JP2023138078A - Skin integral molding seat pad and vehicular seat - Google Patents

Abstract

To obtain a skin integral molding seat pad in which a device such as a sensor is integrally molded with a skin and a pad material, and which can restrict malfunction of the device such as a sensor by using a simple configuration and without causing constraints to the design of a seat cushion, and to provide a vehicular seat.SOLUTION: A seat pad 14 and a seat skin 16 are integrally molded in a state that a pocket member 32 is provided on a rear face 17 of the seat skin 16 and a seating sensor unit 38 is accommodated inside the pocket member 32. Therefore, an opening for inserting the seating sensor unit 38 is not needed on a design surface 19 side of the seat skin 16, and thus, constraints are not caused to designability. During molding of a skin integral pad 18, an opening 32D is in a closed state, since the pocket member 32 is compressed along its thickness direction. Accordingly, during molding of the skin integral pad 18, a raw material of the seat pad 14 is prevented from intruding into the pocket member 32, and malfunction of the seating sensor unit 38 is suppressed.SELECTED DRAWING: Figure 2

Description

The present invention relates to a skin-integrated seat pad and a vehicle seat.

In recent years, technology has been used to integrally mold the padding material and the skin in order to reduce the number of parts by eliminating the covering work in the seat cushion, or to realize an inverse shape in the padding material of the seat cushion.

On the other hand, there are cases where a sensor such as a seating sensor is installed on the seat cushion, and when the padding material and the skin are integrally molded as in the above technology, the padding material and the skin including the sensor are integrally formed. However, if the raw material of the pad material, adhesive, etc. adhere to the sensor, there is a high possibility that the sensor will malfunction.

For example, Patent Document 1 below discloses a technology that makes it possible to integrally mold the pad material and the skin by sandwiching the sensor between the protection members and setting the protection member in a mold for molding the pad material and the skin using set pins. Disclosed.

Furthermore, in Patent Document 2 listed below, a bag-shaped pocket member is sewn on the back side of the outer skin, and an opening for the pocket member is formed on the front side of the outer skin, so that the outer surface of the pad material is covered with the outer skin. , a technique is disclosed that allows a sensor to be accommodated through the opening.

Japanese Patent Application Publication No. 2014-193689 Japanese Patent Application Publication No. 2020-93079

However, in the prior art described in Patent Document 1, there are a large number of protective parts that protect the sensor, and when the pad material and the skin are integrally molded, a positioning process for the sensor itself occurs, which increases the number of work steps.

Furthermore, in the prior art described in Patent Document 2, the opening of the pocket member is formed on the design surface side of the seat cushion, which imposes restrictions on the design.

The present invention takes the above-mentioned facts into account, and provides a device such as a sensor that is integrally molded with the skin and pad material, thereby suppressing malfunctions of the device such as the sensor with a simple configuration without imposing any restrictions on the design of the seat cushion. The purpose of the present invention is to obtain a seat pad and a vehicle seat with an integrally molded skin.

The skin-integrated seat pad according to the invention described in claim 1 is characterized in that a pad material that constitutes a part of a seat cushion on which an occupant is seated and the pad material are integrally molded, and the design of the seat cushion in the pad material is A pocket member is provided on the back surface of the outer skin and is integrally formed with the pad material and the outer skin and accommodates a device that can be operated while an occupant is seated. .

The skin-integrated seat pad according to the first aspect of the invention includes a pad material, a skin, and a pocket member. The pad material constitutes a part of a seat cushion on which an occupant sits, and the skin is integrally molded with the pad material and covers the design side of the seat cushion in the pad material.

Further, in the present invention, the pocket member is provided on the back surface of the outer skin, and is molded integrally with the pad material and the outer skin in a state where a device (device such as a sensor) that can be operated while the passenger is seated is accommodated. Ru. Therefore, in the present invention, there is no need to form an opening for inserting the device on the design side of the skin, and there is no restriction on the design of the seat cushion.

Here, the skin-integrated seat pad is produced by, for example, placing the skin along the cavity surface of a mold for molding the skin-integrated seat pad, and inserting the foam material, which is the raw material of the pad material, into the mold. The foam material is injected into the mold and foamed to integrate the skin and padding material.

When molding a seat pad with an integrated skin, a pressing force (internal pressure inside the mold) is generated from the space formed in the mold toward the cavity surface of the mold through the foam material. The pressing force acts on the skin disposed along the skin from the back side to the front side of the skin along the thickness direction of the skin.

That is, a pressing force acts on the pocket member provided on the back surface of the skin along the thickness direction of the pocket member. Therefore, during molding of the skin-integrated seat pad, the pocket member is compressed along the thickness direction, and the opening of the pocket member is closed.

As a result, in the present invention, it is possible to prevent the raw material of the pad material from penetrating into the inside of the pocket member during molding of the skin-integrated seat pad. In this way, when molding a seat pad that is integrally molded with the skin, by preventing the raw material of the pad material from penetrating into the inside of the pocket member, it is possible to mold the seat pad that is integrally formed with the skin while the sensor or other device is housed inside the pocket member. It becomes possible to form a molded seat pad.

