Vehicle seat

Abstract

Provided is a vehicle seat that allows a seat heater to be fixed easily to a skin material, and that enables the seat heater to be attached inside a seat main body more efficiently. A vehicle seat (S) comprises: a pad material (10) that supports an occupant; a skin material (20) that covers the pad material (10); and a back seat heater (40) that is attached to the skin material (20). The skin material (20) has a hanging member (22) that is hung and fixed in a skin material hanging groove (11) formed in the pad material (10), and the back seat heater (40) has a heater wire (42) and a heater base fabric (41) on which the heater wire (42) is disposed. The heater base fabric (41) has an insertion portion (411) that is inserted into a slit (221) provided in the hanging member (22) and that engages with the slit (221).

Description

Vehicle seat

[0001] The present invention relates to a vehicle seat, and more particularly to a vehicle seat provided with a seat heater.

[0002] Conventionally, a vehicle seat has been known in which a seat-shaped seat heater is attached inside a seat body to improve the comfort of a passenger sitting on the seat body. As an example of such a vehicle seat, a seat body is configured by placing a pad material on a seat frame serving as a skeleton and further covering it with a skin material, and a seat heater disposed between the pad material and the skin material and sewn to the back surface of the skin material is provided (see, for example, Patent Document 1).

[0003] Japanese Patent Application Laid-Open No. 2023-049732, Japanese Patent Application Laid-Open No. 2022-179315

[0004] According to the vehicle seat described in Patent Document 1, although the work of attaching the seat heater inside the seat body can be made more efficient, further improvement in efficiency has been desired. More specifically, in the vehicle seat described in Patent Document 1, the seat heater is first sewn to the back surface of the skin material, and then attached to the seat body by being inserted into the suspension groove of the pad material together with the skin material. Here, sewing is a laborious and time-consuming operation, and it has been pointed out that it may hinder the efficiency of the entire operation.

[0005] The present invention has been made in view of the above problems, and an object of the present invention is to provide a vehicle seat capable of easily fixing a seat heater to a skin material and more efficiently attaching the seat heater inside a seat body.

[0006] According to the vehicle seat of the present invention, the above problems are solved by providing a vehicle seat including a pad material that supports a passenger, a skin material that covers the pad material, and a seat heater attached to the skin material, wherein the skin material has a suspension portion that is suspended and fixed in a groove formed in the pad material, the seat heater has a heater wire and a heater base fabric on which the heater wire is disposed, and the heater base fabric is inserted into an insertion portion provided in the suspension portion and has an insertion portion that engages with the insertion portion.

[0007] With the above configuration, the seat heater can be easily fixed to the upholstery material by inserting the insertion portion provided in the heater base fabric into the insertion portion provided in the suspension portion of the upholstery material, making it possible to install the seat heater inside the seat body more efficiently. In addition, the seat heater and upholstery material can be fixed with a simple structure, and since sewing thread and adhesive are not required, it is possible to reduce labor costs and suppress material costs.

[0008] Furthermore, the insertion portion has an extension portion extending from the end of the heater base fabric toward the outside of the heater base fabric, and an engaging portion provided at the outer end of the extension portion, wherein the inner end of the engaging portion is preferably located closer to the seating center than the connection portion between the extension portion and the engaging portion. With the above configuration, since the inner end of the engaging portion is located inside the connection portion between the extension portion and the engaging portion, it is possible to prevent the insertion portion from unintentionally detaching from the inserted portion.

[0009] Furthermore, the insertion portion is a slit extending in the suspension direction perpendicular to the seating surface, and the insertion portion is preferably inserted into the slit in a twisted state along the direction in which the slit extends. With the above configuration, the insertion portion is inserted into the slit in a twisted state along the direction in which the slit extends, and returns to its twisted state after passing through the slit. Therefore, it is possible to prevent the insertion portion from unintentionally detaching from the slit.

[0010] Furthermore, the insertion portion may extend in a direction approaching the seating surface and be inserted into the insertion portion after passing over the tip of the suspension portion by wrapping around the suspension portion without being inserted into the insertion portion. With the above configuration, since the insertion portion extends by wrapping around the suspension portion before being inserted into the insertion portion, it is possible to suppress the insertion portion from unintentionally detaching from the insertion portion.

[0011] Furthermore, the insertion portion is preferably inserted into the receiving portion, wraps around the suspension portion, passes the tip of the suspension portion, and then extends in a direction approaching the seating surface. With the above configuration, since the insertion portion extends to circle around the receiving portion after being inserted into it, it is possible to prevent the insertion portion from unintentionally detaching from the receiving portion.

[0012] Furthermore, the heater base fabric has a base fabric slit, and the insertion portion is preferably inserted into the base fabric slit. With the above configuration, the insertion portion is inserted into the insertion portion provided in the suspension portion and the base fabric slit provided in the heater base fabric, so it is possible to prevent the insertion portion from unintentionally detaching from the insertion portion.

[0013] Furthermore, the insertion portion should extend in a direction that intersects with the direction perpendicular to the direction in which the end of the heater base fabric on which the insertion portion is provided is located, and the direction in which the plane parallel to the seating surface is perpendicular. With the above configuration, even if the insertion portion and the inserted portion are deformed by the weight of the person sitting on it, it is possible to prevent the insertion portion from unintentionally detaching from the inserted portion.

[0014] Furthermore, the heater base fabric has a first base fabric portion provided with the insertion portion and a second base fabric portion having a base fabric slit through which the insertion portion can be inserted, and the insertion portion is preferably inserted into the base fabric slit after being inserted into the portion to be inserted. With the above configuration, since the insertion portion is inserted into the portion to be inserted provided in the suspension portion and the base fabric slit provided in the heater base fabric, it is possible to prevent the insertion portion from unintentionally detaching from the portion to be inserted. In addition, by inserting the insertion portion provided in the first base fabric portion into the portion to be inserted and the base fabric slit, the seat heater can be easily and firmly fixed to the surface material.

[0015] Furthermore, the vehicle seat has a central portion located in the center in the seat width direction and bolster portions located on both sides of the central portion in the seat width direction, the first base fabric portion is disposed in the central portion, the second base fabric portion is disposed in the bolster portion, and the insertion portion connects the first base fabric portion and the second base fabric portion. With the above configuration, the insertion portion is inserted through the insertion portion provided in the suspension portion and the base fabric slit provided in the second base fabric portion, so it is possible to prevent the insertion portion from unintentionally detaching from the insertion portion. In addition, by inserting the insertion portion located in the central portion through the base fabric slit provided in the bolster portion, it is possible to easily and firmly fix the seat heater to the entire surface material.

[0016] Furthermore, the insertion portion may have multiple intersecting slits. With the above configuration, it is possible to suppress the insertion portion from unintentionally detaching from the insertion portion, while also reducing the workload on the worker when inserting the insertion portion into the insertion portion.

[0017] Furthermore, the insertion portion has a substantially T-shape, and it is preferable that the insertion portion be inserted into the insertion portion while folded. With the above configuration, the insertion portion is inserted into the insertion portion while folded, and returns to its original state after passing through the insertion portion. Therefore, it is possible to suppress the insertion portion from unintentionally detaching from the insertion portion of the suspension portion, while reducing the workload on the worker when inserting the insertion portion into the insertion portion.

[0018] According to the present invention, the seat heater can be easily fixed to the surface material, and the seat heater can be installed inside the seat body more efficiently. Furthermore, according to the present invention, the seat heater and the surface material can be fixed with a simple structure, and since sewing thread and adhesive are not required, it is possible to reduce labor costs and suppress material costs. Furthermore, according to the present invention, it is possible to prevent the insertion part from unintentionally detaching from the inserted part. Furthermore, according to the present invention, it is possible to prevent the insertion part from unintentionally detaching from the slit. Furthermore, according to the present invention, the seat heater can be easily and firmly fixed to the surface material. Furthermore, according to the present invention, the seat heater can be easily and firmly fixed to the entire surface material. Furthermore, according to the present invention, it is possible to prevent the insertion part from unintentionally detaching from the inserted part.

[0019] This is a perspective view of the vehicle seat of this embodiment, taken from the front at an oblique angle. This is a front view of the back seat heater. This diagram shows the insertion of the insertion part into the slit. This is a cross-sectional view showing the back seat heater suspended in the suspension groove together with the surface material. This diagram shows the insertion of the insertion part into the slit according to the first modification. This diagram shows the insertion of the insertion part into the slit according to the second modification. This is a front view of the back seat heater according to the second embodiment. This is a cross-sectional view showing the back seat heater suspended in the suspension groove together with the surface material. This is a cross-sectional view showing the back seat heater suspended in the suspension groove together with the surface material. This is a front view of the back seat heater according to the third embodiment. This is a front view of the back seat heater according to the fourth embodiment. This diagram shows the insertion of the insertion part into the slit and the base fabric slit. This is a perspective view of the vehicle seat according to the fifth embodiment. This is a top view of the seat cushion. This is a top view of the pad material. This is a view of the surface material and seat heater from the back side, showing the state before they are suspended in the suspension groove. This is a perspective view of the surface material and the seat heater, showing the surface material and the base material fixed together. This is an exploded perspective view of the surface material and the seat heater. This is a front view of the surface material and the seat heater. This is the XX-XX section of Figure 14. This is a perspective view of the surface material and the seat heater, illustrating the positional relationship between the locking part and the connecting part. This is the XXII-XXII section of Figure 14.

