and a second right extension portion 1406R extending downward from the front end of the first right extension portion 1404R.

[0088] As shown in Figure 16, the second left extension 1406L and the second right extension 1406R are joined to the connecting frame 1304. The joining is done, for example, by welding. The joining may also be done by mechanical joining such as screwing. Based on such joining, the headrest pillar 1400 is attached to the seat back frame 1300. Hereinafter, this state will be referred to as the "pillar mounting state".

[0089] In the pillar mounting state, the foremost parts of the second left extension 1406L and the second right extension 1406R are the parts of the headrest pillar 1400 that are located furthest forward. In other words, the second left extension 1406L and the second right extension 1406R are the front ends of the headrest pillar 1400 attached to the seat back frame 1300.

[0090] As shown in Figure 19, a first connecting bracket 1412 is provided on each of the left leg portion 1402L and the right leg portion 1402R. However, the first connecting bracket 1412 is omitted in Figure 16.

[0091] The material of the headrest pillar 1400 is, for example, metal. Also, as shown in Figure 16, the vehicle seat 1010 is used with the headrest pillar 1400 covered by the pillar cover 1430. This prevents the headrest pillar 1400 from being visible to the occupant when the vehicle seat 1010 is in use.

[0092] As shown in Figures 18 and 20, a pillar-side stay 1414 is provided at the front of the upper part 1410 of the headrest pillar 1400. A headrest-side stay (not shown) faces the front of the pillar-side stay 1414. The pillar-side stay 1414 and the headrest-side stay are connected to each other via a support bolt 1418 and nut 1419 shown in Figure 18. In this way, the headrest 1040 is supported by the headrest pillar 1400.

[0093] As shown in Figure 19, a box body 1310 is attached to the upper part of the frame body 1302. The upper part of the box body 1310 is covered with a thin cover plate 1320. That is, the cover plate 1320 is supported by the seat back frame 1300 via the box body 1310. The material of the box body 1310 and the cover plate 1320 may be metal, but it may also be resin. If resin is used as the material, the weight of the vehicle seat 1010 can be reduced.

[0094] The box body 1310 has two second connecting brackets 1312. The two second connecting brackets 1312 are spaced apart from each other at a predetermined distance in the seat width direction. The two first connecting brackets 1412 provided on the headrest pillar 1400 and the two second connecting brackets 1312 are connected to each other via fixing bolts 1314. In this way, the headrest pillar 1400 is supported by the box body 1310.

[0095] In one embodiment, the cover plate 1320 is a cover support 1321 that supports the pillar cover 1430. This will be described later. The cover plate 1320 has two engagement holes 1322. The two engagement holes 1322 are provided on the upper part of the cover plate 1320. The two engagement holes 1322 are spaced apart at a predetermined interval in the seat width direction. As shown in Figure 19, in the pillar mounting state, the two engagement holes 1322 are located between the left leg portion 1402L and the right leg portion 1402R in the seat width direction.

[0096] Next, the pillar cover 1430 will be described. In the following description, as shown in Figure 19, the pillar cover 1430 will be described in an embodiment having a front cover member 1440 made of resin material and a rear cover member 1480 made of resin material. However, the pillar cover 1430 may also be a single component in which the portion corresponding to the front cover member 1440 and the portion corresponding to the rear cover member 1480 are integrally molded.

[0097] As shown in Figure 20, the front cover member 1440 and the rear cover member 1480 are connected to each other to form a pillar cover 1430 that covers the headrest pillar 1400 from the outside. When the front cover member 1440 and the rear cover member 1480 are connected to each other, the pillar-side stay 1414 provided on the upper part 1410 of the headrest pillar 1400 is exposed forward through the front opening 1448. Note that the rear cover member 1480 shown in Figure 19 is connected to the front cover member 1440 after the front cover member 1440 has engaged with the cover plate 1320 (cover support 1321). This will be described later.

[0098] As shown in Figure 19, the front cover member 1440 has a roughly triangular frame shape and has a base portion 1442, a left slanted side portion 1444, a right slanted side portion 1446, and a front opening 1448. The right slanted side portion 1446 and the left slanted side portion 1444 are connected via a gently curved top portion 1450. Each of the left slanted side portion 1444, the right slanted side portion 1446, and the top portion 1450 is provided with a rear projection portion 1452 that protrudes slightly toward the rear. As shown in Figure 18, a connecting hole 1454 is formed in each rear projection portion 1452. Note that Figure 18 shows the connecting hole 1454 formed in the rear projection portion 1452 of the top portion 1450.