Furthermore, during the molding of the skin-integrated seat pad, by preventing the raw material of the pad material from penetrating into the inside of the pocket member, it is possible to suppress malfunctions in devices such as sensors housed inside the pocket member. becomes possible.

Note that the "devices that can be operated while the occupant is seated" include, for example, sensors such as a seating sensor and a temperature sensor, as well as a sheet-like heater, a voice coil that forms part of a speaker, and the like.

The skin-integrated seat pad according to the invention as claimed in claim 2 is the skin-integrated seat pad according to the invention as claimed in claim 1, wherein the skin is composed of a plurality of skin pieces, and the skin pieces are separated from each other. The end portion of the pocket member is co-stitched to the sewing portion to be sewn.

In the skin-integrated seat pad according to the second aspect of the invention, the skin is composed of a plurality of skin pieces, and adjacent skin pieces are sewn together via a sewing part. The end portion of the pocket member is co-stitched to this sewn portion.

For example, the pocket member can be provided on the back side of the epidermis by adhering the pocket member to the backside of the epidermis using double-sided tape, but in this case, an adhesive work is required to adhere the pocket member to the backside of the epidermis. .

In contrast, in the present invention, by co-sewing the ends of the pocket member with the sewing section that sews the outer skin pieces together, the sewing work that is originally necessary for forming the outer skin can be used regardless of the presence or absence of the pocket member. A pocket member can be provided on the back side of the skin. Therefore, in the present invention, it is possible to reduce the work of adhering the pocket member to the back surface of the outer skin, and it is possible to suppress costs.

The skin-integrated seat pad according to the invention according to claim 3 is the skin-integrated seat pad according to the invention according to claim 1 or 2, in which the opening of the pocket member into which the device is inserted is connected to the pocket. A cover member that covers the pocket member from the outside along the depth direction is provided on the back surface of the outer skin.

In the seat pad with an integrally molded skin, a cover member is provided on the back surface of the skin. This cover member covers the opening of the pocket member into which a device such as a sensor is inserted from the outside of the pocket member along the depth direction of the pocket member. Thereby, during molding of the skin-integrated seat pad, it is possible to more reliably prevent the raw material of the pad material from penetrating into the inside of the pocket member.

The skin-integrated seat pad according to the invention set forth in claim 4 is the skin-integrated seat pad according to the invention set forth in claim 3, in which one end portion of the cover member along the depth direction of the pocket member is formed by the sewing. The parts are sewn together.

In the skin-integrated seat pad according to the invention described in claim 4, one end of the cover member along the depth direction of the pocket member is co-stitched to the sewing portion, so that adhesive bonding of the cover member to the back surface of the skin is unnecessary. Work can be reduced and costs can be suppressed.

The skin-integrated seat pad according to the invention according to claim 5 is the skin-integrated seat pad according to any one of claims 1 to 4, in which the device is attached to the pocket member. Positioning means are provided for determining the position.

In the seat pad integrally molded with a skin according to the invention set forth in claim 5, a positioning means is provided, and the position of a device such as a sensor with respect to the pocket member is set by the positioning means.

Here, the pocket member is provided on the back side of the outer skin, but if the pocket member is sewn to the outer skin, for example, the sewn portion of the pocket member will come out on the design side of the seat pad integrally formed with the outer skin. Therefore, in the outer skin, for example, by co-sewing the side edges of the pocket member with the sewing section that sews the outer skin pieces together, it is possible to sew the side edges of the pocket member and eliminate the need for a dedicated sewing section for the pocket member. This allows the pocket member to be made inconspicuous.

On the other hand, the sewing section that sews the skin pieces together generally sews the center portion and both side portions of the seat cushion in the seat width direction. For this reason, when a pocket member is provided in the center portion of the seat cushion in the seat width direction, the pocket member may be too large for some devices such as sensors.

In such a case, with a device such as a sensor housed within the pocket member, play will occur between the device and the pocket member. Therefore, here it is necessary to position a device such as a sensor with respect to the pocket member. Therefore, in the present invention, by providing the positioning means, the position of the device such as the sensor can be set with respect to the pocket member by the positioning means.

The skin-integrated seat pad according to the invention as set forth in claim 6 is the skin-integrated seat pad according to the invention as set forth in claim 5, wherein the device includes a sheet-like seating sensor capable of detecting a state in which an occupant is seated. The seating sensor unit is configured to include a sensor section that senses that the occupant is seated, and a harness section that is electrically connected to the sensor section and a control device on the vehicle side, and the seating sensor unit is configured to The means includes a first positioning part that is arranged in the pocket member along an opening into which the seating sensor unit is inserted, and that is formed to match the width of the harness part.

In the skin-integrated seat pad according to the sixth aspect of the present invention, the device that can be operated while the occupant is seated is a seat-like seating sensor unit that can detect the seated state of the occupant. The seating sensor unit includes a sensor section and a harness section, and the sensor section senses that the occupant is seated. The sensor section and the vehicle-side control device are electrically connected by the harness section.

Further, the positioning means includes a first positioning section. The first positioning portion is disposed in the pocket member along an opening into which the seating sensor unit is inserted, and is formed to match the width of the harness portion of the seating sensor unit.