[0020] One embodiment of the present invention will be described below. The embodiments described below are merely examples to facilitate understanding of the present invention and do not limit it. The present invention can be modified and improved without departing from its spirit, and of course, equivalents thereof are included. Furthermore, the descriptions below regarding the material, shape, and size of the components of the vehicle seat are merely specific examples and do not limit the present invention. In other words, the material, shape, and size of each device and its components can be freely designed as long as they satisfy the specific requirements of the present invention.

[0021] In the following, a vehicle seat S, which is installed in a vehicle, will be given as an example of a vehicle seat, and its configuration will be described. However, the present invention is not limited to seats installed in ground vehicles with wheels, such as automobiles and trains, but can also be applied to seats installed in aircraft, ships, and other vehicles that move on surfaces other than the ground. Furthermore, the seat of the present invention can also be applied to chairs used indoors other than in vehicles.

[0022] In the following explanation, "seat longitudinal direction" refers to the longitudinal direction of the vehicle seat S, which coincides with the direction of travel when the vehicle is in motion. "Seat width direction" refers to the width direction of the vehicle seat S, which coincides with the left-right direction as viewed from an occupant seated on the vehicle seat S. "Vertical direction" refers to the vertical direction of the vehicle seat S, which coincides with the vertical direction when the vehicle is traveling on a horizontal plane. The outer and inner directions are determined with respect to the occupant. That is, the direction approaching the center in the seat width direction is the inner direction, and the direction away from the center is the outer direction. Components provided in pairs on the left and right are assigned a common number, and when specifying the left and right, "left side" or "right side" is added to the name indicating the component, and the letters "L" or "R" are added to the symbol.

[0023] <Vehicle Seat S> The basic configuration of the vehicle seat S according to this embodiment will be described with reference to Figure 1. Figure 1 is a perspective view of the vehicle seat S seen from the front at an angle, and for illustrative purposes, a part of the vehicle seat S in Figure 1 is shown with the surface materials 1b, 3b, and 20 removed. The vehicle seat S is placed on the floor of the vehicle and is a seat on which the occupants of the vehicle (hereinafter sometimes referred to as occupants) sit. In this embodiment, the vehicle seat S is used as a front seat corresponding to the front seat of the vehicle. However, it is not limited to this, and the vehicle seat S can also be used as a rear seat, and can also be used as a middle seat in the second row or a rear seat in the third row in a vehicle equipped with three rows of seats in the front-to-back direction.

[0024] The vehicle seat S mainly consists of a seat cushion 1, a seat back 2, and a headrest 3. In the following, the seat cushion 1, seat back 2, and headrest 3 may be collectively referred to as the seat body. The vehicle seat S also has a reclining device 4 that rotatably connects the seat back 2 to the seat cushion 1.

[0025] <<Seat Cushion 1>> The seat cushion 1 is a support member that supports the buttocks of a seated person and supports the seated person from below. The seat cushion 1 has a central part 1A located in the center in the width direction of the seat, and side bolster parts 1B located to the left and right of the central part 1A. The central part 1A functions as a seating area for an occupant seated on a vehicle seat S. The upper surface of the side bolster parts 1B bulges upward from the upper surface of the central part 1A.

[0026] The seat cushion 1 mainly consists of a seat cushion frame (not shown) that forms the skeleton of the seat cushion 1, a pad material 1a that covers the seat cushion frame and supports the occupant, and a surface material 1b that covers the pad material 1a. The seat cushion 1 also has a cushion seat heater 30 between the pad material 1a and the surface material 1b.

[0027] The seat cushion frame consists of a rectangular frame when viewed from above, and its main components are left and right side frames, a pan frame installed on the front portion of the left and right side frames, and a rear connecting frame that connects the rear portions of the left and right side frames. The seat cushion frame also has pressure-receiving members that are attached to the pan frame and the rear connecting frame.

[0028] The pad material 1a is a cushioning material made of foamed urethane or the like, and has a surface material suspension groove 11 formed therein. A fixing member (for example, a clip, etc.) for fixing the surface material 1b is attached to the back of the surface material suspension groove 11. The surface material 1b is made of an elastic fabric material or leather material, and is formed, for example, by sewing together a base fabric made of natural fibers or synthetic fibers. The surface material 1b is fixed to the fixing member provided at the back of the surface material suspension groove 11 as described above.

[0029] The cushion seat heater 30 is a planar heating element that warms the buttocks of an occupant sitting in a vehicle seat S, providing comfort to the occupant. The cushion seat heater 30 is flexible and is attached to the back surface of the upholstery material 1b, and is attached together with the upholstery material 1b to the upholstery material suspension groove 11.

[0030] <<Seat Back 2>> The seat back 2 is a support member that supports the back of the occupant, and supports the occupant from the rear. The seat back 2 has a central part 2A located in the center in the width direction of the seat, and side bolster parts 2B located on the left and right sides of the central part 2A. The central part 2A functions as the seating area for the occupant sitting in the vehicle seat S. The front surface of the side bolster parts 2B bulges forward more than the front surface of the central part 2A. The side bolster parts 2B correspond to the bolster part of the present invention.

[0031] The seat back 2 mainly consists of a seat back frame (not shown) that forms the skeleton of the seat back 2, a pad material 10 that covers the seat back frame and supports the occupant, and a surface material 20 that covers the pad material 10. The seat back 2 also has a back seat heater 40 between the pad material 10 and the surface material 20.

[0032] The back frame, when viewed from the front, consists of a rectangular frame and mainly comprises left and right back side frames, an upper frame connecting the upper ends of the left and right back side frames, and a plate-shaped lower frame connecting the lower ends of the left and right back side frames. The back frame also has pressure-receiving members that are hooked onto the left and right back side frames. A reclining device 4 is attached to the connecting portion of the seat cushion 1 and the seat back 2, and the seat back frame is rotatably connected to the seat cushion frame.

[0033] The pad material 10 is a cushioning material made of foamed urethane or the like, and has a surface material suspension groove 11 formed therein. A fixing member (for example, a clip, etc.) for fixing the surface material 20 is attached to the back of the surface material suspension groove 11. The surface material 20 is made of an elastic fabric material or leather material, and is formed, for example, by sewing together a base fabric made of natural fibers or synthetic fibers. The surface material 20 is fixed to the fixing member provided at the back of the surface material suspension groove 11 as described above.

[0034] The back seat heater 40 is a planar heating element that warms the back of the occupant seated in the vehicle seat S, providing comfort to the occupant. The back seat heater 40 is flexible and is attached to the back surface of the upholstery material 20, and is attached together with the upholstery material 20 to the upholstery material suspension groove 11. Details of the mounting structure of the back seat heater 40 will be described later. The back seat heater 40 corresponds to the seat heater of the present invention.

[0035] <<Headrest 3>> The headrest 3 is a support member that supports the head of the seated person, and supports the head of the seated person from the rear. The headrest 3 mainly consists of a headrest pillar (not shown) that forms the frame of the headrest 3, a pad material 3a that covers the headrest pillar, and a surface material 3b that covers the headrest pillar and the pad material 3a. The headrest 3 is supported at the upper end of the seat back 2 so as to be adjustable in position.

[0036] <Backseat Heater 40> The following explanation will use the backseat heater 40 as an example. The cushion seat heater 30 has the same configuration as the backseat heater 40, so a detailed explanation of the cushion seat heater 30 will be omitted. Figure 2 is a front view of the backseat heater 40. As shown in Figure 2, the backseat heater 40 is a planar heating element whose main components are a heater base fabric 41 and heater wires 42 arranged on the heater base fabric 41.

[0037] The heater base fabric 41 is made of a stretchable fabric and supports the heater wire 42 as the base material for the back seat heater 40. Insertion portions 411 are provided at both ends of the heater base fabric 41 in the seat width direction. The heater base fabric 41 is fixed to the surface material 20 by inserting the insertion portions 411 through slits 221 formed in the suspension member 22. Details of the mounting structure of the back seat heater 40 will be described later.

[0038] The heater wire 42 is an electrical resistor arranged in a meandering manner to uniformly cover the heater base fabric 41. By uniformly covering the entire heater base fabric 41 with the heater wire 42, the back seat heater 40 can evenly warm the back of the occupant. The heater wire 42 is a nichrome heating wire, but is not limited to this. The heater wire 42 only needs to have a heat output sufficient to warm the occupant and provide comfort, and the heater wire 42 may be metal foil.

[0039] The back seat heater 40 has a first heater section 401, a second heater section 402, and a third heater section 403, which are formed to avoid the surface material suspension groove 11. This prevents the heater wire 42 from breaking when the back seat heater 40 is suspended in the surface material suspension groove 11. The first heater section 401 and the second heater section 402, and the second heater section 402 and the third heater section 403 are connected by a heater connecting section 404. This makes it possible to supply electrical energy to the first heater section 401, the second heater section 402, and the third heater section 403 from a single power supply unit.

