JP2022046015A - Vehicle seat and manufacturing method therefor - Google Patents

Abstract

To provide a vehicle seat that is simple in structure and comfortable despite a battery provided therein.SOLUTION: A vehicle seat 10 includes: a cushion pad (a seat pad) 12 formed of a foam resin body for elastically supporting the body of a seated person; and a lithium-ion battery module 14. The lithium-ion battery module 14 is flexible and has: a lithium-ion battery 16 including a positive electrode current collector 24 composed by containing resin; and a negative electrode current collector 32 composed by containing resin; and an exterior film 18 made of resin, covering the lithium-ion battery 16. A storage space 20 for storing the lithium-ion battery module 14 is formed in an inner part of the cushion pad 12, and the lithium-ion battery module 14 is housed in a storage space 20 of the cushion pad 12 so as to be in contact with an internal surface of the storage space 20.SELECTED DRAWING: Figure 1

Description

The present invention relates to a seat for a vehicle such as an aircraft and a method for manufacturing the same.

Conventionally, in a vehicle such as an aircraft, electric power is supplied to the seat from the main power source of the vehicle via an electric wire for entertainment equipment such as a display installed in the seat and various electric devices. On the other hand, wiring may be complicated because electricity is supplied to many seats. Also, supplying electricity to many seats may lack power for other uses in the vehicle. Therefore, there is a need to install batteries in each seat. To meet such needs, aircraft seats equipped with fuel cells are known (see Patent Document 1). However, the fuel cell has a problem that the system configuration is complicated due to the supply of hydrogen and oxygen (air), the discharge of generated water, and the like. On the other hand, seats for automobiles equipped with lithium ion batteries are known (see Patent Documents 2 and 3).

Japanese Patent No. 6389454 Japanese Unexamined Patent Publication No. 2008-284946 Japanese Unexamined Patent Publication No. 2010-083191 Japanese Unexamined Patent Publication No. 2015-07754

However, when the lithium ion battery is deformed by the action of an external force, the internal separator may be damaged and abnormal heat generation may occur. Therefore, it is necessary to provide a gap between the seat pad deformed by sitting and the lithium ion battery so that the deformation of the seat due to sitting does not reach the lithium ion battery. Further, in order to cool the lithium ion battery, it is necessary to provide a gap around the lithium ion battery. Further, in order to prevent the lithium ion battery from impairing the sitting comfort of the seated person, it is necessary to provide a gap between the seat pad and the lithium ion battery. Therefore, there is a problem that the installation structure of the lithium ion battery becomes complicated. Further, in order to improve the sitting comfort, it is preferable to suppress the resonance frequency to a predetermined value or less (for example, 4 Hz or less) (see Patent Document 4). However, it may be difficult to suppress the resonance frequency to a predetermined value or less due to the metal current collector of the lithium ion battery. The present invention has been made in view of these problems, and an object of the present invention is to provide a comfortable passenger seat having a simple structure while being equipped with a battery.

The vehicle seat according to one aspect of the present invention includes a foamed resin seat pad for elastically supporting the seated person's body and a lithium ion battery module, and the lithium ion battery module contains a resin. It is flexible and has a lithium ion battery including a configured positive current collector and a negative negative current collector configured to include a resin, and a resin exterior film covering the lithium ion battery, and lithium is inside the seat pad. A storage space for accommodating the ion battery module is formed, and the lithium ion battery module is accommodated in the accommodating space of the seat pad in contact with the inner surface of the accommodating space.

In this vehicle seat, the lithium-ion battery module is accommodated in the accommodation space of the seat pad in contact with the inner surface of the accommodation space, so that the configuration is compared with a configuration in which a gap is provided between the lithium-ion battery module and the seat pad. The structure is simple. Further, since the lithium ion battery includes a positive electrode current collector configured to include a resin and a negative electrode current collector configured to include a resin, the resonance frequency can be suppressed to a low value.

It is preferable that the resonance frequency value of the battery-built seat pad in which the lithium-ion battery module is housed in the seat pad storage space is 3.4 Hz or less.

According to one theory, the frequency of vibration that a person feels uncomfortable is around 6 Hz. According to another theory, the frequency of vibration that a person feels uncomfortable depends on the direction of vibration. In this theory, the frequency of vertical vibration that humans find unpleasant is around 5 Hz. By suppressing the resonance frequency value of the battery-built seat pad to 3.4 Hz or less, vibrations having a frequency of around 6 Hz and vibrations having a frequency of around 5 Hz are significantly suppressed.

The lithium ion battery module may be housed in the seat pad accommodating space so as to be deformed as the seat pad is deformed due to seating. Since the above-mentioned lithium-ion battery module is flexible, even if it is deformed together with the seat pad by sitting, damage to the separator inside the lithium-ion battery is unlikely to occur. Therefore, abnormal heat generation is unlikely to occur. Further, since the above-mentioned lithium ion battery module is flexible, it is comfortable without impairing the sitting comfort of the seated person.

Further, the lithium ion battery module may be in the shape of a seat or a plate, and the accommodation space of the seat pad may be formed along the surface of the seat pad facing the seated person. Since the seat-shaped or plate-shaped lithium-ion battery module is arranged along the surface of the seat pad facing the seated person, the local deformation of the lithium-ion battery due to seating is reduced. In addition, the arrangement of the lithium-ion battery module also contributes to improving the sitting comfort of the seated person.