When the seating sensor unit is inserted into the pocket member, the harness portion of the seating sensor unit is aligned with the first positioning portion formed in the opening of the pocket member, so that the seating sensor unit is inserted in the width direction of the pocket member. You can determine the location of your units.

The skin-integrated seat pad according to the invention as set forth in claim 7 is the skin-integrated seat pad according to the invention as set forth in claim 6, wherein the first positioning portion is formed to match the width of the harness portion. They are a pair of first notches.

In the skin-integrated seat pad according to the invention as set forth in claim 7, the first positioning portion is a pair of first notch portions formed to match the width of the harness portion of the seating sensor unit. By arranging the harness portion of the seating sensor unit between the first notch portion and the first notch portion, the position of the seating sensor unit can be determined with respect to the width direction of the pocket member.

The skin-integrated seat pad according to the invention according to claim 8 is the skin-integrated seat pad according to claim 6 or 7, in which the positioning means is formed in the harness part and in the pocket member. The device further includes a second positioning portion that overlaps the opening in a state in which the sensor portion is accommodated.

In the skin-integrated seat pad according to the eighth aspect of the invention, the positioning means further includes a second positioning section. The second positioning portion is formed in the harness portion of the seating sensor unit, and is set to overlap with the opening of the pocket member when the sensor portion of the seating sensor unit is accommodated within the pocket member.

As described above, since the pocket member is provided on the back side of the outer skin, when the pocket member is sewn to the outer skin, the sewn portion of the pocket member will come out on the design side of the seat pad integrally formed with the outer skin. Therefore, by co-sewing the ends of the pocket member in the sewing part that sews the skin pieces together, the sewing part dedicated to the pocket member can be eliminated and the pocket member can be made inconspicuous. .

In addition, as mentioned above, the skin is sewn at the center and both sides of the seat cushion, but in addition to this, the skin is sewn at the center and both sides of the seat cushion. A sewn portion may be provided. In this case, by co-sewing the bottom end of the pocket member with the sewing part, the bottom end of the pocket member can be sewn, and the sewing part dedicated to the pocket member can be eliminated, making the pocket member less noticeable. be able to.

On the other hand, when the bottom end of the pocket member is co-sewn using the sewing part, there is play between the tip of the seating sensor unit and the bottom end of the pocket member with the seating sensor unit housed in the pocket member. may occur. In this case, it is necessary to position the seating sensor unit in the depth direction of the pocket member.

In the present invention, the second positioning part overlaps the second positioning part formed in the harness part of the seating sensor unit and the opening of the pocket member with the sensor part of the seating sensor unit accommodated in the pocket member. By this, the position of the seating sensor unit can be determined with respect to the depth direction of the pocket member.

The skin integrally molded seat pad according to the invention according to claim 9 is the skin integrally molded seat pad according to the invention according to claim 8, wherein the second positioning part is a second notch part formed in the harness part. It is said that

In the skin-integrated seat pad according to the invention as set forth in claim 9, the second positioning portion is a second notch portion formed in the harness portion of the seating sensor unit, and the second notch portion and the opening of the pocket member are connected to each other. By overlapping the positions of the portions, the position of the seating sensor unit can be determined with respect to the depth direction of the pocket member.

In the vehicle seat according to the invention described in claim 10, the skin-integrated seat pad according to any one of claims 1 to 9 is applied to a seat cushion on which an occupant sits. .

In the vehicle seat according to the tenth aspect of the present invention, the integrally molded skin seat pad is applied to the seat cushion on which the occupant sits, thereby eliminating the covering work and reducing the number of parts. Further, in a vehicle seat, a device such as a sensor can be housed inside the pocket member without affecting the design of the seat cushion.

As explained above, according to the present invention, devices such as sensors are integrally molded together with the skin and padding material, and there are no restrictions on the design of the seat cushion, and malfunctions of devices such as sensors can be prevented with a simple configuration. It is possible to obtain a seat pad and a vehicle seat with an integrally molded skin that can be suppressed.

FIG. 2 is a plan view showing a seat cushion of a vehicle seat to which the skin-integrated seat pad according to the present embodiment is applied. FIG. 1 is a cross-sectional view showing a state in which the seat cushion of a vehicle seat to which the skin-integrated seat pad according to the present embodiment is applied is cut along the longitudinal direction of the vehicle. 2 is an enlarged cross-sectional view taken along line AA shown in FIG. 1. FIG. FIG. 2 is an exploded front view for explaining the main parts of the skin-integrated seat pad according to the present embodiment. FIG. 2 is a front view for explaining the main parts of the skin-integrated seat pad according to the present embodiment. FIG. 6 is a front view corresponding to FIG. 5 shown as a comparative example. FIG. 2 is a schematic cross-sectional view for explaining a state when the skin-integrated seat pad according to the present embodiment is molded. FIG. 2 is a plan view corresponding to FIG. 1 showing a modification example 1 of a seat cushion for a vehicle seat to which the skin-integrated seat pad according to the present embodiment is applied. FIG. 5 is an exploded front view corresponding to FIG. 4 for explaining the main parts of the skin-integrated seat pad according to the present embodiment. FIG. 2 is a plan view corresponding to FIG. 1 showing a second modification of a seat cushion for a vehicle seat to which the skin-integrated seat pad according to the present embodiment is applied. 11 is an enlarged sectional view taken along line BB shown in FIG. 10. FIG.