[0040] <<Mounting Structure of Back Seat Heater 40>> Next, the mounting structure of the back seat heater 40 will be described with reference to Figures 2 to 4. As described above, insertion portions 411 for fixing the back seat heater 40 to the surface material 20 are provided on both sides of the heater base fabric 41 in the seat width direction. The insertion portion 411 is an engaging member that protrudes outward in the seat width direction and is inserted into a slit 221 formed in the suspension member 22, which will be described later. The mounting structure of the back seat heater 40, which consists of the insertion portion 411 and the slit 221, will be described in detail below.

[0041] As shown in FIGS. 2 and 3, the insertion portion 411 has an extension portion 412 extending outward from an end portion of the heater base fabric 41 in the sheet width direction, and an engagement portion 413 provided at the outer end portion of the extension portion 412. The engagement portion 413 has an umbrella shape protruding outward in the sheet width direction, and has a tip portion 413a and a pair of engagement pieces 413b that extend inclined in a direction away from the extension portion 412 as they extend inward in the sheet width direction from the tip portion 413a.

[0042] As shown in FIGS. 3 and 4, a suspension member 22 provided at the skin terminal portion 20a of the skin material 20 is formed with a slit 221 extending in the suspension direction (the direction indicated by arrow A in FIGS. 3 and 4). The slit 221 is an elongated hole and extends in a direction orthogonal to the seating surface. The slit 221 corresponds to the insertion portion of the present invention.

[0043] The slit 221 has a dimension that allows the insertion portion 411 to be inserted therethrough. More specifically, the outer width W of the pair of engagement pieces 413b is larger than the dimension L1 in the short side direction of the slit 221 and smaller than the dimension L2 in the long side direction of the slit 221. Therefore, the insertion portion 411 can be inserted into the slit 221 by being twisted 90 degrees along the long side direction of the slit 221. When the inner end portion 413c of the engagement portion 413 passes through the slit 221, the insertion portion 411 returns from the twisted state of 90 degrees, and the engagement piece 413b engages with the suspension member 22.

[0044] Here, as shown in FIG. 2, the inner end portion 413c of the engagement piece 41; b is inside in the sheet width direction from the connection portion 414 between the extension portion 412 and the engagement portion 413 and is located on the seating center side. Therefore, even when the back seat heater 40 or the skin material 20 is deformed by the load of the occupant when the insertion portion 411 is inserted into the slit 221, it is possible to prevent the insertion portion from inadvertently detaching from the slit 221.

[0045] Figure 4 is a cross-sectional view showing a state in which the backsheet heater 40 is suspended in the skin material suspension groove 11 together with the skin material 20. The skin material 20 is attached by sewing a cotton-like slab material 21 (padding material) over substantially the entire back surface. Further, a suspension member 22 is attached to a position on the back surface of the skin material 20 corresponding to the skin terminal portion 20a along the extending direction of the skin terminal portion 20a. The suspension member 22 is sewn to the skin material 20 in the same manner as the slab material 21.

[0046] The insertion portion 411 is inserted into the slit 221 of the suspension member 22 and engaged with each other. In other words, the backsheet heater 40 is fixed to the skin material 20 by engaging the insertion portion 411, and is suspended and fixed in the skin material suspension groove 11 together with the skin material 20. Therefore, the backsheet heater 40 can be easily fixed to the skin material 20 without using sewing threads or adhesives, and the backsheet heater 40 can be more efficiently attached inside the seat back 2.

[0047] <Manufacturing Method of Vehicle Seat S> Next, a manufacturing method of the vehicle seat S will be described. First, the seat frame is assembled. Specifically, a seat cushion frame forming the skeleton of the seat cushion 1 and a seat back frame forming the skeleton of the seat back 2 are assembled.

[0048] Next, the pad material 10 is placed on the seat back frame. Further, the backsheet heater 40 is fixed to the skin material 20 by inserting the insertion portion 411 of the backsheet heater 40 into the slit 221 formed in the suspension member 22 of the skin material 20. Subsequently, the suspension member 22 is suspended in the skin material suspension groove 11 of the pad material 10, whereby the backsheet heater 40 is attached to the seat back 2 together with the skin material 20. Similarly, the pad material 1a, the cushion seat heater 30, and the skin material 1b are attached to the seat cushion 1. The headrest 3 is assembled by covering the headrest pillar with the skin material 3b and injecting the unfoamed pad material 3a inside the skin material 3b and then foaming it. <000*********Finally, the seat back 2 is rotatably connected to the seat cushion 1, and the headrest 3 is connected to the upper end of the seat back 2. In this way, the seat cushion 1, seat back 2, and headrest 3 are connected, the seat body is assembled, and the manufacturing of the vehicle seat S is completed.

[0050] The above-described embodiment of a vehicle seat S is merely an example to facilitate understanding of the present invention and does not limit it. In other words, the present invention can be modified and improved without departing from its spirit, and of course, equivalents thereof are included in the present invention. In the above-described embodiment, the slit 221 formed in the suspension member 22 was described as an elongated hole extending in the suspension direction, but the slit 221 is not limited to an elongated hole.

[0051] <First Modified Example> Figure 5 shows the insertion portion 411 being inserted into the slit 221A according to the first modified example. As shown in Figure 5, the slit 221A has a length L3 and is composed of a first slit 221A1, a second slit 221A2, and a third slit 221A3 that extend in different directions at 120-degree intervals. The first slit 221A1, the second slit 221A2, and the third slit 221A3 intersect at the slit center 221A4 of the slit 221A.

[0052] The outer width W of the pair of engaging pieces 413b is greater than the dimension L3 of the first slit 221A1, the second slit 221A2, or the third slit 221A3, and less than twice the dimension L3 of the first slit 221A1, the second slit 221A2, or the third slit 221A3. Therefore, when the insertion portion 411 is inserted into the slit 221A, the insertion portion 411 is inserted into the slit 221A in a bent state corresponding to the shape of the slit 221A. When the inner end portion 413c of the engaging portion 413 passes through the slit 221A, the engaging portion 413 returns to its bent state, and the engaging piece 413b engages with the suspension member 22.

[0053] As described above, similar to the embodiment described above, the back seat heater 40 is fixed to the surface material 20 by engaging the insertion portion 411, and is suspended in the surface material suspension groove 11 and fixed together with the surface material 20. Therefore, the back seat heater 40 can be easily fixed to the surface material 20 without using sewing thread or adhesive, and the back seat heater 40 can be installed inside the seat back 2 more efficiently. In addition, since the slit 221A has a first slit 221A1, a second slit 221A2, and a third slit 221A3 that extend in different directions from each other, it is possible to reduce the workload on the worker when inserting the insertion portion 411 into the slit 221A.

[0054] <Second Modification> Figure 6 shows the insertion portion 411 being inserted into the slit 221B according to the second modification. As shown in Figure 6, the slit 221B has a substantially T-shape and consists of a first slit 221B1 and a second slit 221B2 that extends in a direction perpendicular to the first slit 221B1 and connects to the center of the first slit 221B1. The first slit 221B1 and the second slit 221B2 have a length L4.

[0055] The outer width W of the pair of engaging pieces 413b is greater than the length L4 of the first slit 221B1 and the second slit 221B2, and half of the outer width W (W / 2) is less than the length L4. Therefore, when inserting the insertion portion 411 into the slit 221B, the insertion portion 411 is inserted into the second slit 221B2 in a folded state along the central fold line C shown in Figure 6. When the inner end 413c of the engaging portion 413 passes through the slit 221B, the insertion portion 411 moves upward, returns from its folded state in the first slit 221B1, and the engaging piece 413b engages with the suspension member 22.

[0056] As described above, similar to the embodiment described, the back seat heater 40 is fixed to the surface material 20 by engaging the insertion portion 411, and is suspended in the surface material suspension groove 11 and fixed together with the surface material 20. Therefore, the back seat heater 40 can be easily fixed to the surface material 20 without using sewing thread or adhesive, and the back seat heater 40 can be installed inside the seat back 2 more efficiently. In addition, since the length L4 of the first slit 221B1 is smaller than the outer width W, it is possible to prevent the insertion portion 411 from unintentionally detaching from the slit 221B.

[0057] <<Second Embodiment>> Next, the backsheet heater 40C according to the second embodiment will be described with reference to Figures 7 to 9. In the first embodiment, the insertion portion 411 was described as being inserted through a slit 221 formed in the suspension member 22, but in the second embodiment, the insertion portion 411 is inserted not only through the slit 221 but also through a base fabric slit 415C formed in the heater base fabric 41C. Note that the explanation of the contents that overlap with the backsheet heater 40 according to the first embodiment will be omitted.

[0058] Figure 7 is a front view of the backsheet heater 40C. As shown in Figure 7, the backsheet heater 40C is a planar heating element mainly consisting of a heater base fabric 41C and heater wires 42 arranged on the heater base fabric 41C.

[0059] The heater base fabric 41C is provided with insertion portions 411 at both ends in the sheet width direction, and a base fabric slit 415C is formed therein. The base fabric slit 415C is expandable and contractible, and has dimensions that allow the engaging portion 413 to be inserted when extended. The heater base fabric 41C is fixed to the surface material 20 by inserting the insertion portions 411 into the slit 221 and the base fabric slit 415C formed in the suspension member 22.