Further, both sides of the lithium ion battery module may be in contact with the inner surface of the accommodation space. The lithium-ion battery module is held so as to be sandwiched by the seat pad, so that the structure is simple.

Further, an elastic auxiliary member installed on one surface of the lithium ion battery module may be further provided. The elasticity of the seat pad can be adjusted by providing the elastic auxiliary member. It is also possible to suppress the deformation of the lithium ion battery module.

Further, the method for manufacturing a vehicle seat according to one aspect of the present invention is to manufacture a vehicle seat including a foamed resin seat pad for elastically supporting the seated person's body and a lithium ion battery module. It is a method, as a lithium ion battery module, a lithium ion battery including a positive electrode current collector composed of a resin and a negative electrode current collector composed of a resin, and a resin exterior film covering the lithium ion battery. The outer shape of the lithium-ion battery module so that a storage space for accommodating the lithium-ion battery module is formed inside the seat pad and the process of preparing the lithium-ion battery module for preparing the flexible lithium-ion battery module having A foam molding process in which a core having an outer shape corresponding to the above is placed in a mold to foam-mold the seat pad, and a storage process in which the lithium-ion battery module is housed in the seat pad storage space in contact with the inner surface of the storage space. And, including.

According to this manufacturing method, it is possible to easily manufacture the above-mentioned vehicle seat which is equipped with a battery but has a simple structure and is comfortable.

Further, the method for manufacturing a vehicle seat according to another aspect of the present invention is a vehicle seat including a foamed resin seat pad for elastically supporting the seated person's body and a lithium ion battery module. As a lithium ion battery module, a lithium ion battery including a positive electrode current collector composed of a resin and a negative electrode current collector composed of a resin, and a resin covering the lithium ion battery. A lithium-ion battery module preparation process for preparing a flexible lithium-ion battery module having an exterior film, and a storage space for accommodating the lithium-ion battery module are formed inside the seat pad, and the lithium-ion battery module is formed. Includes a foam molding step of arranging a lithium ion battery module in a mold and foam molding the seat pad so that the seat pad is accommodated in the accommodation space in contact with the inner surface of the accommodation space.

According to this manufacturing method, it is not necessary to use a core. Further, the foam molding process also serves as a storage process. Therefore, it is possible to more easily manufacture the above-mentioned vehicle seat, which is equipped with a battery but has a simple structure and is comfortable.

According to the present invention, it is possible to realize a comfortable passenger seat having a simple structure while being equipped with a battery.

A side sectional view schematically showing the configuration of a passenger seat according to the first embodiment of the present invention. Perspective view schematically showing the configuration of the cushion pad of the passenger seat A cross-sectional view schematically showing an enlarged configuration of a lithium-ion battery module provided in a passenger seat. A cross-sectional view schematically showing an enlarged part of the lithium ion battery provided in the lithium ion battery module. Flowchart showing how to manufacture passenger seats Sectional drawing which shows typically the foam molding process of the cushion pad of a passenger seat Cross-sectional view schematically showing the structure of the cushion pad from which the core was taken out after the foam molding process. Sectional drawing which shows typically the process of accommodating a lithium ion battery module in the cushion pad. Sectional drawing which shows typically the structure of the passenger seat of 2nd Embodiment of this invention. Sectional drawing which shows typically the structure of the passenger seat of 3rd Embodiment of this invention. Sectional drawing which shows typically the structure of the vehicle seat of 4th Embodiment of this invention. Sectional drawing which shows typically the foam molding process of the manufacturing method of the vehicle seat of 5th Embodiment of this invention. A flowchart showing a method of manufacturing a vehicle seat according to the fifth embodiment.

As shown in FIGS. 1 and 2, the vehicle seat 10 of the first embodiment of the present invention includes a foamed resin cushion pad (seat pad) 12 for elastically supporting the seated body and lithium. It includes an ion battery module 14. The vehicle seat 10 is used, for example, as a seat for passengers of an aircraft. The lithium ion battery module 14 is used as an auxiliary power source for entertainment equipment such as a display installed in a seat, various electric equipment, and the like. As shown in FIGS. 3 and 4, the lithium ion battery module 14 includes a lithium ion battery 16 including a positive electrode current collector 24 configured to include a resin and a negative electrode current collector 32 configured to include a resin, and lithium. It has a resin exterior film 18 that covers the ion battery 16 and is flexible. A storage space 20 for accommodating the lithium ion battery module 14 is formed inside the cushion pad 12, and the lithium ion battery module 14 is housed in the accommodating space 20 of the cushion pad 12 in contact with the inner surface of the accommodating space 20. There is.

The cushion pad 12 constitutes a seat pad for the seat of the vehicle seat 10. The accommodation space 20 is formed along the seat surface (the surface facing the seated person) of the cushion pad 12. The vehicle seat 10 is provided with a back pad 22 as a seat pad on the backrest portion. The material of the cushion pad 12 and the back pad 22 is a flexible foamed resin such as polyurethane. The cushion pad 12 and the back pad 22 are covered with a skin material (not shown). Further, the cushion pad 12 and the back pad 22 are assembled to a predetermined frame (not shown) or the like.