[0099] The top portion 1450 is provided with a forward projection 1456 that protrudes slightly forward. A first insertion hole 1458 is formed in the forward projection 1456. The first insertion hole 1458 overlaps with a second insertion hole 1416 formed on the upper surface of the pillar-side stay 1414.

[0100] As shown in Figure 19, the base portion 1442 has a substantially flat tab portion 1460 and an engaging claw 1462 provided on the tab portion 1460. The tab portion 1460 protrudes slightly rearward from the lower end on the rear surface of the base portion 1442 and is bent so as to incline downward as it extends further rearward. As shown in Figures 21 and 22, the engaging claw 1462 has an overlapping portion 1464 that overlaps the left leg portion 1402L or the right leg portion 1402R when the pillar cover 1430 is viewed from the seat width direction. The overlapping portion 1464 protrudes from the lower surface of the tab portion 1460 so as to incline forward as it extends downward. Note that the tab portion 1460 is not essential. For example, the engaging claw 1462 may be provided on the base portion 1442. Also, although there are two engaging claws 1462 in the illustrated example, there may be one or three or more engaging claws 1462.

[0101] The engaging claw 1462 further has a locking portion 1466 extending from the overlapping portion 1464. The locking portion 1466 is bent relative to the overlapping portion 1464 and extends forward. As shown in Figure 21, in the engaging claw 1462, the lower part of the overlapping portion 1464 and the locking portion 1466 are inserted into the engagement hole 1322 of the cover plate 1320. That is, the engaging claw 1462 engages with the engagement hole 1322. As a result, the pillar cover 1430 engages with the cover plate 1320 (cover support 1321). The front end of the locking portion 1466 is located in front of the front end of the engagement hole 1322. This prevents the engaging claw 1462 from coming out of the engagement hole 1322. The front end of the locking portion 1466 is the front end of the engaging claw 1462.

[0102] As shown in Figure 19, the two engagement holes 1322 are located between the left leg portion 1402L and the right leg portion 1402R of the headrest pillar 1400. Therefore, in each engagement claw 1462 that engages with each engagement hole 1322, the overlapping portion 1464 is located between the left leg portion 1402L and the right leg portion 1402R.

[0103] Figure 23 is a schematic bottom view of the headrest pillar 1400 and pillar cover 1430 as seen from the XXIII direction (downward) in Figure 20. The rear cover member 1480 is omitted. The imaginary straight line M1 is a straight line connecting the front end of the second left extension 1406L and the front end of the second right extension 1406R, and indicates the front end position of the headrest pillar 1400. The front end of the locking part 1466 (the front end of the engaging claw 1462) is behind the imaginary straight line M1 in the seat longitudinal direction. That is, the front end of the engaging claw 1462 is located behind the front end of the headrest pillar 1400 (the front ends of the second left extension 1406L and the second right extension 1406R).

[0104] Figure 24 is a schematic side view of the vehicle seat 1010 as seen from the left. However, the cushion of the seat back 1030 is omitted, and only the seat back frame 1300, the casing 1062 of the airbag module 1060, the box body 1310, and the cover plate 1320 are shown. Also, only the front cover member 1440 of the pillar cover 1430 is shown. The imaginary straight line M2 is a straight line that extends along the vertical direction and passes through the rear end of the casing 1062. The front end of the locking part 1466 is behind the imaginary straight line M2 in the front-rear direction of the seat. That is, the front end of the engaging claw 1462 is located behind the airbag 1064 before deployment.

[0105] As shown in Figure 19, the bottom portion 1442 of the front cover member 1440 has a rib 1468. The rib 1468 is located above the tab portion 1460 on the rear surface of the bottom portion 1442 and extends along the sheet width direction. In the sheet width direction, the length of the rib 1468 is greater than the length of the tab portion 1460.

[0106] The front cover member 1440 has a left wall portion 1470 and a right wall portion 1472. The left wall portion 1470 is the portion enclosed by the bottom portion 1442 and the left slanted portion 1444 on the left side of the front opening 1448. The right wall portion 1472 is the portion enclosed by the bottom portion 1442 and the right slanted portion 1446 on the right side of the front opening 1448. Two insertion portions 1474 are provided on the rear surfaces of the left wall portion 1470 and the right wall portion 1472, respectively. The two insertion portions 1474 protrude rearward from the left wall portion 1470 and the right wall portion 1472, respectively. The rib 1468 is located between the two insertion portions 1474.