[0060] Figure 8 is a cross-sectional view showing the back seat heater 40C suspended in the surface material suspension groove 11 together with the surface material 20. As shown in Figure 8, the insertion portion 411 is inserted through the slit 221 formed in the suspension member 22, passes through the tip portion 222 (lower end portion in Figure 8) of the suspension member 22 as it wraps around the suspension member 22, and then moves in a direction approaching the seating surface (upward in Figure 8). The engaging portion 413 is inserted through the base fabric slit 415C and engages with the heater base fabric 41C and the suspension member 22.

[0061] Furthermore, as shown in Figure 9, the insertion portion 411 may wrap around the suspension member 22, pass through the tip portion 222 (lower end portion in Figure 9) of the suspension member 22, and then move toward the seating surface (upward in Figure 9) and be inserted into the slit 221. The engaging portion 413 is inserted through the slit 221 and the base fabric slit 415C and engages with the heater base fabric 41C and the suspension member 22.

[0062] As described above, similar to the embodiment described above, the back seat heater 40 is fixed to the surface material 20 by engaging the insertion portion 411, and is suspended in the surface material suspension groove 11 and fixed together with the surface material 20. Therefore, the back seat heater 40C can be easily fixed to the surface material 20 without using sewing thread or adhesive, and the back seat heater 40C can be installed inside the seat back 2 more efficiently. In addition, since the insertion portion 411 extends around the suspension member 22 and engages in a state where it is inserted into the slit 221 and the base fabric slit 415C, it is possible to prevent the insertion portion 411 from unintentionally detaching from the slit 221.

[0063] <<Third Embodiment>> Next, the back seat heater 40D according to the third embodiment will be described with reference to Figure 10. In the embodiments described above, the insertion portion 411 was described as extending from the outer end of the heater base fabric 41 in the seat width direction in a direction perpendicular to the extending direction of the end of the heater base fabric 41 (seat width direction). In contrast, the insertion portion 411D of the third embodiment extends in a direction that intersects the seat width direction in a plane parallel to the seating surface.

[0064] Figure 10 is a front view of the backsheet heater 40D. As shown in Figure 10, the backsheet heater 40D is a planar heating element mainly consisting of a heater base fabric 41D and heater wires 42 arranged on the heater base fabric 41D.

[0065] Insertion portions 411D are provided at both ends of the heater base fabric 41D in the sheet width direction. The heater base fabric 41D is fixed to the surface material 20 by inserting the insertion portions 411D through the slits 221 formed in the suspension member 22.

[0066] Furthermore, the insertion portion 411D extends in a direction that intersects with the sheet width direction (the direction in which the end of the heater base fabric 41D extends in the sheet width direction (up and down direction in Figure 10)) and the plane parallel to the seating surface (the plane parallel to the paper in Figure 10).

[0067] As described above, similar to the embodiment described above, the back seat heater 40D is fixed to the upholstery material 20 by engaging the insertion portion 411D, and is suspended in the upholstery material suspension groove 11 and fixed together with the upholstery material 20. Therefore, the back seat heater 40D can be easily fixed to the upholstery material 20 without using sewing thread or adhesive, and the back seat heater 40D can be installed inside the seat back 2 more efficiently. In addition, since the insertion portion 411D extends in a direction intersecting the seat width direction, even if the upholstery material 20 and the back seat heater 40D are deformed by the load of the occupant, it is possible to prevent the insertion portion 411D from unintentionally detaching from the slit 221.

[0068] <<Fourth Embodiment>> Next, the back seat heater 40E according to the fourth embodiment will be described with reference to Figures 11 and 12. In the embodiments described above, the heater base fabric 41 was described as being disposed at a position corresponding to the central part 2A of the seat back 2. In contrast, the heater base fabric 41E of the fourth embodiment has a first base fabric portion 41E1 disposed at a position corresponding to the central part 2A, and a second base fabric portion 41E2 disposed at a position corresponding to the side bolster portion 2B. In addition, the insertion portion 411 is inserted not only through the slit 221 formed in the suspension member 22, but also through the base fabric slit 415E formed in the second base fabric portion 41E2.

[0069] Figure 11 is a front view of the backsheet heater 40E. As shown in Figure 11, the backsheet heater 40E is a planar heating element whose main components are a heater base fabric 41E and heater wires 42 arranged on the heater base fabric 41E.

[0070] The heater base fabric 41E is made of a stretchable fabric material and supports the heater wire 42 as the base material for the backsheet heater 40E. The heater base fabric 41E has a first base fabric portion 41E1 located in the center in the sheet width direction and second base fabric portions 41E2 located to the left and right of the first base fabric portion 41E1. The first base fabric portion 41E1 and the second base fabric portion 41E2 are connected to each other at both left and right ends of the first heater portion 401E, but are not limited to this. The first base fabric portion 41E1 and the second base fabric portion 41E2 may also be connected to each other at both left and right ends of the third heater portion 403E.

[0071] Insertion portions 411 are provided at both ends of the first base fabric portion 41E1 in the sheet width direction. In addition, a base fabric slit 415E is formed on the inside of the second base fabric portion 41E2 in the sheet width direction. The base fabric slit 415E is expandable and contractible, and has dimensions that allow the engaging portion 413 of the insertion portion 411 to be inserted when extended. The heater base fabric 41E is fixed to the surface material 20 by inserting the insertion portion 411 into the slit 221 and the base fabric slit 415E formed in the suspension member 22.

[0072] Figure 12 shows how the insertion portion 411 is inserted through the slit 221 and the base fabric slit 415E. The suspension member 22 has a slit 221 that extends in the suspension direction (the direction indicated by arrow A in Figure 12). The slit 221 is an elongated hole and extends in a direction perpendicular to the seating surface.

[0073] When the insertion portion 411 is inserted into the slit 221, the insertion portion 411 is inserted into the slit 221 in a state where it is twisted 90 degrees along the longitudinal direction of the slit 221. Also, when the insertion portion 411 is inserted into the base fabric slit 415E, the base fabric slit 415E is deformed and stretched when the insertion portion 411 is inserted. When the inner end portion 413c of the engaging portion 413 passes through the slit 221 and the base fabric slit 415E, the insertion portion 411 returns to its original state from the 90-degree twisted state. At the same time, the base fabric slit 415E returns to its original state from the stretched state. As a result, the engaging piece 413b engages with the suspension member 22.

[0074] As described above, similar to the embodiment described above, the back seat heater 40E is fixed to the surface material 20 by engaging the insertion portion 411, and is suspended in the surface material suspension groove 11 and fixed together with the surface material 20. Therefore, the back seat heater 40E can be easily fixed to the surface material 20 without using sewing thread or adhesive, and the back seat heater 40E can be installed inside the seat back 2 more efficiently. In addition, the insertion portion 411 engages with the surface material 20 and the second base fabric portion 41E2 when inserted through the base fabric slit 415E formed in the side bolster portion 2B. Therefore, the back seat heater 40E can be easily and firmly fixed to the entire surface material 20 of the seat back 2.

[0075] In the embodiments described above, the surface material 20 of the seat back 2 and the back seat heater 40 were used as examples, but the present invention may also be applied to the surface material 1b of the seat cushion 1 and the cushion seat heater 30. Furthermore, the seat heater may be built into the headrest 3, and the present invention may be applied to the surface material 3b of the headrest 3 and the seat heater.

[0076] Furthermore, in the embodiments described above, the heater base fabric 41 was described as having a total of 10 or 8 insertion portions 411 at both ends in the sheet width direction, but the number and arrangement of the insertion portions 411 are not limited to those shown in Figures 2, 10, and 11. The heater base fabric 41 may have fewer than 8 insertion portions 411, or more than 10 insertion portions 411. Also, the insertion portions 411 may protrude vertically from the vertical ends of the heater base fabric 41.

[0077] Furthermore, although the above-described embodiment explained that the engaging portion 413 has an umbrella shape with two engaging pieces 413b, the shape of the engaging portion 413 is not limited to this. The engaging portion 413 may have four engaging pieces 413b. In this case, each engaging piece 413b may be configured to spread out from the tip portion 413a in directions that are 90 degrees apart from each other.

[0078] <<Fifth Embodiment>> The fifth embodiment of the vehicle seat S5 according to the present invention will be described below with reference to Figures 13 to 22.

[0079] Conventionally, vehicle seats that improve the comfort of occupants by installing a sheet-shaped seat heater inside the seat body are known. One example of such a vehicle seat is a seat body consisting of a seat frame that forms the skeleton, on which a pad material is placed and which is further covered with a surface material, and a seat heater that is placed between the pad material and the surface material and attached to the back surface of the surface material.

[0080] For example, Patent Document 2 (Japanese Patent Application Publication No. 2022-179315) describes a sheet heater having a base material and a heating element. Specifically, the sheet heater is fixed to a slab material provided on the back surface of the surface material by tag pins.

[0081] In the vehicle seat described in Patent Document 2, both the base material and the surface material of the seat heater are made of flexible material. Therefore, when fixing the surface material and the seat heater with tag pins, it was difficult to fix the seat heater in the appropriate position relative to the surface material. Accordingly, there was a need for a technology that could easily position the seat heater in the appropriate position relative to the surface material.