The lithium ion battery module 14 has a sheet shape or a plate shape, and is housed in the storage space 20 in a posture along the seat surface of the cushion pad 12. Both sides of the lithium ion battery module 14 are in contact with the inner surface of the accommodation space 20. The lithium ion battery module 14 is housed in the storage space 20 of the cushion pad 12 so as to be deformed with the deformation of the cushion pad 12 due to sitting. The tips of the terminals 14A and 14B of the lithium ion battery module 14 extend to the outside of the cushion pad 12.

The lithium ion battery 16 has a positive electrode current collector 24, a positive electrode active material layer 26, a separator 28, a negative electrode active material layer 30, and a negative electrode current collector 32, and these layers are laminated in this order. Further, the lithium ion battery 16 holds the separator 28 by sandwiching the outer edges of the separator 28 that separates the positive electrode active material layer 24 and the negative electrode active material layer 30 from both sides in the stacking direction, and holds the positive electrode active material layer 26 and the negative electrode active material layer 26. It has a frame member 34 that surrounds the outer periphery of the material layer 30. The positive electrode current collector 24 is fixed to one side of the frame member 34 at its outer edge so as to cover the positive electrode active material layer 26. The negative electrode current collector 32 is fixed to the other side of the frame material 34 at its outer edge so as to cover the negative electrode active material layer 30.

The positive electrode current collector 24 is, for example, a resin collector of a conductive resin, or a resin collector in which a non-conductive polymer material and a conductive filler are mixed. The conductive resin is, for example, polyaniline, polypyrrole, polythiophene, polyacetylene, polyparaphenylene, polyphenylene vinylene, polyoxadiazole and the like. Non-conductive polymer materials include, for example, polyethylene (PE; high density polyethylene (HDPE), low density polyethylene (LDPE), etc.), polypropylene (PP), polyethylene terephthalate (PET), polyether nitrile (PEN), polyimide (PI). ), Polypropyleneimide (PAI), Polyethylene (PA), Polytetrafluoroethylene (PTFE), Styrene-butadiene rubber (SBR), Polyacrylonitrile (PAN), Polymethylacrylate (PMA), Polymethylmethacrylate (PMMA), Poly Vinyl chloride (PVC), polyvinylidene fluoride (PVdF), polystyrene (PS) and the like. The conductive filler is metal and / or conductive carbon. The metal is, for example, at least one metal selected from the group consisting of nickel, titanium, aluminum, copper, platinum, iron, chromium, tin, zinc, indium, antimony, and potassium, or an alloy or metal oxide containing these metals. Is. Conductive carbon comprises, for example, acetylene black, vulcan (registered trademark), black pearl (registered trademark), carbon nanofiber, Ketjen black (registered trademark), carbon nanotube (CNT), carbon nanohorn, carbon nanoballoon, and fullerene. At least one selected from the group. The negative electrode current collector 32 is a resin current collector similar to the positive electrode current collector 24.

The positive electrode active material layer 26 is a mixture of positive electrode active material particles and an electrolytic solution. The positive electrode active material layer 26 is in a semi-solid state, for example, a slurry, a funicular, or a pendulum. The positive electrode active material particles are LiCoO ₂ , LiNiO ₂ , LiMnO ₂ , LiMn ₂ O ₄ , LiFePO ₄ , a ternary material, and the like. The surface of the positive electrode active material particles may be coated with a coating resin. Further, the positive electrode active material layer 26 may contain a conductive auxiliary agent. The conductive auxiliary agent is, for example, a carbon material such as acetylene black or a metal such as aluminum. The coating resin that coats the positive electrode active material particles may also contain a conductive filler made of the same material as the conductive auxiliary agent. Further, the positive electrode active material layer 26 may contain a binder. The binder is, for example, polyvinylidene fluoride or the like. The electrolytic solution contains an electrolyte and a non-aqueous solvent. The electrolytes are LiPF ₆ , LiBF ₄ , LiSbF ₆ , LiAsF ₆ , LiClO ₄ , LiN (CF ₃ SO ₂ ) ₂ , LiN (C ₂ F ₅ SO ₂ ) ₂ , LiC (CF ₃ SO ₂ ) ₃ , and the like. The non-aqueous solvent is a lactone compound, a cyclic or chain carbonate ester, a chain carboxylic acid ester, a cyclic or chain ether, a phosphoric acid ester, a nitrile compound, an amide compound, a sulfone, a sulfone, or a mixture thereof. The positive electrode active material layer 26 is housed in a space surrounded by the positive electrode current collector 24, the separator 28, and the frame material 34.

The negative electrode active material layer 30 is a mixture of negative electrode active material particles and an electrolytic solution. The negative electrode active material layer 30 is also in a semi-solid state, for example, a slurry, a funicular, or a pendulum. The negative electrode active material particles are carbon-based active materials such as graphitizable carbon (hard carbon) and graphite, metals, alloys, or oxides. The surface of the negative electrode active material particles may also be coated with a coating resin. Further, the negative electrode active material layer 30 may also contain the same conductive auxiliary agent as the conductive auxiliary agent contained in the positive electrode active material layer 26. The coating resin that coats the negative electrode active material particles may also contain a conductive filler made of the same material as the conductive auxiliary agent. Further, the negative electrode active material portion may contain a binder. The binder is an aqueous polymer such as a styrene-butadiene copolymer. The electrolytic solution contained in the negative electrode active material layer 30 is the same as the electrolytic solution contained in the positive electrode active material layer 26. The negative electrode active material layer 30 is housed in a space surrounded by the negative electrode current collector 32, the separator 28, and the frame material 34.