[0107] The rear cover member 1480 has a roughly triangular frame shape and includes a claw protection portion 1482, a rear opening 1484, and an insertion hole 1486 extending along the front-rear direction of the seat. As shown in Figure 21, when the front cover member 1440 and the rear cover member 1480 are connected to each other, the front surface of the claw protection portion 1482 faces the rear surface of the bottom portion 1442 of the front cover member 1440. Therefore, when the rear cover member 1480 is viewed from the rear, the claw protection portion 1482 covers and shields the engaging claw 1462.

[0108] Furthermore, as shown in Figure 18, the engaging claw 1462 is located between the headrest 1040 and the claw protection portion 1482 in the front-rear direction of the seat. In other words, when the engaging claw 1462 is viewed from the front-rear direction of the seat, the engaging claw 1462 overlaps with the headrest 1040.

[0109] As shown in Figure 19, the outer peripheral edge of the rear cover member 1480 has an outwardly protruding wall portion 1488 that slightly protrudes forward. As shown in Figure 18, a plurality of connecting claws 1490 are provided on the inner surface of the outwardly protruding wall portion 1488. Note that Figure 18 shows the connecting claws 1490 provided on the top of the rear cover member 1480.

[0110] As shown in Figure 19, the rear cover member 1480 has an inwardly protruding wall portion 1492 that extends along the front-rear direction of the sheet at the periphery of the rear opening 1484. As shown in Figure 18, a storage space 1494 is formed between the inwardly protruding wall portion 1492 and the outwardly protruding wall portion 1488. Most of the front cover member 1440 is housed in the storage space 1494.

[0111] As shown in Figure 20, the rear cover member 1480 has two pillar retaining portions 1496 and two tongue portions 1498 on its front surface. The two pillar retaining portions 1496 are spaced apart from each other at a predetermined interval in the seat width direction. The two pillar retaining portions 1496 each hold the left leg portion 1402L and the right leg portion 1402R of the headrest pillar 1400, respectively.

[0112] The tongue portion 1498 is a thin-walled protrusion that slightly projects forward from the front surface of the rear cover member 1480, located below the rear opening 1484. Therefore, as shown in Figure 22, an engagement recess 1500 is formed between the upper surface of the tongue portion 1498 and the lower surface of the inwardly protruding wall portion 1492. Since there are two tongue portions 1498, there are also two engagement recesses 1500. Alternatively, there may be one tongue portion 1498 and one engagement recess 1500.

[0113] When the rear cover member 1480 is connected to the front cover member 1440, the outwardly protruding wall portion 1488 covers the rear projection portion 1452 of the front cover member 1440 (see Figures 17 and 18). Accordingly, the connecting claw 1490 engages with the connecting hole 1454 (see Figure 18). Also, the slightly downwardly inclined rear end of the tab portion 1460 engages with the engaging recess 1500 (see Figure 22). Furthermore, the insertion portion 1474 is inserted into the insertion hole 1486. ​​A clip 1501 attached to the rear end of the insertion portion 1474 inside the insertion hole 1486 (see Figure 19) prevents the insertion portion 1474 from coming out of the insertion hole 1486.

[0114] As shown in Figure 20, when the tab portion 1460 engages with the two engagement recesses 1500, the two engagement recesses 1500 are located between the two engagement claws 1462. If there are three or more engagement claws 1462, at least one engagement recess 1500 is located between two adjacent engagement claws 1462.

[0115] As shown in Figure 21, when the pillar cover 1430 is configured, the tab portion 1460 is located in the vertical direction between the upper surface of the cover plate 1320 (cover support 1321) and the lower surface of the inwardly protruding wall portion 1492 of the rear cover member 1480.

[0116] Next, we will explain how to assemble the pillar cover 1430 to the headrest pillar 1400 and how to assemble the headrest 1040 to the headrest pillar 1400 for the vehicle seat 1010 shown in Figure 16.