[0082] The object of the present invention is to provide a vehicle seat that allows for easy positioning of a seat heater in an appropriate location on the surface material.

[0083] In the following explanation, "forward-backward direction" refers to the forward-backward direction of the vehicle seat, which coincides with the direction of travel when the vehicle is moving. "Seat width direction" refers to the width direction of the vehicle seat, which coincides with the left-right direction as viewed from the perspective of an occupant seated in the vehicle seat. "Up-down direction" refers to the up-down direction of the vehicle, which coincides with the vertical direction when the vehicle is traveling on a horizontal plane.

[0084] As shown in Figure 13, the vehicle seat S5 is a seat placed on the vehicle floor where the occupants of the vehicle sit. In this embodiment, the vehicle seat S5 is used as a front seat corresponding to the front seat of the vehicle. However, it is not limited to this, and the vehicle seat S5 may also be a rear seat of the vehicle, and can also be used as a middle seat in the second row or a rear seat in the third row in a vehicle equipped with three rows of seats in the front-to-back direction.

[0085] As shown in Figure 13, the vehicle seat S5 comprises a seat cushion 501, a seat back 502, a headrest 503 connected to the upper part of the seat back 502, and a reclining device 504 that rotatably connects the seat back 502 to the seat cushion 501. In the following description, the seat cushion 501, seat back 502, and headrest 503 may be collectively referred to as the seat body.

[0086] As shown in Figure 13, the seat cushion 501 is a seating portion that supports the occupant from below, and a seat frame (specifically, a cushion frame) is provided inside it. The seat cushion 501 has a central portion 501A located in the center in the seat width direction, and side bolster portions 501B located on both sides of the central portion 501A in the seat width direction. The upper surface of the side bolster portions 501B bulges upward from the upper surface of the central portion 501A.

[0087] As shown in Figure 13, the seat cushion 501 comprises a cushion frame made of a substantially rectangular frame-like body, a pad material 510 (specifically, a cushion pad material) placed on the cushion frame, and a surface material 520 (specifically, a cushion surface material) that covers the cushion frame and the cushion pad material. The seat cushion 501 has a seat heater 530 between the pad material 510 and the surface material 520. The surface material 520 and the seat heater 530 are fixed to each other in an overlapping state by a fixing member 540. The surface material 520 and the seat heater 530 are suspended from the pad material 510 by a suspension member 550.

[0088] As shown in Figure 13, the seat back 502 is a backrest that supports the occupant's back from the rear, and a seat frame (specifically, a back frame) is provided inside it. The seat back 502 has a central portion 502A located in the center in the seat width direction, and side bolster portions 502B located on both sides of the central portion 502A in the seat width direction. The front of the side bolster portions 502B bulges forward from the front of the central portion 502A.

[0089] As shown in Figure 13, the seat back 502 includes a back frame made of a substantially rectangular frame-like body, a pad material 510 (specifically, a back pad material) placed on the back frame, and a surface material 520 (specifically, a back surface material) that covers the back frame and the back pad material. The back frame is connected to the cushion frame via a reclining device 504. The seat back 502 has a seat heater 530 between the pad material 510 and the surface material 520. The surface material 520 and the seat heater 530 are fixed to each other in an overlapping state by a fixing member 540. The surface material 520 and the seat heater 530 are suspended from the pad material 510 by a suspension member 550.

[0090] As shown in Figure 13, the headrest 503 is a head support that supports the occupant's head from the rear, and its main components are a headrest pillar that forms the frame, a pad material 510 that covers the headrest pillar, and a surface material 520 that covers the headrest pillar and the pad material 510. The headrest 503 is supported at the upper end of the seat back 502 in an adjustable position.

[0091] As shown in Figure 13, the reclining device 504 is a device that rotatably connects the back frame to the cushion frame and can lock the back frame. The reclining device 504 switches the seat back 502 between a normal state in which an occupant can sit and a reclined state in which the seat back is rotated backward from the normal state. The reclining device 504 can switch the state of the back frame between a locked state in which it is fixed to the cushion frame and an unlocked state in which it can rotate relative to it.

[0092] As shown in Figure 14, the vehicle seat S5 includes a seat frame (not shown) which forms the skeleton of the seat body, a pad material 510 placed on the seat frame, a surface material 520 that covers the pad material 510, a seat heater 530 attached to the back surface of the surface material 520, a fixing member 540 that fixes the seat heater 530 to the surface material 520, and a suspension member 550 for suspending the surface material 520 from the pad material 510. In the following description, the configuration of each component (pad material 510, surface material 520, seat heater 530, fixing member 540, and suspension member 550) in the seat cushion 501 will be described in detail. The components of the seat back 502 have substantially the same configuration as those of the seat cushion 501, so their description will be omitted. The seat heater 530 may be placed only in the seat cushion 501, or only in the seat back 502.

[0093] As shown in Figure 15, the pad material 510 is a cushioning member made of foamed urethane or the like. The pad material 510 has suspension grooves 511 that penetrate in the thickness direction of the pad material 510 and are used to suspend the surface material 520 into the pad material 510. More specifically, the pad material 510 has a plurality of first suspension grooves 511a that extend in a long length in the front-rear direction and a plurality of second suspension grooves 511b that extend in the sheet width direction. The groove ends 511c on both sides of the second suspension grooves 511b in the sheet width direction are in communication with the first suspension grooves 511a. In the central part of the suspension groove 511 in the sheet width direction (corresponding to the position of the locking portion 551 and connecting portion 531d described later), a storage portion 511d is formed to house the locking portion 551 and connecting portion 531d. When viewed from the thickness direction of the pad material 510, the groove width W1 of the storage section 511d is wider than the groove width W2 of the groove end 511c of the suspension groove 511 in the extending direction of the suspension groove 511.

[0094] The surface material 520 is made of an elastic nylon material or the like and is formed in a shape that can cover the seat frame and pad material 510. As shown in Figure 16, the seat heater 530 is laminated on the back surface of the surface material 520. The surface material 520 and the seat heater 530 are fixed together by a fixing member 540. The surface material 520 and the seat heater 530 are then suspended inside the suspension groove 511 with the seat heater 530 attached to the back surface of the surface material 520. Figure 16 shows the surface material 520 that covers the central part 501A of the pad material 510 of the seat cushion 501, and shows the state before the surface material 520 is suspended in the suspension groove 511.

[0095] As shown in Figure 16, the surface material 520 includes a first surface 521, a second surface 522 sewn to the first surface 521, a third surface 523 sewn to the second surface 522, and a positioning portion 524 indicating the mounting position to the seat heater 530. The surface material 520 also includes side surface materials that cover the side bolster portion 501B, as shown in Figure 14. Note that in Figure 16, the side surface materials are omitted for illustrative purposes. The first surface 521 covers the front portion of the seating surface of the seat cushion 501. The second surface 522 covers the central portion of the seating surface of the seat cushion 501. The third surface 523 covers the rear portion of the seating surface of the seat cushion 501.

[0096] The rear end of the first skin 521 and the front end of the second skin 522 are fixed to the fixing member 540 together with the seat heater 530 in an overlapping state. The rear end of the second skin 522 and the front end of the third skin 523 are fixed to the fixing member 540 together with the seat heater 530 in an overlapping state. In other words, the rear end of the first skin 521 and the front end of the second skin 522 and the rear end of the second skin 522 and the front end of the third skin 523 correspond to the skin end 520a of the present invention. The skin end 520a is the end in the direction in which the skin material 520 extends. In other words, the skin end 520a is the end in the direction in which the first skin 521 and the second skin 522 are connected (the direction in which the second skin 522 and the third skin 523 are connected). As shown in Figure 14, the surface end 520a of the surface material 520, which is fixed by the fixing member 540, and the base material end 530a of the sheet heater 530 are suspended in the suspension groove 511 by the suspension member 550.

[0097] As shown in Figures 17 and 18, the alignment portion 524 is a marker for indicating the mounting position to the seat heater 530, and is formed on the surface end portion 520a of the first surface 521. The alignment portion 524 protrudes from the surface end portion 520a in a direction along the surface of the surface material 520. The alignment portion 524 has a rectangular shape and is integrally formed with the surface end portion 520a. Figures 17 and 18 show the mounting structure of the seat heater 530 (specifically, the first base portion 531a and the second base portion 531b, which will be described later) to the first surface 521 and the second surface 522. The mounting structure of the seat heater 530 (specifically, the second base portion 531b and the third base portion 531c, which will be described later) to the second surface 522 and the third surface 523 is similar, so its description is omitted.

[0098] As shown in Figure 18, the first skin 521 has a first seam allowance 521a which is overlapped with and sewn to the second skin 522. The second skin 522 has a second seam allowance 522a which is overlapped with and sewn to the first skin 521. The first skin 521 and the second skin 522 are sewn together with thread 525 with the first seam allowance 521a and the second seam allowance 522a overlapping in the front-rear direction. The first seam allowance 521a and the second seam allowance 522a are positioned in the hanging groove 511. In other words, in the skin material 520, the portion extending in the front-rear direction is the seating surface, and the portion extending in the vertical direction is the portion that is hung in the hanging groove 511.