The separator 28 is a microporous film of polyolefin such as polyethylene and polypropylene. The material of the frame material 34 is, for example, acrylic resin, urethane resin, epoxy resin, polyethylene resin, polypropylene resin, polyimide resin, rubber (ethylene-propylene-diene rubber: EPDM), isocyanate-based adhesive, acrylic resin-based adhesive, cyanoacrylate. It is a system adhesive, a hot melt adhesive (urethane resin, polyamide resin, polyolefin resin), a resin obtained by copolymerizing ethylene, propylene, butene containing a non-crystalline polypropylene resin as a main component, and the like. The material of the frame material 34 is preferably ethylene-vinyl acetate copolymer or maleic anhydride-modified polyethylene.

The lithium ion battery 16 is a sheet-shaped or plate-shaped single cell having a positive electrode current collector 24 on one side and a negative electrode current collector 32 on the other side. The lithium ion battery module 14 has a plurality of laminated lithium ion batteries 16. The positive electrode current collector 24 and the negative electrode current collector 32 of the adjacent lithium ion batteries 16 are in contact with each other and are electrically connected in series. Further, the lithium ion battery module 14 may have only one lithium ion battery 16. The plurality of laminated lithium ion batteries 16 or one lithium ion battery 16 are covered with an exterior film 18. The exterior film 18 is, for example, a laminated film having a three-layer structure in which polypropylene (PP), aluminum, and nylon are laminated in this order.

Next, the operation of the vehicle seat 10 will be described. In the vehicle seat 10, the lithium ion battery module 14 is accommodated in the accommodating space 20 of the cushion pad 12 in contact with the inner surface of the accommodating space 20, so that there is a gap between the lithium ion battery module 14 and the cushion pad 12. The structure is simple compared to the configuration provided. Further, both sides of the lithium ion battery module 14 are in contact with the inner surface of the accommodation space 20, and the lithium ion battery module 14 is held so as to be sandwiched by the cushion pad 12, so that the structure is also simple in this respect as well. Further, since the positive electrode current collector 24 and the negative electrode current collector 32 are resin current collectors composed of resin, the resonance frequency can be suppressed to a lower value than that of the metal current collector. The resonance frequency value of the battery-built cushion pad (battery-built seat pad) in which the lithium-ion battery module 14 is housed in the storage space 20 of the cushion pad 12 is preferably 3.4 Hz or less.

Further, since the lithium ion battery module 14 is flexible, even if it is deformed together with the cushion pad 12 by sitting, the separator 28 inside the lithium ion battery 16 is unlikely to be damaged. Therefore, abnormal heat generation is unlikely to occur. Further, since the lithium ion battery module 14 is flexible, it does not give a sense of discomfort to the seated person. Therefore, the vehicle seat 10 is comfortable and comfortable to sit on. Further, since the lithium ion battery module 14 is in the shape of a sheet or a plate and is arranged along the seating surface of the cushion pad 12, local deformation of the lithium ion battery 16 due to seating is reduced. Further, the arrangement of the lithium ion battery module 14 also contributes to the improvement of the sitting comfort of the seated person.

Next, a method of manufacturing the vehicle seat 10 will be described with reference to the flowchart shown in FIG. First, it is flexible having a lithium ion battery 16 including a positive electrode current collector 24 configured to include a resin and a negative electrode current collector 32 configured to include a resin, and a resin exterior film covering the lithium ion battery 16. A sexual lithium-ion battery module 14 is prepared (S102: lithium-ion battery module preparation step).

Next, as shown in FIG. 6, the core 36 having an outer shape corresponding to the outer shape of the lithium ion battery module 14 is arranged in the mold 38 to foam-mold the cushion pad 12 (S104: foam molding step). The core 36 having an outer shape corresponding to the outer shape of the lithium ion battery module 14 is a core having the same outer shape as the outer shape of the lithium ion battery module 14. Further, the core 36 having an outer shape corresponding to the outer shape of the lithium ion battery module 14 may be a core having a slightly reduced outer shape of the lithium ion battery module 14. The portion of the core 36 corresponding to the terminals 14A and 14B is a single plate having a shape including the terminals 14A and 14B. In this plate-shaped portion, the core 36 is sandwiched and held by the mold 38. After foam molding, as shown in FIG. 7, the core 36 is taken out, and a storage space 20 for housing the lithium ion battery module 14 is formed inside the cushion pad 12.

Next, as shown in FIG. 8, the lithium ion battery module 14 is accommodated in the accommodating space 20 of the cushion pad 12 (S106: accommodating step). The tips of the terminals 14A and 14B of the lithium ion battery module 14 extend to the outside of the opening of the cushion pad 12. The lithium ion battery module 14 is housed in the storage space 20 of the cushion pad 12 with both sides in contact with the inner surface of the storage space 20.