[0117] As shown in Figure 19, in the pillar mounting state, the upper part of the left leg portion 1402L, the upper part of the right leg portion 1402R, and the upper part of the pillar 1410 are exposed upward from the top of the seat back 1030. From this state, as shown in Figure 25, the front of the headrest pillar 1400 is covered by the front cover member 1440. Specifically, the two engaging claws 1462 of the front cover member 1440 engage with the two engaging holes 1322 of the cover plate 1320, respectively. This engagement supports the front cover member 1440 on the cover plate 1320.

[0118] As a result of the above engagement, the second insertion hole 1416 on the upper surface of the pillar-side stay 1414 and the first insertion hole 1458 in the front projection 1456 of the front cover member 1440 overlap (see Figure 18). The front cover member 1440 is supported by the headrest pillar 1400 when a nut (not shown) is screwed onto the connecting bolt 1502 that passes through the second insertion hole 1416 and the first insertion hole 1458. In this way, by engaging the engaging claw 1462 with the engaging hole 1322, the alignment of the second insertion hole 1416 and the first insertion hole 1458 is easily achieved.

[0119] Next, the headrest 1040 is supported by a pillar-side stay 1414 located at the front of the upper part 1410 of the headrest pillar 1400 via a support bolt 1418. After that, as shown in Figure 26, the display 1050 is attached to the seat back 1030.

[0120] Next, the rear cover member 1480 is connected to the front cover member 1440. That is, as shown in Figures 20 and 22, the tab portion 1460 is engaged with the engagement recess 1500. This aligns the connecting claw 1490 of the rear cover member 1480 with the connecting hole 1454 of the front cover member 1440. By engaging the tab portion 1460 with the engagement recess 1500 in this way, the positioning of the rear cover member 1480 relative to the front cover member 1440 becomes easier. Subsequently, as shown in Figure 18, the connecting claw 1490 of the rear cover member 1480 is engaged with the connecting hole 1454 of the front cover member 1440. This completes the pillar cover 1430 shown in Figure 17, and the headrest pillar 1400 is covered by the pillar cover 1430.

[0121] The vehicle seat 1010, with the headrest pillar 1400, headrest 1040, and pillar cover 1430 assembled as described above, provides the following effects.

[0122] As can be seen from Figures 18 and 19, in the vehicle seat 1010, the pillar cover 1430 is supported by the headrest pillar 1400 and engages with a cover support 1321, which is a separate component from the headrest pillar 1400. Therefore, even if an excessive load is applied to the headrest 1040 from the occupant's head, deformation of the pillar cover 1430 can be suppressed.

[0123] In the above-described embodiment, the cover support 1321 is a cover plate 1320 attached to the seat back frame 1300, but the cover support 1321 may be the seat back frame 1300 itself. Alternatively, the cover support 1321 may be another member attached to the seat back frame 1300. In other words, the pillar cover 1430 may be indirectly supported by the seat back frame 1300, or it may be directly supported by the seat back frame 1300.

[0124] The pillar cover 1430 has engaging claws 1462. The cover plate 1320, which is the cover support 1321, has engaging holes 1322 into which the engaging claws 1462 engage.

[0125] Thus, the simple structure in which the engaging claw 1462 engages with the engaging hole 1322 effectively suppresses deformation of the pillar cover 1430.

[0126] As shown in Figure 20, the pillar cover 1430 has a front cover member 1440 and a rear cover member 1480. The front cover member 1440 has an engaging claw 1462. The rear cover member 1480 has a claw protection portion 1482. When the rear cover member 1480 is viewed from the rear in the front-rear direction of the seat, the claw protection portion 1482 shields the engaging claw 1462.

[0127] With this configuration, the rear of the engaging claw 1462 is covered by the claw protection portion 1482, thereby protecting the engaging claw 1462.

[0128] As shown in Figures 21 and 22, the overlapping portion 1464 of the engaging claw 1462 overlaps the headrest pillar 1400 when the vehicle seat 1010 is viewed from the seat width direction.

[0129] In this case, the headrest pillar 1400 functions as a protective part for the engaging claw 1462 in the seat width direction. Therefore, the transmission of external force to the engaging claw 1462 in the seat width direction is suppressed.

[0130] The headrest pillar 1400 has a left leg portion 1402L and a right leg portion 1402R (two legs 1402). As shown in Figure 16, the left leg portion 1402L and the right leg portion 1402R are spaced apart from each other in the seat width direction and supported by the connecting frame 1304 of the seat back frame 1300. As can be seen from Figures 19 to 22, the overlapping portion 1464 of the engaging claw 1462 is located between the left leg portion 1402L and the right leg portion 1402R.