Hereinafter, a skin-integrated seat pad according to an embodiment of the present invention will be described with reference to the drawings. Note that the arrow FR shown as appropriate in these figures indicates the front direction of the vehicle seat (the direction toward which the occupant faces), the arrow UP indicates the upward direction of the vehicle seat, and the arrow RH indicates the direction of the vehicle seat. It shows the right direction. In the following, when explanations are simply made using front and back, top and bottom, and left and right directions, unless otherwise specified, this refers to the front and back of the vehicle seat, the top and bottom of the vehicle seat, and the left and right of the vehicle seat when facing the direction of travel. shall be taken as a thing.

(Composition of seat pad with integrated skin)
First, the structure of the skin-integrated seat pad according to the present embodiment will be explained.

As shown in FIG. 1, the vehicle seat 10 is a rear seat arranged on the rear side of the front seat (not shown) in the longitudinal direction of the vehicle, and includes a seat cushion 12 on which an occupant sits, and a seat (not shown). A seat back that stands upright from the rear end 12A of the cushion 12 and supports the upper body of the occupant seated on the seat cushion 12; and a headrest that is attached to the upper end of the seat back and supports the head of the occupant seated on the seat cushion 12. It is equipped with.

Note that the headrest may be applied to a left and right separate type vehicle seat, or may be applied to a bench seat type vehicle seat. Therefore, the shape of the headrest can be changed as appropriate depending on the seat to which it is applied. Of course, the headrest is not always necessary.

As shown in FIG. 2, the seat cushion 12 includes a seat frame (not shown) that is a skeleton member, a seat pad (pad material) 14, and a seat skin (skin) 16 that covers the seat pad 14. (described later).

In this embodiment, the seat pad 14 and the seat skin 16 are integrally molded, and the top surface 14A, front surface 14B, rear surface 14C, and both side surfaces 14D (see FIG. 1) of the seat pad 14 are covered with the seat skin 16. . The seat pad 14 in which the seat skin 16 is integrally molded in this way is hereinafter referred to as a skin-integrated pad (skin-integrated seat pad) 18.

On the other hand, as shown in FIG. 1, the seat cushion 12 includes a seat cushion 12R arranged on the right side of the vehicle and a seat cushion 12L arranged on the left side of the vehicle. For example, although not shown, an armrest can be placed between the seat cushion 12R and the seat cushion 12L in a state where it is folded forward.

Here, each of the seat cushions 12R and 12L is provided with a main part 20 at the center in the seat width direction, and the buttocks and thighs of the occupant are arranged in the main part 20. A side portion 22 is provided on the outside of the main portion 20 in the vehicle width direction. A center portion 24 is provided between the main portion 20 of the seat cushion 12R and the main portion 20 of the seat cushion 12L, and an armrest can be placed above the center portion 24. Note that this armrest is not always necessary.

In this embodiment, the seat skin 16 is composed of a plurality of skin pieces 16A, 16B, and 16C corresponding to the main part 20, side part 22, and center part 24 of the seat cushion 12. The piece 16B is sewn by a sewing part 26, and the skin piece 16A and the skin piece 16C are sewn by a sewing part 28. The skin piece 16A is divided into a skin piece 16A1 and a skin piece 16A2 at the front and back of the seat in the front-rear direction, and the skin piece 16A1 and the skin piece 16A2 are sewn by the sewing section 30.

In this embodiment, as shown in FIGS. 1 and 2, a pocket member 32 is provided on the back surface 17 of the seat cover 16 on the rear 20A side of the main portion 20 of the seat cushion 12L. Although the pocket member 32 is illustrated only on the seat cushion 12L side here, the pocket member 32 is also provided on the seat cushion 12R side.

In this embodiment, the seat cushion 12R and the seat cushion 12L shown in FIG. 1 have substantially the same configuration, so in the following description, the seat cushion 12R and the seat cushion 12L will not be distinguished and will be described as the seat cushion 12.

The pocket member 32 provided in the seat cushion 12 has, for example, a substantially rectangular shape in plan view, and is formed of a sheet member that is not impregnated with the raw material of the seat pad 14. For example, the sheet member is preferably made of polyvinyl chloride (PVC), film-laminated slab urethane, or other materials that are non-breathable and hard enough to be used for general skin materials.

In this embodiment, the side ends 32A and 32B of the pocket member 32 are co-stitched to the sewing parts 26 and 28, respectively, and as shown in FIG. are sewn together. In this embodiment, a so-called pocket portion is formed between the pocket member 32 and the back surface 17 of the seat skin 16, but the pocket portion may be formed only by the pocket member 32. Here, FIG. 3 shows an enlarged cross-sectional view of essential parts taken along the line AA shown in FIG. Note that, in FIG. 3, hatching on the seat pad 14 is not shown for ease of viewing.