[0099] As shown in Figure 18, the alignment portion 524 is formed in the first seam allowance 521a of the first skin 521. A skin insertion hole 521b is formed in the skin end portion 520a of the first seam allowance 521a through which a fixing member 540 (specifically, a fixing pin 542, which will be described later) is inserted. The skin insertion hole 521b is formed in a position that overlaps with the alignment portion 524 in the direction in which the skin material 520 extends. In other words, the skin insertion hole 521b is formed at the base end portion of the alignment portion 524.

[0100] In this way, the alignment portion 524 is formed on the first seam allowance 521a. Therefore, the base material 531 can be easily superimposed on the sutured skin material 520. The alignment portion 524 may also be formed on the second skin 522, or on both the first skin 521 and the second skin 522.

[0101] At the end of the second seam allowance 522a, a notch 522b is formed in a direction along the surface of the skin material 520 at a position corresponding to the alignment portion 524 formed in the first seam allowance 521a. The notch 522b is formed at a position where the first seam allowance 521a and the second seam allowance 522a overlap in the stacking direction (front-to-back direction). In this way, because the notch 522b is provided in the second seam allowance 522a, the fixing position of the fixing member 540 can be easily positioned using the notch 522b as a guide. In addition, when attaching the fixing member 540, the amount of skin material 520 through which the fixing member 540 passes is reduced, thus reducing resistance during insertion.

[0102] As shown in Figure 16, the seat heater 530 is a planar heating element and comprises a base material 531 laminated on the surface material 520, a heating element 532 fixed to the base material 531, and an alignment portion 533 indicating the mounting position on the surface material 520. The seat heater 530 is flexible and is attached to the back surface of the surface material 520 and attached to the suspension groove 511 together with the surface material 520. A backing cloth may be provided on the back surface of the base material 531. By providing a backing cloth, friction between the back surface of the base material 531 and the surface of the pad material 510 can be suppressed.

[0103] As shown in Figure 16, the base material 531 is made of a slab material, nonwoven fabric, or stretchable fabric, and is a member that supports the heating element 532. The base material 531 has a first base portion 531a which is laminated with the first surface 521, a second base portion 531b which is laminated with the second surface 522, a third base portion 531c which is laminated with the third surface 523, and two connecting portions 531d which connect the first base portion 531a, the second base portion 531b, and the third base portion 531c, respectively. The first base portion 531a covers the front portion of the seating surface of the seat cushion 501. The second base portion 531b covers the central portion of the seating surface of the seat cushion 501. The third base portion 531c covers the rear portion of the seating surface of the seat cushion 501.

[0104] The rear end of the first base 531a and the front end of the second base 531b are fixed to the fixing member 540 together with the surface material 520 in an overlapping state. The rear end of the second base 531b and the front end of the third base 531c are fixed to the fixing member 540 together with the surface material 520 in an overlapping state. In other words, the rear end of the first base 531a and the front end of the second base 531b, and the rear end of the second base 531b and the front end of the third base 531c correspond to the base material end 530a of the present invention. The base material end 530a is the end in the direction in which the sheet heater 530 extends. In other words, the base material end 530a is the end in the direction in which the first base 531a and the second base 531b are connected (the direction in which the second base 531b and the third base 531c are connected). As shown in Figure 14, the surface end 520a of the surface material 520, which is fixed by the fixing member 540, and the base material end 530a of the sheet heater 530 are suspended in the suspension groove 511 by the suspension member 550.

[0105] As shown in Figure 16, the heating element 532 is an electrical resistor arranged to uniformly cover the base material 531 in a meandering manner. The heating element 532 is positioned between the surface material 520 and the base material 531. By uniformly covering the entire base material 531 with the heating element 532, the seat heater 530 can heat the seating surface evenly. The heating element 532 is a nichrome heating wire, but is not limited to this. The heating element 532 only needs to have a heat output sufficient to warm the seating surface and provide comfort, and the heating element 532 may be a metal foil.

[0106] As shown in Figures 17 and 18, the alignment portion 533 is a marker for indicating the attachment position to the surface material 520, and is formed on the base material end 530a of the base material 531. More specifically, the alignment portion 533 has a first alignment portion 533a formed on the base material end 530a of the first base portion 531a, and a second alignment portion 533b formed on the base material end 530a of the second base portion 531b. The alignment portion 533 protrudes from the base material end 530a in a direction along the surface of the base material 531. The alignment portion 533 has a rectangular shape and is formed integrally with the base material end 530a.

[0107] As shown in Figure 18, the first base portion 531a has a first overlap portion 531a1 that overlaps with the first surface 521. The second base portion 531b has a second overlap portion 531b1 that overlaps with the second surface 522. The first base portion 531a and the second base portion 531b are fixed by a fixing member 540 with the first overlap portion 531a1 and the second overlap portion 531b1 overlapped in the front-rear direction. The first overlap portion 531a1 and the second overlap portion 531b1 are positioned in the suspension groove 511. In other words, in the base material 531, the portion extending in the front-rear direction is the seating surface, and the portion extending in the vertical direction is the portion that is suspended in the suspension groove 511.

[0108] As shown in Figure 18, the first alignment portion 533a is formed in the first overlap 531a1. A first insertion hole 531a2 is formed in the base material end 530a of the first overlap 531a1 through which a fixing member 540 (specifically, a fixing pin 542) is inserted. The first insertion hole 531a2 is formed at a position that overlaps with the first alignment portion 533a in the direction in which the surface material 520 extends. In other words, the first insertion hole 531a2 is formed at the base end portion of the first alignment portion 533a. As shown in Figure 18, the second alignment portion 533b is formed in the second overlap 531b1. A second insertion hole 531b2 is formed in the base material end 530a of the second overlap 531b1 through which a fixing member 540 (specifically, a fixing pin 542) is inserted. The second insertion hole 531b2 is formed at a position that overlaps with the second alignment portion 533b in the direction in which the surface material 520 extends. In other words, the second insertion hole 531b2 is formed at the base end portion of the second alignment portion 533b.

[0109] As shown in Figure 17, a fitted portion 524 is formed at the outer edge 520a of the outer material 520, which is superimposed on the fitted portion 533. Similarly, a fitted portion 533 is formed at the base material edge 530a of the base material 531 of the seat heater 530, which is superimposed on the fitted portion 524. In other words, when the outer material 520 and the seat heater 530 are superimposed, a fitted portion 524 and a fitted portion 533 are formed at mutually opposing positions on the outer edge 520a and base material edge 530a, respectively, serving as markers. As shown in Figure 19, the fitted portion 533 and the fitted portion 524 have substantially the same shape when viewed from the front. Therefore, the seat heater 530 can be easily positioned relative to the outer material 520 simply by superimposing the fitted portion 533 and the fitted portion 524.

[0110] In particular, since the alignment portion 533 is formed on the base material end 530a and the fitted portion 524 is formed on the surface end 520a, the recognizability of the alignment portion 533 and the fitted portion 524 can be improved. Also, because the alignment portion 533 and the fitted portion 524 are formed on each end, when the surface end 520a is suspended from the pad material 510, the alignment portion 533 and the fitted portion 524 are not exposed on the seating surface. Therefore, the seating feeling can be improved.

[0111] In this embodiment, the alignment portion 533 and the part to be aligned 524 have substantially the same shape. Specifically, the skin end portion 520a and the base material end portion 530a have a convex shape. Therefore, the mounting position of the base material 531 on the skin material 520 can be easily recognized both visually and tactilely. In this way, since the alignment portion 533 and the part to be aligned 524 protrude from their respective ends, the recognizability of the alignment portion 533 and the part to be aligned 524 can be further enhanced. In addition, the mounting position can be recognized by touch, and the alignment portion 533 and the part to be aligned 524 can be positioned without visual inspection.

[0112] Furthermore, the configuration is not limited to the alignment portion 533 and the alignment portion 524 having substantially the same shape; any marking that allows for easy recognition of the mounting position of the base material 531 on the surface material 520 is acceptable. For example, the alignment portion 533 and the alignment portion 524 may have different shapes or be marked in a manner that allows for easy recognition of the mounting position of the base material 531 on the surface material 520a and the base material 530a, respectively.

[0113] As shown in Figure 16, the front connecting portion 531d connects the base material end 530a of the first base portion 531a and the base material end 530a of the second base portion 531b. Specifically, the front connecting portion 531d connects the central portion of the rear end of the first base portion 531a and the central portion of the front end of the second base portion 531b. The rear connecting portion 531d connects the base material end 530a of the second base portion 531b and the base material end 530a of the third base portion 531c. Specifically, the rear connecting portion 531d connects the central portion of the rear end of the second base portion 531b and the central portion of the front end of the third base portion 531c.

[0114] As shown in Figure 17, the fixing member 540 is a fastener that fixes the surface material 520 and the seat heater 530. The fixing member 540 is, for example, a tag pin or a crimp pin, and fixes the base material end 530a and the surface material end 520a when the alignment portion 533 and the alignment portion 524 are superimposed. Note that the fixing member 540 is not limited to a tag pin or a crimp pin, but may also be a stapler, double-sided tape, adhesive, screw, etc. The fixing member 540 has a fixing portion 541 provided on the first base portion 531a side and a fixing pin 542 provided on the second base portion 531b side. The fixing pin 542 passes through the second insertion hole 531b2, the notch portion 522b, the surface material insertion hole 521b, and the first insertion hole 531a2 in this order and is fixed to the fixing portion 541. In other words, the fixing member 540 is attached to the first overlap 531a1 and the second overlap 531b1 of the base material 531, and to the first seam allowance 521a and the second seam allowance 522a of the surface material 520.