[0131] Since the engaging claw 1462 is positioned between the left leg portion 1402L and the right leg portion 1402R, the transmission of external forces to the engaging claw 1462 in the seat width direction is further suppressed.

[0132] As shown in Figure 23, the engaging claw 1462 is positioned behind the front end of the headrest pillar 1400 in the seat's front-rear direction.

[0133] In this case, compared to the case where the engaging claw 1462 is positioned in front of the front end of the headrest pillar 1400, the distance between the point on the pillar cover 1430 that receives the load of the occupant's head and the engaging claw 1462 is increased. As a result, the load of the occupant's head is less likely to be transmitted to the engaging claw 1462. Consequently, the pillar cover 1430 becomes even less prone to deformation.

[0134] As shown in Figures 19 and 22, the front cover member 1440 has a tab portion 1460 that protrudes rearward in the front-rear direction of the seat. The engaging claw 1462 is provided on this tab portion 1460. In the vertical direction, the tab portion 1460 is located between the rear cover member 1480 and the cover support 1321.

[0135] Since the tab portion 1460 is located between the rear cover member 1480 and the cover support 1321, deformation of the tab portion 1460 and the engaging claw 1462 can be suppressed even when a load is transmitted to the tab portion 1460.

[0136] As shown in Figure 22, the rear cover member 1480 has an engaging recess 1500 into which the tab portion 1460 engages. By engaging the tab portion 1460 with the engaging recess 1500 in this way, the front cover member 1440 can be easily assembled to the rear cover member 1480. Furthermore, deformation of the front cover member 1440 can be suppressed.

[0137] As shown in Figure 20, the front cover member 1440 has two or more engaging claws 1462. The engaging recess 1500 is located between two adjacent engaging claws 1462. In this case, when engaging the tab portion 1460 with the engaging recess 1500, positioning the tab portion 1460 relative to the engaging recess 1500 is easy.

[0138] As shown in Figure 24, the vehicle seat 1010 is equipped with an airbag 1064. The engaging claw 1462 is located behind the airbag 1064 in the front-rear direction of the seat before it is deployed.

[0139] Since the engaging claw 1462 is located behind the airbag 1064, interference between the engaging claw 1462 and the airbag 1064 is avoided when the airbag 1064 deploys.

[0140] As shown in Figure 25, when viewed from the front-to-back direction of the seat, the engaging claw 1462 overlaps with the headrest 1040. Therefore, it is difficult for a load to be applied to the engaging claw 1462 from the front. In other words, with this configuration, the engaging claw 1462 can be protected by the headrest 1040.

[0141] As shown in Figure 19, a rib 1468 extending along the sheet width direction is provided above the tab portion 1460 on the bottom portion 1442 of the front cover member 1440. The rib 1468 reinforces the tab portion 1460 and the bottom portion 1442, thereby suppressing deformation of the tab portion 1460 and the bottom portion 1442.

[0142] With regard to the embodiments described above, the following additional information is disclosed.

[0143] (Note 1) The vehicle seat (10) of the present disclosure is a vehicle seat comprising a seat back frame (22) and a headrest (40) attached to the upper part of the seat back frame, wherein the headrest comprises a frame member (41) supported by the seat back frame and a cover member (44) that covers the frame member and has a front wall portion (441a) facing forward in the front-rear direction of the seat, the cover member having a through hole (443) in the front wall portion, and the frame member is positioned to overlap with the through hole when viewed from the front-rear direction of the seat.

[0144] (Note 2) The vehicle seat described in Note 1, wherein the frame member may have a protruding portion (413) that passes through the through hole and protrudes forward from the front wall portion of the cover member.

[0145] (Note 3) A vehicle seat as described in Note 2, further comprising a connecting portion (43) joined to the rear surface of the protruding portion and for supporting the frame member on the seat back frame, wherein the cover member has a rear wall portion (442a) facing rearward in the front-rear direction of the seat, the frame member is positioned between the front wall portion and the rear wall portion, and an insertion hole (451) for passing the connecting portion is formed in the rear wall portion, and the insertion hole may be positioned to overlap the through hole when viewed from the front-rear direction of the seat.

[0146] (Note 4) In the vehicle seat described in Note 3, the vertical length (L2) of the insertion hole may be smaller than the vertical length (L1) of the through hole.