The back pad 22 is also produced by foam molding in the same manner. After that, the cushion pad 12 and the back pad 22 are covered with a skin material, and further assembled to a predetermined frame or the like to complete the vehicle seat 10. After that, the production of the vehicle seat 10 is repeated in the same manner.

Next, a second embodiment of the present invention will be described. As shown in FIG. 9, the vehicle seat 50 of the second embodiment further includes an elastic auxiliary member 52 installed on one surface of the lithium ion battery module 14. Since the other configurations are the same as those of the vehicle seat 10 of the first embodiment, the same configurations will be omitted with reference to the same reference numerals as those in FIGS. 1 to 8. The elastic auxiliary member 52 is an elastic plate-like body and is installed in contact with the lower surface of the lithium ion battery module 14. Therefore, the elastic auxiliary member 52 is also arranged along the seat surface. The material of the elastic auxiliary member 52 is, for example, a thermoplastic resin such as polyetheretherketone (PEEK), a thermosetting resin such as an epoxy resin or a vinyl ester resin, or GFRP or CFRP containing these resins. The elasticity of the cushion pad 12 can be adjusted by providing the elastic auxiliary member 52. It is also possible to suppress the deformation of the lithium ion battery module 14. Further, since the elastic auxiliary member 52 is held so as to be sandwiched by the cushion pad 12 together with the lithium ion battery module 14, the structure is simple.

In order to manufacture the vehicle seat 50, in the foam molding step S104, a core having an outer shape corresponding to the outer shape of the lithium ion battery module 14 and the elastic auxiliary member 52 installed on the lower surface thereof is used. For example, it is an outer core of the lithium ion battery module 14 and the elastic auxiliary member 52 installed on the lower surface thereof. Further, the outer shape of the lithium ion battery module 14 and the elastic auxiliary member 52 installed on the lower surface thereof may be a core having a slightly reduced outer shape. For example, a core having the same outer shape as the outer shape of the lithium ion battery module 14 may be used. Further, in the accommodation step S106, the elastic auxiliary member 52 is accommodated together with the lithium ion battery module 14 in the accommodation space 20 of the cushion pad 12. The lithium ion battery module 14 may be inserted after the elastic auxiliary member 52 is inserted into the accommodation space 20. Further, the elastic auxiliary member 52 may be inserted after the lithium ion battery module 14 is inserted into the accommodation space 20.

Next, a third embodiment of the present invention will be described. As shown in FIG. 10, the vehicle seat 60 of the third embodiment includes a lithium ion battery module 14 in the accommodation space 62 of the back pad 22 (seat pad) of the backrest portion. The accommodation space 62 is formed along the surface of the back pad 22 facing the back of the seated person (the surface of the seat pad facing the seated person). Therefore, the sheet-shaped or plate-shaped lithium-ion battery module 14 is arranged along the surface of the back pad 22 facing the back of the seated person. Since the other configurations are the same as those of the vehicle seat 10 of the first embodiment, the same configurations will be omitted with reference to the same reference numerals as those in FIGS. 1 to 8. Since the lithium ion battery module 14 is also accommodated in the vehicle seat 60 in contact with the inner surface of the accommodation space 62 in the accommodation space 62 of the back pad 22, there is a gap between the lithium ion battery module 14 and the back pad 22. The structure is simple compared to the configuration provided. Further, both sides of the lithium ion battery module 14 are in contact with the inner surface of the accommodation space 62, and the lithium ion battery module 14 is held so as to be sandwiched by the back pad 22, so that the structure is also simple in this respect as well. Further, since the positive electrode current collector 24 and the negative electrode current collector 32 are resin current collectors composed of resin, the resonance frequency can be suppressed to a lower value than that of the metal current collector. The resonance frequency value of the battery-built back pad (battery-built seat pad) in which the lithium-ion battery module 14 is housed in the storage space 62 of the back pad 22 is preferably 3.4 Hz or less.

Further, since the lithium ion battery module 14 is flexible, even if it is deformed together with the back pad 22 by sitting, the separator 28 inside the lithium ion battery 16 is unlikely to be damaged. Therefore, abnormal heat generation is unlikely to occur. Further, since the lithium ion battery module 14 is flexible, it does not give a sense of discomfort to the seated person. Therefore, the vehicle seat 60 is comfortable and comfortable to sit on. Further, since the lithium ion battery module 14 is in the shape of a sheet or a plate and is arranged along the surface of the back pad 22 facing the back of the seated person, the local deformation of the lithium ion battery 16 due to seating is reduced. Will be done. Further, the arrangement of the lithium ion battery module 14 also contributes to the improvement of the sitting comfort of the seated person.

In order to manufacture the vehicle seat 60, as in the first embodiment, the back pad 22 in which the accommodation space 62 is formed by using the core of the outer shape corresponding to the outer shape of the lithium ion battery module 14 in the foam molding step S104. Is formed, and the lithium ion battery module 14 is inserted into the accommodation space 62 of the back pad 22 in the accommodation step S106.