Further, in this embodiment, as shown in FIGS. 3 and 5, a seating sensor unit (device) 38 is housed in the interior 33 of the pocket member 32. The position of the seating sensor unit 38 can be set.

Specifically, in this embodiment, as shown in FIGS. 3 and 4, the opening 32D of the pocket member 32 has a first positioning portion 35A extending toward the bottom end 32C of the pocket member 32. A pair of wedge-shaped notches 34 and 36 are arranged along the opening 32D. The distance between the notch portion 34 and the notch portion 36 is set to be approximately the same as the width dimension of a harness portion 40 of a seating sensor unit 38, which will be described later.

Note that although the seating sensor unit 38 is shown thicker here to show that the seating sensor unit 38 is housed in the interior 33 of the pocket member 32, the seating sensor unit 38 is sheet-shaped. It is actually thin.

On the other hand, the seating sensor unit 38 is sheet-shaped and includes a sensor section 46 that is H-shaped when viewed from the front and a harness section 40 that is belt-shaped. It is sensed that you are seated. In this embodiment, the sensor section 46 has an H-shape, but the shape of the sensor section 46 is not limited to the H-shape.

Further, a notch portion 48 cut out in a wedge shape along the width direction of the harness portion 40 is formed as the second positioning portion 35B in the harness portion 40. Although not shown, the harness section 40 is electrically connected to an in-vehicle ECU (ECU; Electronic Control Unit, hereinafter simply referred to as "ECU") as a control device on the vehicle side, and the harness section 40 connects the ECU. and the sensor section 46 are connected.

The ECU includes a CPU, a ROM, a RAM, a storage, and a communication interface, and these components are connected to each other via a bus so that they can communicate with each other. Further, the ECU has a control section as a functional configuration. The functional configuration of the control unit is realized by the CPU reading and executing a program stored in the ROM or storage. The control unit may be configured to detect that an occupant is seated on the seat cushion 12 (see FIG. 1), and thereby, for example, control an air conditioner such as a heater on the rear seat side. .

By the way, in this embodiment, as an example, a mold for molding the skin-integrated pad 18 (see FIG. 2) (hereinafter referred to as a "mold") is made of an aluminum alloy. The mold includes a lower mold 42 and an upper mold (not shown) shown in FIG. 7, and a space 44 is formed between the upper mold and the lower mold 42. Foaming material such as urethane, which is the raw material for the seat pad, is injected.

Here, when molding the skin-integrated pad 18, the sheet skin 16 is placed on the lower die 42 along the cavity surface 42A. In this state, a foam material is injected to close the upper mold, and the foam material foams to form the seat pad 14 (see FIG. 2) integrally with the seat skin 16.

(Functions and effects of the skin-integrated seat pad)
Next, the functions and effects of the skin-integrated seat pad according to the present embodiment will be explained.

As shown in FIG. 2, in this embodiment, the seat skin 16 is integrally molded with the seat pad 14, and the design surfaces 19 (top surface 14A, front surface 14B, rear surface 14C, Both side surfaces 14D) are covered. In this way, by integrally molding the seat skin 16 and the seat pad 14, in this embodiment, covering work is eliminated and the number of parts is reduced.

Further, in this embodiment, a pocket member 32 is provided on the back surface 17 of the seat skin 16, and a seating sensor unit 38 is accommodated in the pocket member 32. That is, in this embodiment, the seating sensor unit 38 is molded integrally with the seat pad 14 and the seat skin 16 in a housed state.

Therefore, in this embodiment, there is no need to form an opening for inserting the seating sensor unit 38 on the design surface 19 side of the seat cover 16, and there is no restriction on the design of the seat cushion 12.

Here, the skin-integrated pad 18, which is formed by integrally molding the seat pad 14 and the seat skin 16, is formed under a mold 41 that forms part of a mold 41 for molding the skin-integrated pad 18, as shown in FIG. With the seat skin 16 placed on the side of the mold 42, a foaming material that will be the raw material for the seat pad 14 (see FIG. 2) is injected into the mold 41, and the foaming material is foamed in the mold 41 to form the seat skin. 16 and the seat pad 14 are integrated.

When molding the skin-integrated pad 18, the sheet skin 16 is placed on the lower mold 42 side of the mold 41, and from the space 44 formed between it and the upper mold (not shown) constituting the other part of the mold 41. A pressing force (in the direction of the arrow) is generated toward the cavity surface 42A of the lower mold 42 via the foam material.

As a result, the seat skin 16 disposed on the lower mold 42 side has a pattern from the back surface 17 side of the seat skin 16 toward the front surface (design surface 19) side along the thickness direction (arrow direction) of the seat skin 16. The pressing force will act.

That is, a pressing force acts on the pocket member 32 provided on the back surface 17 of the seat skin 16 along the thickness direction of the pocket member 32. Therefore, when molding the skin-integrated pad 18, the pocket member 32 is compressed along the thickness direction, and the opening 32D of the pocket member 32 is closed.

Thereby, in this embodiment, it is possible to prevent the raw material of the seat pad 14 from penetrating into the interior 33 of the pocket member 32 during molding of the skin-integrated pad 18. Note that the harness portion 40 of the seating sensor unit 38 is made to come out of the mold 41 from a not-shown parting line where the upper mold and the lower mold 42 come into contact.