[0147] (Note 5) A vehicle seat as described in Note 2, wherein the frame member further has a protrusion (421) projecting toward the cover member, and the cover member has a receiving portion (448) that engages with the protrusion.

[0148] (Note 6) A vehicle seat as described in Note 5, wherein the convex portion has a plurality of convex parts (422) and a concave portion (423) formed between the convex parts, and the convex portion may engage with the receiving portion at the concave portion.

[0149] (Note 7) In the vehicle seat described in Note 5, the dimension of the protruding portion (W1) in the seat width direction may be larger than the dimension of the receiving portion (W2) in the seat width direction.

[0150] (Note 8) A vehicle seat as described in Note 5, wherein the cover member has a first surface (446) on which the receiving portion is provided and a second surface (447) opposite to the first surface, the receiving portion protrudes from the first surface, and the second surface may have a convex portion (450) that protrudes in the direction opposite to the direction in which the receiving portion protrudes.

[0151] (Note 9) A vehicle seat as described in any one of Notes 2 to 4, further comprising an airbag (50), wherein the protruding portion has a protruding surface (415) that supports the occupant's head, and the rear end of the airbag may be located behind the protruding surface in the front-rear direction of the seat.

[0152] (Note 10) The present disclosure is a method for manufacturing a vehicle seat comprising a seat back frame and a headrest attached to the upper part of the seat back frame, wherein the headrest comprises a frame member supported by the seat back frame and a cover member covering the frame member and having a front wall portion facing forward in the front-rear direction of the seat, the cover member having a through hole in the front wall portion, and the frame member being positioned to overlap with the through hole when viewed from the front-rear direction of the seat, the method for manufacturing a vehicle seat comprising a first step (S20) of attaching the cover member to the frame member and a second step (S40) of attaching the headrest to the seat back frame after the first step.

[0153] (Note 11) The vehicle seat (1010) of the present disclosure is a vehicle seat mounted on a vehicle and comprises a seat back frame (1300), a headrest pillar (1400) supported by the seat back frame, a pillar cover (1430) that covers the headrest pillar from the outside and is supported by the headrest pillar, and a cover support (1321) which is a separate member from the headrest pillar and engages with the pillar cover.

[0154] Since the pillar cover engages with the cover support, deformation of the pillar cover can be suppressed even when a large load is applied to the pillar cover from the headrest.

[0155] (Note 12) In the vehicle seat described in Note 11, the pillar cover may have an engaging claw (1462), and the cover support may have an engaging hole (1322) into which the engaging claw engages.

[0156] The simple structure, in which the engaging claws engage with the engaging holes, effectively suppresses deformation of the pillar cover.

[0157] (Note 13) In the vehicle seat described in Note 12, the pillar cover comprises a front cover member (1440) and a rear cover member (1480) which is a separate member from the front cover member and is located behind the front cover member in the front-rear direction of the seat, the front cover member having the engaging claws, and the rear cover member having a claw protection portion (1482), and when the rear cover member is viewed from the rear in the front-rear direction of the seat, the claw protection portion may shield the engaging claws.

[0158] Since the rear of the engaging claw is covered by the claw protection part, the engaging claw can be protected.

[0159] (Note 14) In the vehicle seat described in Note 13, the engaging claw may have an overlapping portion (1464) that overlaps the headrest pillar when the vehicle seat is viewed from the seat width direction.

[0160] When viewed from the seat width direction, the headrest pillar overlaps the overlapping portion of the engaging claw, so in the seat width direction, the headrest pillar functions as a protective part for the engaging claw. Therefore, the transmission of external forces to the engaging claw is suppressed in the seat width direction.

[0161] (Note 15) In the vehicle seat described in Note 14, the headrest pillar has two legs (1402) supported by the seat back frame and spaced apart from each other in the seat width direction, and the overlapping portion of the engaging claw may be located between the two legs.

[0162] Since the engaging claws are positioned between the two legs, the transmission of external forces to the engaging claws in the width direction of the seat is further suppressed.

[0163] (Note 16) In the vehicle seat described in any one of Notes 13 to 15, the engaging claw may be positioned behind the front end of the headrest pillar in the front-rear direction of the seat.

[0164] In this case, compared to when the engaging claw is positioned forward of the front end of the headrest pillar, the distance between the point on the pillar cover that receives the load of the occupant's head and the engaging claw is greater. As a result, the load of the occupant's head is less likely to be transmitted to the engaging claw.