Next, a fourth embodiment of the present invention will be described. As shown in FIG. 11, the vehicle seat 70 of the fourth embodiment further includes an elastic auxiliary member 52 installed on one surface of the lithium ion battery module 14 as compared with the third embodiment. Since other configurations are the same as those of the passenger car seat 60 of the third embodiment, the same configurations will be omitted with reference to the same reference numerals as those in FIG. The elastic auxiliary member 52 is installed in contact with the rear surface of the lithium ion battery module 14. Therefore, the elastic assisting member 52 is arranged along the surface of the backrest portion facing the back of the seated person. The elasticity of the back pad 22 can be adjusted by providing the elastic auxiliary member 52. It is also possible to suppress the deformation of the lithium ion battery module 14. Further, since the elastic auxiliary member 52 is held so as to be sandwiched by the back pad 22 together with the lithium ion battery module 14, the structure is simple.

In order to manufacture the vehicle seat 70, as in the second embodiment, in the foam molding step S104 of the back pad 22, the outer shape corresponding to the outer shape of the lithium ion battery module 14 and the elastic auxiliary member 52 installed on the rear surface thereof. The core is used. For example, it is an outer core of the lithium ion battery module 14 and the elastic auxiliary member 52 installed on the rear surface thereof. Further, the outer shape of the lithium ion battery module 14 and the elastic auxiliary member 52 installed on the rear surface thereof may be a core having a slightly reduced outer shape. For example, a core having the same outer shape as the outer shape of the lithium ion battery module 14 may be used. Further, in the accommodation step S106, the elastic auxiliary member 52 is accommodated together with the lithium ion battery module 14 in the accommodation space 62 of the back pad 22. The lithium ion battery module 14 may be inserted after the elastic auxiliary member 52 is inserted into the accommodation space 62. Further, the elastic auxiliary member 52 may be inserted after the lithium ion battery module 14 is inserted into the accommodation space 62.

Next, a fifth embodiment of the present invention will be described. In the first to fourth embodiments, the accommodating space 20 (or 62) is formed in the cushion pad 12 (or the back pad 22) by using the core 36 in the foam molding step S104, and the accommodating space 20 (or the accommodating space 20) is formed in the accommodating step S106. The lithium ion battery module 14 is housed in 62). On the other hand, in the fifth embodiment, the core is not used in the foam molding step S104, and the lithium ion battery module 14 is housed inside the cushion pad 12 (or the back pad 22) as shown in FIG. A storage space 20 (or 62) is formed, and the lithium ion battery module 14 contacts the inner surface of the storage space 20 (or 62) in the storage space 20 (or 62) of the cushion pad 12 (or back pad 22). The lithium-ion battery module 14 is arranged in the mold 38 and the cushion pad 12 (or back pad 22) is foam-molded so as to be accommodated. Further, in the foam molding step S104, the lithium ion battery module 14 is held in the mold 38 at the terminals 14A and 14B. When the elastic auxiliary member 52 is provided as in the second and fourth embodiments, the elastic auxiliary member 52 is previously attached to the lower surface (or the rear surface) of the lithium ion battery module 14 with an adhesive or the like, and the elastic auxiliary member 52 is provided. Is held together with the lithium ion battery module 14 in the foam molding step S104. As shown in FIG. 13, in the fifth embodiment, the foam molding step S104 also serves as the accommodating step, and the accommodating step is not executed after the foam molding step S104. Since the other configurations are the same as those of the first to fourth embodiments, the same configurations will be referred to with the same reference numerals as those of FIGS. 1 to 11 and the description thereof will be omitted. According to the fifth embodiment, it is not necessary to use the core in the foam molding step S104. Further, since the foam molding step S104 also serves as the accommodating step, the vehicle seats 10, 50, 60, and 70 can be manufactured more easily.

In the first embodiment, the lithium ion battery module 14 is provided on the cushion pad 12 of the seat portion, and in the third embodiment, the lithium ion battery module 14 is provided on the back pad 22 of the backrest portion. A lithium ion battery module 14 may be provided on both the cushion pad 12 and the back pad 22 of the backrest portion. In this case, the elastic auxiliary member 52 may be installed on the cushion pad 12 of the seat portion as in the second embodiment. Further, the elastic auxiliary member 52 may be installed on the back pad 22 of the backrest portion as in the fourth embodiment. Further, the elastic auxiliary member 52 may be installed on both the cushion pad 12 and the back pad 22.

Further, in the second embodiment, the elastic auxiliary member 52 is installed in contact with the lower surface of the lithium ion battery module 14 in the cushion pad 12, but the elastic auxiliary member 52 is the lithium ion battery module in the cushion pad 12. It may be installed in contact with the upper surface of 14. Further, the two elastic auxiliary members 52 may be installed in contact with both sides of the lithium ion battery module 14 in the cushion pad 12. Similarly, in the fourth embodiment, the elastic auxiliary member 52 is installed in contact with the rear surface of the lithium ion battery module 14 in the back pad 22, but the elastic auxiliary member 52 is a lithium ion battery in the back pad 22. It may be installed in contact with the front surface of the module 14. Further, the two elastic auxiliary members 52 may be installed in contact with both sides of the lithium ion battery module 14 in the back pad 22.

Further, in the first to fifth embodiments, an aircraft is exemplified as a vehicle in which the vehicle seats 10, 50, 60, 70 are used, but the vehicle seats 10, 50, 60, 70 are of a bus or the like. It can also be applied to other vehicles such as automobiles and ships.