[0115] Furthermore, as shown in Figure 20, the base material 531 and the surface material 520 are fixed by the fixing member 540 with the alignment portion 524 sandwiched between the first alignment portion 533a and the second alignment portion 533b. In other words, when the base material 531 and the surface material 520 of the seat heater 530 are suspended in the suspension groove 511 by the suspension member 550, the alignment portion 524, the alignment portion 533 and the fixing member 540 are not exposed on the seating surface. Note that the suspension member 550 is not shown in Figure 20 for illustrative purposes.

[0116] In this way, since the alignment portion 524 is fixed by the fixing member 540 while sandwiched between the first alignment portion 533a and the second alignment portion 533b, the surface material 520 and the seat heater 530 can be fixed with a single fixing member 540, reducing the number of parts. Furthermore, since the fixing member 540 is attached to the first overlap portion 531a1 and the second overlap portion 531b1, and the first seam portion 521a and the second seam portion 522a, the fixing member 540 is not exposed on the seating surface when the surface edge 520a and the base material edge 530a are suspended from the pad material 510. Therefore, the seating feel can be improved.

[0117] As shown in Figures 21 and 22, the suspension member 550 is positioned inside the suspension groove 511 and is a member for suspending the surface material 520 onto the pad material 510. The suspension member 550 has a locking portion 551 attached to the surface end 520a and a receiving portion 552 provided in the suspension groove 511 of the pad material 510. The locking portion 551 locks into the receiving portion 552 provided in the suspension groove 511. As shown in Figure 13, the suspension member 550 (locking portion 551) is provided in the central portion and both ends in the sheet width direction of the surface material 520. Multiple suspension members 550 (receiving portions 552) are arranged in the suspension groove 511 along the extending direction of the suspension groove 511.

[0118] Figure 21 illustrates the state in which the surface material 520 and the seat heater 530 are bent so as to sandwich the locking portion 551 of the suspension member 550, and shows the surrounding structure of the connecting portion 531d. The locking portion 551 is a member that extends elongated in the direction of extension of the suspension groove 511, and has a locking base portion 551a that is sewn to the surface material 520, and a locking end portion 551b that is formed at the extended end of the locking base portion 551a. The locking base portion 551a is a flat plate-shaped member formed from, for example, a cloth material or a resin material. The locking end portion 551b is a member that is hooked onto the locked portion 552.

[0119] As shown in Figure 22, the locking portion 552 has a C-ring 552a embedded in the pad material 510 and a wire 552b that fixes the C-ring 552a to the pad material 510. The locking end 551b of the locking portion 551 is hooked onto the upper end of the C-ring 552a, allowing the surface material 520 and the seat heater 530 to be suspended inside the suspension groove 511.

[0120] The connecting portion 531d of the base material 531 is bent so as to sandwich the locking portion 551 and is positioned in the suspension groove 511. As shown in Figure 21, the connecting portion 531d has a pair of opposing surfaces 531e that face each other with the locking portion 551 in between, and a bent portion 531f that is bent when the surface material 520 and the sheet heater 530 are suspended in the suspension groove 511. The pair of opposing surfaces 531e are surfaces that extend linearly in the depth direction of the suspension groove 511. The bent portion 531f is a curved portion formed by folding back in a U-shape.

[0121] A position reference portion 531e1 is formed on at least one of the pair of opposing surfaces 531e to indicate the position of the locking portion 551. More specifically, a position reference portion 531e1 is formed on each of the pair of opposing surfaces 531e. One opposing surface 531e has two position reference portions 531e1. In other words, the connecting portion 531d has four position reference portions 531e1. The position reference portion 531e1 has a shape that is cut out in the direction of extension of the suspension groove 511 (the direction of extension of the locking portion 551). Specifically, the position reference portion 531e1 has a V-shape.

[0122] As shown in Figure 22, the position reference portion 531e1 is formed at a position opposite the locking base portion 551a of the locking portion 551 and the suspension groove 511 in the width direction. In addition, the pair of position reference portions 531e1 formed on the pair of opposing surfaces 531e are formed at positions opposite each other in the width direction of the suspension groove 511. By providing the position reference portions 531e1 on each of the pair of opposing surfaces 531e in this way, the position of the folding portion 531f of the connecting portion 531d can be easily grasped and aligned when folding the seat heater 530.

[0123] As shown in Figure 21, a guide portion 531f1 is formed in the bent portion 531f of the connecting portion 531d to guide the bending of the connecting portion 531d. The guide portion 531f1 consists of two notches formed along the extending direction of the suspension groove 511 (the extending direction of the locking portion 551), and is formed at both ends in the extending direction of the suspension groove 511. Specifically, the guide portion 531f1 consists of two V-shaped notches. Note that the guide portion 531f1 is not limited to notches and may also be perforations. As shown in Figure 22, when the surface material 520 and the sheet heater 530 are placed in the suspension groove 511, the connecting portion 531d of the base material 531 is bent at the guide portion 531f1. At this time, the locking portion 551 and the connecting portion 531d are housed in the storage portion 511d of the suspension groove 511, where the groove width W1 is wider than the groove width W2 at the groove end portion 511c.

[0124] In this way, by providing a guide portion 531f1 that guides the bending of the connecting portion 531d, the connecting portion 531d can be easily bent when bending the base material 531 of the sheet heater 530. In addition, it is possible to prevent the connecting portion 531d from bending at an unintended position. Furthermore, by providing a storage portion 511d in the suspension groove 511, the position of the connecting portion 531d relative to the suspension groove 511 can be easily grasped and aligned. In addition, because the storage portion 511d is formed to be wide, it becomes easier to position the locking portion 551 and the connecting portion 531d in the suspension groove 511.

[0125] <<Manufacturing Method>> Next, we will explain the manufacturing method of the vehicle seat S5. Note that, regarding the manufacturing method of the vehicle seat S5, explanations of manufacturing processes other than those listed below will be omitted.

[0126] A method for manufacturing a vehicle seat S5 includes a preparation step of preparing each component of the vehicle seat S5, an assembly step of assembling each component of the vehicle seat S5, and an assembly step of assembling the seat cushion 501 and the seat back 502.

[0127] More specifically, in the preparation process, the worker first prepares the seat frame, pad material 510, surface material 520, seat heater 530, fixing member 540, and suspension member 550, which constitute the seat cushion 501 and seat back 502, respectively. In the preparation process, the worker prepares the seat heater 530, which consists of a base material 531 and a heating element 532 fixed to the base material 531. Then, in the assembly process, the worker aligns the surface material 520 and the base material 531 by overlapping the alignment portion 533, which is formed on the base material end 530a of the base material 531 and indicates the mounting position to the surface material 520, with the fitted alignment portion 524, which is formed on the surface end 520a of the surface material 520 and overlaps with the alignment portion 533. Then, with the alignment portion 533 and the part to be aligned 524 overlapping, the worker fixes the skin end portion 520a and the base material end portion 530a with the fixing member 540.

[0128] Subsequently, the worker suspends the surface material 520 and the seat heater 530 into the suspension groove 511 using the suspension member 550. Specifically, the worker locks the locking portion 551 attached to the surface edge 520a to the locking portion 552 provided in the suspension groove 511. In this way, the surface material 520 and the seat heater 530 are suspended from the pad material 510. In this manner, a seat cushion 501 and a seat back 502 are manufactured, with the pad material 510 covered by the surface material 520.

[0129] Furthermore, during the assembly process, the worker connects the seat cushion 501 and the seat back 502 via the reclining device 504. Specifically, the worker assembles the back frame of the seat back 502 to the cushion frame of the seat cushion 501 via the reclining device 504. In this way, the vehicle seat S5 is manufactured. With the above manufacturing method of the vehicle seat S5, the seat heater 530 can be easily positioned in an appropriate position on the surface material 520.

[0130] <<Note>> The above problem is solved by providing a vehicle seat comprising a pad material, a surface material covering the pad material, and a seat heater attached to the back surface of the surface material, wherein the seat heater comprises a base material laminated on the surface material and a heating element fixed to the base material, an alignment portion for indicating the attachment position to the surface material is formed at the base material end of the base material, and a fitted alignment portion that overlaps with the alignment portion is formed at the surface end of the surface material.

[0131] With the above configuration, the alignment portion is formed on the base material of the seat heater, and the portion to be aligned is formed on the surface material, allowing for easy positioning simply by overlapping the alignment portion and the portion to be aligned. In particular, since the alignment portion is formed at the end of the base material and the portion to be aligned is formed at the end of the surface material, the visibility of the alignment portion and the portion to be aligned can be improved. Furthermore, because the alignment portion and the portion to be aligned are formed at each end, when the surface material end is attached to the pad material, the alignment portion and the portion to be aligned are not exposed on the seating surface. Therefore, the seating feel can be improved. Consequently, the seat heater can be easily positioned in the appropriate location on the surface material.