In this way, by preventing the raw material of the seat pad 14 (see FIG. 2) from entering the inside 33 of the pocket member 32 during molding of the skin-integrated pad 18, In the sensor unit 38, it is possible to suppress malfunctions. In other words, in this embodiment, it is possible to mold the skin-integrated pad 18 (see FIG. 2) with devices such as the seating sensor unit 38 accommodated in the interior 33 of the pocket member 32.

That is, according to the present embodiment, as shown in FIG. 2, devices such as the seating sensor unit 38 are integrally molded with the seat cover 16 and the seat pad 14, and the design of the seat cushion 12 is not restricted. With a simple configuration, malfunctions of devices such as the seating sensor unit 38 can be suppressed. Thereby, yield can be improved and manufacturing costs can be reduced as a result.

According to this embodiment, as described above, when the skin-integrated pad 18 is molded, the pocket member 32 is compressed along the thickness direction, and the opening 32D of the pocket member 32 is closed. Of course, after inserting a device such as the seating sensor unit 38 into the interior 33 of the pocket member 32, the opening 32D of the pocket member 32 may be closed by adhesive or the like as necessary.

As a comparative example, for example, when covering the surface of the seat pad 14 with the seat skin 16, if the seat pad has an inverse shape (not shown), the seat skin may float with respect to the seat pad. , it becomes necessary to bond the seat pad and the seat skin with an adhesive.

In contrast, in this embodiment, the seat pad 14 and the seat skin 16 are integrally molded, so the seat skin does not float with respect to the seat pad. That is, in this embodiment, it is possible to realize an inverse shape in the seat pad, and the degree of freedom in designing the seat cushion 12 is improved.

Further, according to the present embodiment, devices such as the seating sensor unit 38 can be integrally molded together with the seat skin 16 and the seat pad 14. Therefore, after the seat skin 16 and the seat pad 14 are integrally molded, the seat skin 16 There is no need to dispose a device such as the seating sensor unit 38 between the seat pad 14 and the seat pad 14, and manufacturing costs can be reduced.

Further, in this embodiment, as shown in FIG. The adjacent skin pieces 16A and 16C are sewn together through sewing portions 28. Side end portions 32A and 32B of the pocket member 32 are co-sewn to the sewn portions 26 and 28, respectively.

For example, as a comparative example, although not shown, the pocket member 32 may be provided on the back surface 17 of the seat skin 16 by adhering the pocket member 32 to the back surface 17 of the seat skin 16 (see FIG. 2) using double-sided tape or the like. However, in this case, an adhesive work is required to adhere the pocket member 32 to the back surface 17 of the seat skin 16.

On the other hand, in this embodiment, the side edges 32A, 32B of the pocket member 32 are sewn together by the sewing parts 26, 28 that sew the skin pieces 16A, 16B, 16C together, so that the presence or absence of the pocket member 32 can be determined. Regardless, the pocket member 32 can be provided on the back surface 17 of the seat skin 16 using the originally necessary sewing work. Therefore, in this embodiment, it is possible to reduce the bonding work for bonding the pocket member 32 to the back surface 17 of the seat skin 16, and it is possible to suppress costs.

Here, in this embodiment, as shown in FIGS. 4 and 5, the position of the device such as the seating sensor unit 38 is set with respect to the pocket member 32 by the positioning section 35. Further, as shown in FIG. 3, the pocket member 32 is provided on the back surface 17 of the seat skin 16.

For example, as a comparative example, although not shown, when the pocket member 32 is sewn to the seat skin 16, the sewn portion of the pocket member 32 comes out on the side of the design surface 19 of the skin-integrated pad 18.

Therefore, in this embodiment, as shown in FIG. 1, in the seat skin 16, the side ends 32A, 32B of the pocket member 32 are attached to the sewing parts 26, 28 where the skin pieces 16A, 16B, 16C are sewn together. I'm having them sew. As a result, in this embodiment, the side ends 32A and 32B of the pocket member 32 can be sewn, and a sewing section dedicated to the pocket member can be eliminated, and the pocket member 32 can be made inconspicuous.

On the other hand, the sewing parts 26 and 28 that sew the skin pieces 16A, 16B, and 16C together sew the main part 20, side part 22, and center part 24 of the seat cushion 12, respectively. For this reason, when the pocket member 32 is provided in the main portion 20 of the seat cushion 12, the pocket member 32 may be too large for the seating sensor unit 38 depending on the device such as the seating sensor unit 38.

In such a case, when a device such as the seating sensor unit 38 is housed in the pocket member 32, play will occur between the seating sensor unit 38 and the pocket member 32, as shown in FIG. Furthermore, there is a possibility that the seating sensor unit 38 is disposed in a shifted or tilted state with respect to the pocket member 32 in the seat width direction.

Therefore, as shown in FIG. 5, it is necessary to position devices such as the seating sensor unit 38 with respect to the pocket member 32. Therefore, in this embodiment, as shown in FIG. 4 and FIG. Can be set.