[Example]
As shown in FIGS. 1 and 2, a seat pad with a built-in battery in which a lithium ion battery module is housed in a cushion pad (seat pad) was created. The configuration of the lithium-ion battery module is as follows. The frame material is composed of two pieces. More specifically, the positive electrode side frame material and the negative electrode side frame material sandwich the separator.
Single cell size: 900 mm x 900 mm x 600 μm
Frame material size: 900 mm x 900 mm x 250 μm x 2 pieces Frame material hole size: 880 mm x 880 mm
Size of positive electrode current collector and negative electrode current collector: 900 mm x 900 mm x 50 μm
Separator size: 885 mm x 885 mm x 25 μm x 1 Sheet Frame material: Ethylene-vinyl acetate copolymer (trade name "Mersen (registered trademark) G7055")
Materials for positive electrode collector and negative electrode current collector: Polypropylene (trade name "SunAllomer (registered trademark) PL500A", manufactured by SunAllomer Ltd.) (B-1) 75% by mass, acetylene black (AB) (denka black (registered) Trademark)) 20% by mass, modified polyolefin resin (SunAllomer Ltd. Umex (registered trademark) 1001) 5% by mass
Separator material: Polypropylene microporous membrane (trade name "Celguard (registered trademark) 3501")
Positive electrode active material: Nickel / aluminum / lithium cobalt oxide (core-shell (resin) structure) 100% by mass, acetylene black 0.1% by mass
Negative electrode active material: non-graphitizable carbon (hard carbon) (core-shell (resin) structure) 100% by mass, acetylene black 1.6% by mass
Electrolyte: Mixed solvent of ethylene carbonate (EC) and propylene carbonate (PC) (volume ratio 1: 1), Li [(FSO ₂ ) 2N] (LiFSI) 2 mol / L
Number of laminated lithium-ion batteries (single cell): 10 sheets Exterior film: 3-layer laminated film (polypropylene (PP), aluminum, nylon)

The cushion pad (seat pad) was manufactured as follows, and various physical properties were measured. Polyurethane A-1 (60 parts), A-2 (40 parts), A-3 (2 parts), A-4 (1 part) polyol premix and organic polyisocyanate with an NCO index of 100 parts Component B-1, catalyst C-1 (0.4 parts), C-2 (0.02 parts), foaming agent D-1 (2.3 parts), and foam stabilizer E-1 (0. 6 parts) and the foam were formed by foaming a flexible polyurethane foam in a mold under the following foaming conditions, and then the foam was taken out from the mold and left for a whole day and night to obtain a flexible polyurethane foam.
(Foaming condition)
Mold size: 400 mm x 400 mm x 100 mm (height)
Mold temperature: 65 ° C
Mold material: Aluminum mixing method: Polyol premix and organic polyisocyanate are mixed at 15 MPa using a high-pressure urethane foaming machine (manufactured by PEC).

Among the raw materials for flexible polyurethane foam, the polyol components are as follows.
A-1: The number of functional groups is 4.0, the hydroxyl value is 30, and the content of terminal EO units is obtained by adding PO to pentaerythritol using tris (pentafluorophenyl) borane as a catalyst and then adding EO. Polyoxyethylene polyoxypropylene polyol A-2 with 10.0%, primary OH conversion rate of terminal hydroxyl group 90%, monool content 0.03meq / g, diol content 16%: pentaerythritol with potassium hydroxide as a catalyst The average number of functional groups obtained by block addition of PO and EO was 4.0, the hydroxyl value was 28, the content of terminal EO units was 12.0%, the primary OH conversion rate of terminal hydroxyl groups was 80%, and the monool content was 0. A polyoxyethylene polyoxypropylene polyol having a diol content of 0.07 meq / g and a hydroxyl group having an average number of functional groups of 3.0 obtained by blocking addition of PO and EO to glycerin using potassium hydroxide as a catalyst. A mixture of polyoxyethylene polyoxypropylene polyol having a value of 34, a terminal EO unit content of 14.0%, a primary OH conversion rate of the terminal hydroxyl group of 82%, a monool content of 0.06 meq / g, and a diol content of 0.0%. Polymer polyol (polymer content 33.0%) obtained by copolymerizing styrene and acrylonitrile (weight ratio: 30/70) in (weight ratio: 20:80), hydroxyl value 22.
A-3: PO adduct of sorbitol, hydroxyl value 490
A-4: Triethanolamine, hydroxyl value 1120

In addition, among the raw materials of the flexible polyurethane foam, those other than the polyol component are as follows.
B-1: TDI-80 (2,4- and 2,6-TDI, ratio of 2,4-form is 80%) / crude MDI (average number of functional groups: 2.9) = 80/20 (weight ratio)
C-1: "DABCO-33LV" manufactured by Air Products Japan Co., Ltd. (33% dipropylene glycol solution of triethylenediamine)
C-2: "TOYOCAT ET" manufactured by Tosoh Corporation (70% dipropylene glycol solution of bis (dimethylaminoethyl) ether)
D-1: Water E-1: "TEGOSTAB B8737" manufactured by EVONIK (polysiloxane-based defoaming agent)