[0132] In this configuration, the alignment portion preferably protrudes from the end of the base material in a direction along the surface of the base material, and the part to be aligned protrudes from the end of the surface material in a direction along the surface of the surface material. With this configuration, since the alignment portion and the part to be aligned protrude from their respective ends, the recognizability of the alignment portion and the part to be aligned can be further enhanced. In addition, the mounting position can be recognized by touch, and the alignment portion and the part to be aligned can be positioned without visual inspection.

[0133] In this case, it is preferable to have a fixing member that fixes the base material end and the surface end when the alignment portion and the part to be aligned are superimposed. With the above configuration, by using the fixing member, misalignment of the sheet heater relative to the surface material can be suppressed.

[0134] In this case, the surface material has a first surface and a second surface that is sewn to the first surface, the first surface has a first seam allowance that is overlapped and sewn to the second surface, the second surface has a second seam allowance that is overlapped and sewn to the first surface, the alignment portion is formed in the first seam allowance, and the fixing member is preferably attached to the base material, the first seam allowance and the second seam allowance. With the above configuration, the fixing member is attached to the first seam allowance and the second seam allowance, so that the fixing member is not exposed on the seating surface when the edge of the surface is suspended from the pad material. Therefore, the seating feeling can be improved.

[0135] In this case, it is preferable that a notch be formed at the end of the second seam allowance at a position corresponding to the alignment portion formed in the first seam allowance, and cut in a direction along the surface of the skin material. With the above configuration, a notch is provided in the second seam allowance, so the fixing position of the fixing member can be easily positioned using the notch as a guide. In addition, when attaching the fixing member, the amount of skin material through which the fixing member passes is reduced, so the resistance during insertion can be reduced.

[0136] In this configuration, the base material has a first base portion laminated with the first surface layer and a second base portion laminated with the second surface layer, and the alignment portion has a first alignment portion formed at the end of the base material in the first base portion and a second alignment portion formed at the end of the base material in the second base portion, and the base material and the surface layer material are fixed by the fixing member with the part to be aligned sandwiched between the first alignment portion and the second alignment portion. With the above configuration, since the part to be aligned is fixed by the fixing member with the part to be aligned sandwiched between the first alignment portion and the second alignment portion, the surface layer material and the seat heater can be fixed with a single fixing member, and the number of parts can be reduced.

[0137] In this configuration, the pad material has a suspension member for suspending the surface material, the pad material has a suspension groove for suspending the surface material, the suspension member is attached to the surface end and has a locking portion that locks into a locking portion provided in the suspension groove, the base material has a connecting portion that connects the base material end at the first base and the base material end at the second base, the first seam allowance and the second seam allowance are arranged in the suspension groove, the connecting portion is bent so as to sandwich the locking portion and is arranged in the suspension groove, and the bent portion of the connecting portion has a notch formed along the extending direction of the suspension groove and preferably has a guide portion that guides the bending of the connecting portion. With the above configuration, by providing a guide portion that guides the bending of the connecting portion, the connecting portion can be easily bent when bending the seat heater. In addition, it is possible to prevent the connecting portion from bending in an unintended position.

[0138] In this configuration, the connecting portion has a pair of opposing surfaces that face each other with the locking portion in between, and a position reference portion for indicating the position of the locking portion is formed on at least one of the pair of opposing surfaces, and the position reference portion is preferably formed at a position opposite the locking portion in the width direction of the suspension groove. With the above configuration, by providing the position reference portion on the connecting portion, the position of the connecting portion relative to the locking portion can be easily grasped and aligned.

[0139] In this case, a position reference portion is formed on each of the pair of opposing surfaces, and the position reference portion preferably has a shape that is cut out in the direction of extension of the suspension groove. With the above configuration, by providing a position reference portion on each of the pair of opposing surfaces, the position of the folded portion of the connecting part can be easily grasped and aligned when folding the sheet heater.

[0140] In this configuration, a storage section is formed in the suspension groove at a position corresponding to the locking section and the connecting section, and it is preferable that the groove width of the storage section is wider than the groove width at the end of the suspension groove in the extending direction of the suspension groove when viewed from the thickness direction of the pad material. With this configuration, by providing a storage section in the suspension groove, the position of the connecting section relative to the suspension groove can be easily determined and aligned. In addition, because the storage section is formed to be wide, it becomes easier to position the locking section and the connecting section in the suspension groove.

[0141] <First to Fourth Embodiments> S Vehicle Seat 1 Seat cushion 1A Center part 1B Side bolster part 1a Pad material 1b Upholstery material 2 Seat back 2A Center part 2B Side bolster part (bolster part) 3 Headrest 3a Pad material 3b Upholstery material 4 Reclining device 10 Pad material 11 Upholstery material suspension groove (groove part) 20 Upholstery material 20a Upholstery end part 21 Slab material 22 Suspension member (suspension part) 221, 221A, 221B Slit (insertion part) 221A1 First slit 221A2 Second slit 221A3 Third slit 221A4 Slit center 222 Tip part 30 Cushion seat heater 40, 40C, 40D Back seat heater (seat heater) 401, 401E First heater section 402 Second heater section 403 Third heater section 404 Heater connecting section 41, 41C, 41D, 41E Heater base fabric 41E1 First base fabric section 41E2 Second base fabric section 411, 411D Insertion section 412 Extension section 413 Engaging section 413a Tip section 413b Engaging piece 413c Inner end section 414 Connection section 415C, 415E Base fabric slit 42 Heater wire <Fifth Embodiment> S5 Vehicle seat 501 Seat cushion 501A Central section 501B Side bolster section 502 Seat back 502A Central section 502B Side bolster section 503 Headrest 504 Reclining device 510 Pad material 511 Hanging groove 511a First hanging groove 511b Second hanging groove 511c Groove end 511d Storage section 520 Surface material 520a Surface end 521 First surface 521a First seam allowance 521b Surface insertion hole 522 Second surface 522a Second seam allowance 522b Notch 523 Third surface 524 Alignment section 525 Thread 530 Sheet heater 530a Base material end 531 Base material 531a First base 531a1 First overlap allowance 531a2 First insertion hole 531b Second base 531b1 Second overlap allowance 531b2 Second insertion hole 531c Third base 531d Connecting section 531e Opposing surface 531e1 Position reference part531f Bending section 531f1 Guide section 532 Heating element 533 Alignment section 533a First alignment section 533b Second alignment section 540 Fixing member 541 Fixing section 542 Fixing pin 550 Suspension member 551 Locking section 551a Locking base section 551b Locking end 552 Locked section 552a C-ring 552b Wire

Claims

1. A vehicle seat comprising a pad material for supporting an occupant, a surface material covering the pad material, and a seat heater attached to the surface material, wherein the surface material has a suspension portion that is suspended and fixed in a groove formed in the pad material, and the seat heater comprises a heater wire and a heater base fabric on which the heater wire is arranged, and the heater base fabric has an insertion portion that is inserted into an insertion portion provided in the suspension portion and engages with the insertion portion.

2. The seat for a vehicle according to claim 1, wherein the insertion portion has an extension portion extending from the end of the heater base fabric toward the outside of the heater base fabric, and an engaging portion provided at the outer end of the extension portion, and the inner end of the engaging portion is located closer to the seating center than the connection portion between the extension portion and the engaging portion.

3. The seat for a vehicle according to claim 1, wherein the insertion portion is a slit extending in a suspension direction perpendicular to the seating surface, and the insertion portion is inserted into the slit in a twisted state along the direction in which the slit extends.

4. The vehicle seat according to claim 1, characterized in that the insertion portion does not pass through the insertion portion but wraps around the suspension portion, passes the tip of the suspension portion, extends in a direction approaching the seating surface, and is then inserted into the insertion portion.

5. The vehicle seat according to claim 1, characterized in that the insertion portion is inserted into the insertion portion, passes through the tip of the suspension portion so as to wrap around the suspension portion, and then extends in a direction approaching the seating surface.

6. The heater base fabric has a base fabric slit formed therein, and the insertion portion is inserted into the base fabric slit, as described in claim 4 or claim 5.

7. The vehicle seat according to claim 1, characterized in that the insertion portion extends in a direction that intersects with the direction in which the end of the heater base fabric on which the insertion portion is provided is perpendicular to the direction in which the end is perpendicular to the direction in which the end is perpendicular to the plane parallel to the seating surface.

8. The heater base fabric comprises a first base fabric portion provided with the insertion portion and a second base fabric portion having a base fabric slit through which the insertion portion can be inserted, wherein the insertion portion is inserted into the base fabric slit after being inserted into the portion to be inserted, as described in claim 1 for a vehicle seat.

9. The vehicle seat according to claim 8, wherein the vehicle seat has a central portion located in the center in the seat width direction, and bolster portions located on both sides of the central portion in the seat width direction, the first base fabric portion is disposed in the central portion, the second base fabric portion is disposed in the bolster portions, and the insertion portion connects the first base fabric portion and the second base fabric portion.

10. The vehicle seat according to claim 1, characterized in that the insertion portion has a plurality of slits that intersect with each other.

11. The vehicle seat according to claim 1, characterized in that the insertion portion has a substantially T-shape, and the insertion portion is inserted into the insertion portion in a folded state.

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