Here, as shown in FIG. 1, in addition to sewing the main part 20, side parts 22, and center part 24 of the seat cushion 12, the main part 20 of the seat cushion 12 is sewn along the seat width direction. 30 may be provided.

In this case, as shown in FIG. 3, by co-sewing the bottom end 32C of the pocket member 32 with the sewing section 30, the bottom end 32C of the pocket member 32 can be sewn, and a sewing section exclusively for the pocket member can be sewn. Therefore, the pocket member 32 can be made unnoticeable.

When sewing together the bottom end 32C of the pocket member 32 using the sewing section 30, as shown in FIG. Play may occur between the bottom end portion 32C of the pocket member 32 and the bottom end portion 32C of the pocket member 32. In this case, it is necessary to position the seating sensor unit 38 in the depth direction of the pocket member 32.

From the above, in this embodiment, the positioning section 35 includes a first positioning section 35A provided on the pocket member 32 side and a second positioning section 35B provided on the seating sensor unit 38 side. has been done.

Specifically, the first positioning part 35A is arranged in the pocket member 32 along the opening 32D into which the seating sensor unit 38 is inserted, and is formed to match the width of the harness part 40 of the seating sensor unit 38. They are a pair of notch parts 34 and 36. By arranging the harness portion 40 of the seating sensor unit 38 between the notch portion 34 and the notch portion 36, the position of the seating sensor unit 38 can be determined in the width direction of the pocket member 32.

In this embodiment, the harness section 40 has a band shape, and the harness section 40 and the notch sections 34 and 36 determine the position of the seating sensor unit 38 in the width direction of the pocket member 32. The shape of 40 is not limited to a band shape. For example, although not shown, the harness portion 40 may have a linear shape. In this case, the position of the seating sensor unit 38 in the width direction of the pocket member 32 may be determined by one notch.

Further, the second positioning portion 35B is formed in the harness portion 40 of the seating sensor unit 38, and overlaps with the opening 32D of the pocket member 32 when the sensor portion 46 of the seating sensor unit 38 is accommodated in the pocket member 32. This is the notch portion 48. By overlapping the notch portion 48 and the opening 32D of the pocket member 32, the position of the seating sensor unit 38 can be determined with respect to the depth direction of the pocket member 32.

As described above, in this embodiment, the position of the seating sensor unit 38 can be determined with respect to the pocket member 32 in the width direction and the depth direction. In the seating sensor unit 38 positioned in the width direction and the depth direction with respect to the pocket member 32 in this manner, the sensor portion 46 is adhered to the inner surface of the pocket member 32 via an adhesive such as double-sided tape.

Here, the seating sensor unit 38 may malfunction due to the raw material, adhesive, etc. of the seat pad 14 adhering to the sensor portion 46 during molding of the skin-integrated pad 18 . For this reason, the sensor portion 46 of the seating sensor unit 38 is preferably disposed on the back side of the pocket member 32. Therefore, the notch portion 48 is made such that the notch portion 48 is not completely exposed from the pocket member 32.

In addition, in this embodiment, the notch parts 34, 36, and 48 cut out in a wedge shape are taken as an example as the first positioning part 35A and the second positioning part 35B. It is only necessary to be able to position the seating sensor unit 38 in the depth direction, and the present invention is not limited to this. For example, it may be a positioning line that serves as a landmark.

Furthermore, in this embodiment, as shown in FIGS. 1 and 2, a pocket member 32 is provided on the rear 20A side of the main portion 20 of the seat cushion 12, and a seating sensor unit 38 is accommodated in the interior 33 of the pocket member 32. has been done.

(Supplementary information regarding this embodiment)
In this embodiment, as shown in FIG. 1, the side ends 32A and 32B of the pocket member 32 are co-sewn to the sewing parts 26 and 28, respectively. Only one of them may be co-sewn to the sewing parts 26 and 28.

Furthermore, as a first modification, as shown in FIG. 8, it goes without saying that the pocket member 52 may be adhered to the back surface 17 of the seat skin 16 using double-sided tape 50 or the like. In this case, as shown in FIG. 9, the pocket member 52 is formed to match the size of the seating sensor unit 38. Therefore, the seating sensor unit 38 is positioned within the pocket member 52. Therefore, the positioning section 35 shown in FIG. 4 is not needed here.

In addition, as a second modification, in order to prevent the raw material of the seat pad 14 from entering the inside 33 of the pocket member 32, as shown in FIGS. 10 and 11, the opening 32D of the pocket member 32 is further closed. A cover 54 may be provided. Note that FIG. 11 is an enlarged cross-sectional view of essential parts taken along line BB shown in FIG. 10. Further, in FIG. 11, the hatching of the seat pad 14 is not shown for ease of viewing.

In this embodiment, as shown in FIG. 11, one end 54A of the cover 54 along the depth direction of the pocket member 32 is co-stitched with a sewing part 56. As a result, in this embodiment, even if the cover 54 is provided, a sewing section dedicated to the cover can be eliminated, and the cover 54 can be made inconspicuous.

Further, the cover 54 has a notch 58 formed in the center in the width direction of the cover 54, for example, which is cut out in a substantially rectangular shape with an opening on the side of the pocket member 32. It becomes possible to expose the harness part 40 to the outside through this notch part 58.