The physical characteristics of the flexible polyurethane foam thus obtained before the lithium ion battery module was installed were measured. The measurement results are as follows.
Core density: 57.3 kg / m ³ (based on JIS K6400)
Foam hardness (25% -ILD): 271N / 314cm ² (compliant with JIS K6400)
Reboundive elasticity: 64% (based on JIS K6400)
Compressive residual strain rate: 2.5% (based on JIS K6400)
Moist heat compression residual strain rate: 9.7% (based on JIS K6400, temperature 50 ° C, humidity 95%)
Resonance frequency: 3.2Hz (based on JASO B407 test method)

After measuring the above physical properties, a storage space was formed in a portion of the polyurethane foam having a height of 50 mm, and a lithium ion battery module was inserted. The resonance frequency of the seat pad with a built-in battery thus obtained was measured. The measurement results are as follows.
Resonance frequency: 3.4Hz

[Comparison example]
For the above embodiment, the positive electrode current collector of the lithium ion battery and the seat pad with a built-in battery having different negative electrode current collectors were prepared as follows. Other configurations are the same as in the embodiment.
Material of positive electrode current collector: Carbon coated aluminum Thickness of positive electrode current collector: 20 μm
Material of negative electrode current collector: Copper foil Thickness of negative electrode current collector: 35 μm

The resonance frequency of the battery-built seat pad of the comparative example was measured in the same manner as in the examples. The measurement results are as follows.
Resonance frequency: 5.7Hz

The resonance frequency of the battery-built seat pad of the comparative example was 5.7 Hz, which was a frequency close to 6 Hz or 5 Hz, which is said to be unpleasant for humans. On the other hand, the resonance frequency of the battery-built seat pad of the example was 3.4 Hz, which was significantly smaller than 6 Hz or 5 Hz. That is, it was confirmed that according to the examples, a more comfortable passenger seat can be obtained than in the comparative example.

The present invention can be used for seats of vehicles such as aircraft.

10, 50, 60, 70 Seats for vehicles 12 Cushion pads (seat pads)
14 Lithium-ion battery module 14A, 14B terminal 16 Lithium-ion battery 18 Exterior film 20, 62 Storage space 22 Back pad (seat pad)
24 Positive electrode current collector 26 Positive electrode active material layer 28 Separator 30 Negative electrode active material layer 32 Negative electrode current collector 34 Frame material 36 Core 38 type 52 Elastic auxiliary member S102 Lithium ion battery module preparation process S104 Foam molding process S106 Containment process

Claims (8)

A foamed resin seat pad to elastically support the seated person's body,
Equipped with a lithium-ion battery module,
The lithium ion battery module may have a lithium ion battery including a positive electrode current collector composed of a resin and a negative electrode current collector composed of a resin, and a resin exterior film covering the lithium ion battery. It is flexible and
A storage space for accommodating the lithium ion battery module is formed inside the seat pad.
The lithium-ion battery module is a passenger seat housed in the seat pad accommodating space in contact with the inner surface of the accommodating space. In claim 1,
A passenger seat characterized in that the resonance frequency value of the battery-built-in seat pad in which the lithium-ion battery module is housed in the seat pad storage space is 3.4 Hz or less. In claim 1,
The lithium-ion battery module is a passenger seat housed in the accommodation space of the seat pad so as to be deformed according to the deformation of the seat pad due to seating. In any of claims 1 to 3,
The lithium-ion battery module is in the shape of a seat or a plate, and the accommodation space of the seat pad is a passenger seat formed along the surface of the seat pad facing the seated person. In claim 4,
A passenger seat in which both sides of the lithium-ion battery module are in contact with the inner surface of the accommodation space. In claim 4,
A passenger seat further comprising an elastic assisting member installed on one side of the lithium ion battery module. A method of manufacturing a passenger seat including a foamed resin seat pad for elastically supporting the seated body and a lithium ion battery module.
The lithium ion battery module includes a lithium ion battery including a positive electrode current collector composed of a resin and a negative electrode current collector composed of a resin, and a resin exterior film covering the lithium ion battery. Lithium-ion battery module preparation process to prepare a flexible lithium-ion battery module,
The seat pad is provided by arranging a core having an outer shape corresponding to the outer shape of the lithium ion battery module in a mold so that a storage space for accommodating the lithium ion battery module is formed inside the seat pad. Foam molding process for foam molding and
A method for manufacturing a vehicle seat, comprising a storage step of accommodating the lithium ion battery module in the accommodating space of the seat pad in contact with the inner surface of the accommodating space. A method of manufacturing a passenger seat including a foamed resin seat pad for elastically supporting the seated body and a lithium ion battery module.
The lithium ion battery module includes a lithium ion battery including a positive electrode current collector composed of a resin and a negative electrode current collector composed of a resin, and a resin exterior film covering the lithium ion battery. Lithium-ion battery module preparation process to prepare a flexible lithium-ion battery module,
A storage space for accommodating the lithium-ion battery module is formed inside the seat pad, and the lithium-ion battery module is accommodated in the storage space of the seat pad in contact with the inner surface of the accommodation space. A method for manufacturing a passenger seat, comprising a foam molding step of arranging the lithium ion battery module in a mold and foam molding the seat pad.

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