[0165] (Note 17) In the vehicle seat described in any one of Notes 13 to 16, the front cover member has a tab portion (1460) that protrudes rearward in the front-rear direction of the seat, the engaging claw is provided on the tab portion, and the tab portion may be located between the rear cover member and the cover support in the vertical direction.

[0166] Since the tab portion is located between the rear cover member and the cover support in the vertical direction, deformation of the tab portion and the engaging claw can be suppressed even if a load is transmitted to the tab portion from the vertical direction.

[0167] (Note 18) In the vehicle seat described in Note 17, the rear cover member may have an engaging recess (1500) into which the tab portion engages.

[0168] By engaging the tab portion with the engagement recess, the front cover member can be easily assembled to the rear cover member. Furthermore, deformation of the front cover member can be suppressed.

[0169] (Note 19) In the vehicle seat described in Note 18, the front cover member may have two or more of the engaging claws, and the engaging recess may be located between adjacent engaging claws.

[0170] In this case, positioning the tab portion relative to the engagement recess is easy when engaging the tab portion with the engagement recess.

[0171] (Note 20) In a vehicle seat described in any one of Notes 12 to 19, an airbag (1064) may be provided, and the engaging claw may be located behind the airbag in the front-rear direction of the seat.

[0172] Since the engagement claw is located behind the airbag, interference between the engagement claw and the airbag is avoided when the airbag deploys.

[0173] Furthermore, the present invention is not limited to the disclosure described above, and can take various configurations without departing from the spirit of the invention.

Claims

1. A vehicle seat (10) comprising a seat back frame (22) and a headrest (40) attached to the upper part of the seat back frame, wherein the headrest comprises a frame member (41) supported by the seat back frame and a cover member (44) that covers the frame member and has a front wall portion (441a) facing forward in the front-rear direction of the seat, the cover member having a through hole (443) in the front wall portion, and the frame member being positioned so as to overlap the through hole when viewed from the front-rear direction of the seat.

2. A vehicle seat according to claim 1, wherein the frame member has a projection (413) that passes through the through hole and protrudes forward from the front wall portion of the cover member.

3. A vehicle seat according to claim 2, further comprising a connecting portion (43) joined to the rear surface of the protruding portion and for supporting the frame member on the seat back frame, wherein the cover member has a rear wall portion (442a) facing rearward in the front-rear direction of the seat, the frame member is positioned between the front wall portion and the rear wall portion, an insertion hole (451) for passing the connecting portion is formed in the rear wall portion, and the insertion hole is positioned to overlap the through hole when viewed from the front-rear direction of the seat.

4. A vehicle seat according to claim 3, wherein the vertical length (L2) of the insertion hole is smaller than the vertical length (L1) of the through hole.

5. A vehicle seat according to claim 2, further comprising: the frame member having a projection (421) projecting toward the cover member; and the cover member having a receiving portion (448) that engages with the projection.

6. A vehicle seat according to claim 5, wherein the convex portion has a plurality of convex portions (422) and a concave portion (423) formed between the convex portions, and the convex portion engages with the receiving portion at the concave portion.

7. A vehicle seat according to claim 5, wherein the dimension of the protruding portion (W1) in the seat width direction is greater than the dimension of the receiving portion (W2) in the seat width direction.

8. A vehicle seat according to claim 5, wherein the cover member has a first surface (446) on which the receiving portion is provided and a second surface (447) opposite to the first surface, the receiving portion protrudes from the first surface, and the second surface has a convex portion (450) that protrudes in the direction opposite to the direction in which the receiving portion protrudes.

9. A vehicle seat according to any one of claims 2 to 4, further comprising an airbag (50), wherein the protrusion has a protruding surface (415) that supports the head of the occupant, and the rear end of the airbag is located behind the protruding surface in the front-rear direction of the seat.

10. A method for manufacturing a vehicle seat comprising a seat back frame and a headrest attached to the upper part of the seat back frame, wherein the headrest comprises a frame member supported by the seat back frame and a cover member covering the frame member and having a front wall portion facing forward in the front-rear direction of the seat, the cover member having a through hole in the front wall portion, and the frame member being positioned to overlap the through hole when viewed from the front-rear direction of the seat, the method comprising: a first step (S20) of attaching the cover member to the frame member; and a second step (S40) of attaching the headrest to the seat back frame after the first step.

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