As described above, in the present embodiment, the cover 54 covers the opening 32D of the pocket member 32 into which the seating sensor unit 38 is inserted from the outside of the pocket member 32 along the depth direction of the pocket member 32. ing. Thereby, when molding the skin-integrated pad 18, it is possible to more reliably prevent the raw material of the seat pad 14 from penetrating into the inside 33 of the pocket member 32.

Further, in the present embodiment described above, the seating sensor unit 38 is taken as an example of the device housed in the pocket member 32, but the device is not limited to this, and other sensors such as a temperature sensor may be used, and furthermore, a sheet-shaped device may be used. It is also possible to accommodate devices other than sensors, such as heaters and voice coils.

Furthermore, in the present embodiment described above, the opening 32D of the pocket member 32 can be set at any position. In other words, the direction of the opening 32D of the pocket member 32 (the direction in which a device such as a sensor is inserted) can be freely set. Thereby, when inserting a device such as a sensor, it is possible to prevent it from interfering with parts provided on the back side of the seat cushion 12 and on the vehicle body floor side, although not shown.

Further, the position of the pocket member 32 is not limited to this. That is, the position of the pocket member 32 can be changed as appropriate depending on the device accommodated inside the pocket member 32 . For example, the pocket member 32 may be provided on the front surface 14B side and the side surface 14D side of the seat cushion 12.

Further, in the above embodiment, as shown in FIG. 1, an example was explained in which the seat cushion 12 of the vehicle seat 10 is applied. may be applied to. Furthermore, the present invention is not limited to the vehicle seat 10, but may be applied to a massage seat, etc., although not shown.

Although one embodiment of the present invention has been described above, the present invention is not limited to the above, and can be implemented with various modifications other than the above without departing from the spirit thereof. Furthermore, it goes without saying that the scope of the present invention is not limited to the above embodiments.

10 Vehicle seat 12 Seat cushion 14 Seat pad (pad material)
16 Seat skin (epidermis)
16A Epidermis piece 16A1 Epidermis piece 16A2 Epidermis piece 16B Epidermis piece 16C Epidermis piece 17 Back side (back side of epidermis)
18 Skin-integrated pad (skin-integrated seat pad)
20A Rear part (rear part of the seat cushion in the front-back direction of the seat)
26 Sewing section 28 Sewing section 30 Sewing section 32 Pocket member 32A Side end (end of pocket member)
32B Side end (end of pocket member)
32C Bottom end (end of pocket member)
32D opening (opening of pocket member)
34 Notch part (first notch part, first positioning part, positioning means)
35 Positioning part (positioning means)
35A First positioning part (positioning means)
35B Second positioning part (positioning means)
36 Notch part (first notch part, first positioning part, positioning means)
38 Seating sensor unit (device)
40 Harness part (seating sensor unit)
46 Sensor section (seating sensor unit)
48 Notch part (second notch part, second positioning part, positioning means)
52 Pocket member 54 Cover (cover member)
54A One end (one end of the cover member)
56 Sewing section

Claims (10)

A pad material forming part of a seat cushion on which a passenger is seated;
an outer skin that is integrally formed with the pad material and that covers the designed side of the seat cushion in the pad material;
a pocket member that is provided on the back surface of the outer skin and is integrally formed with the pad material and the outer skin and accommodates a device that can be operated while an occupant is seated;
A seat pad with integrally molded skin. 2. The skin-integrated seat pad according to claim 1, wherein the skin is composed of a plurality of skin pieces, and an end portion of the pocket member is co-stitched to a sewing part where the adjacent skin pieces are sewn together. 3. A cover member according to claim 1 or 2, wherein a cover member is provided on the back surface of the outer skin to cover an opening of the pocket member into which the device is inserted from the outside of the pocket member along the depth direction of the pocket member. Seat pad with integrally molded skin. The skin-integrated seat pad according to claim 3, which refers to claim 2, wherein one end of the cover member along the depth direction of the pocket member is co-stitched to the sewn portion. The skin-integrated seat pad according to any one of claims 1 to 4, further comprising positioning means for determining the position of the device with respect to the pocket member. The device is a seat-like seating sensor unit that can detect a state in which an occupant is seated;
The seating sensor unit includes:
a sensor unit that detects when a passenger is seated;
a harness section electrically connected to the sensor section and a vehicle-side control device;
It consists of
The positioning means includes:
The integrated skin according to claim 5, wherein the pocket member includes a first positioning part arranged along an opening into which the seating sensor unit is inserted and formed to match the width of the harness part. Molded seat pad. The skin-integrated seat pad according to claim 6, wherein the first positioning portion is a pair of first notch portions formed to match the width of the harness portion. The positioning means includes:
The integrated skin according to claim 6 or 7, further comprising a second positioning part formed on the harness part and overlapping with the opening when the sensor part is accommodated in the pocket member. Molded seat pad. The skin integrally molded seat pad according to claim 8, wherein the second positioning portion is a second notch portion formed in the harness portion. A vehicle seat, wherein the skin-integrated seat pad according to any one of claims 1 to 9 is applied to a seat cushion on which a passenger is seated.