JP6812228B2 - Vehicle seats and methods for manufacturing vehicle seats - Google Patents

Description

The present invention includes a seat pad having a through hole, a seat cover adhered to a seating surface of the seat pad and an inner surface of the through hole, and a carpet member covering the through hole on the back surface side of the seat pad. The present invention relates to a vehicle seat and a method for manufacturing a vehicle seat.

A general vehicle seat includes a seat pad that elastically supports an occupant and a planar seat cover that covers the seat pad. From the viewpoint of improving the convenience of the seat, the vehicle seat may be provided with a buckle member for locking the seat belt (an example of an accessory part) and an electrical component such as an HV battery. The buckle member is typically inserted through a through hole that penetrates the seat pad in the thickness direction, and the electrical component is arranged on the back side of the seat pad. And in this type of vehicle seat, the heat generated from the electrical components may cause air to flow behind the seat pad. At this time, it is necessary to take care so that air does not leak to the seating side through the gap between the buckle member and the through hole.

Therefore, the vehicle seat disclosed in Patent Document 1 includes a seat pad, a seat cover, a buckle member inserted into a through hole of the seat pad, and a shielding material corresponding to the carpet member of the present invention. The seat cover covers the seating surface of the seat pad, the back surface of the seat pad, and the inner surface of the through hole. Further, the shielding material is a thick face material having a substantially rectangular shape when viewed from the front, and is larger than the opening size of the through hole. The shielding material is provided with a linear slit for inserting the belt of the buckle member. Then, in a known technique, the opening on the back side of the through hole is covered with a shielding material, and the four corners of the shielding material are fixed to the back surface of the seat pad with a ring-shaped fastener. Then, the buckle member is inserted into the through hole, and the belt-shaped belt extending from the buckle member is routed to the back side of the seat pad through the slit of the shielding material. By closing the gap between the buckle member and the through hole with a shielding material in this way, even if air flows on the back side of the seat pad, it is possible to prevent this air from leaking to the seating side as much as possible.

Here, in the above-mentioned vehicle seat, the seat cover may be adhered to the seat pad and stably fixed. For example, in the configuration of a known technique, the seat pad, the planar adhesive, and the seat cover are stacked in this order, and then the adhesive device is pressed from the seat cover side. At this time, the protrusion provided in the adhesive device is inserted into the through hole from the seating side, and the seat cover is pressed against the inner surface of the through hole by this protrusion. Then, by heating the adhesive material with the heating device and its protrusion, the seat cover can be adhered to an appropriate position on the seat pad and stably fixed.

Japanese Unexamined Patent Publication No. 10-129412

By the way, in the above-described configuration, it is desirable to attach a shielding material to the seat cover prior to the bonding process from the viewpoint of simplifying the manufacturing process. However, in the configuration of the known technique, it is necessary to retrofit the shielding material after bonding the seat cover so that the shielding material does not interfere with the bonding work of the seat cover. That is, if a shielding material is attached to the seat cover in advance, the shielding material interferes with the protrusions and adheres to the inner surface of the hole in a state where the seat cover is wrinkled (a state in which the finish is deteriorated). Sometimes. Therefore, the structure of the known technique is unsuitable for both improving the finish of the seat cover and simplifying the work process when the seat cover and the seat pad are adhered to each other. The present invention has been devised in view of the above points, and the problem to be solved by the present invention is to attach the seat cover and the carpet member to the seat pad in a suitable position with a simpler configuration with good performance. ..

As a means for solving the above problems, the method for manufacturing a vehicle seat of the first invention is a method of manufacturing a seat pad in which a planar seat cover is opened from a seating surface to a seating surface of a seat pad that elastically supports an occupant. It includes a bonding step of adhering to the inner surface of the through hole and a covering step of attaching a planar carpet member covering the through hole to the back surface opposite to the seating surface of the seat pad. Then, in the bonding step, the bonding device is pressed against the seat cover on the seat pad to bond them. At this time, the protruding portion of the adhesive device is inserted into the through hole from the seating surface side while pressing a part of the seat cover against the inner surface. In this type of manufacturing method, it is desired that the seat cover and the carpet member can be attached to the seat pad in a suitable place with a simpler configuration with good performance (for example, good finish).

Therefore, in the present invention, the carpet member is attached to the seat cover portion arranged on the back surface side of the seat pad through the through hole. Then, in the bonding step, the protrusion of the bonding device is inserted into the through hole while holding the carpet member at the tip of the protrusion, and in the covering step, the carpet member removed from the tip of the protrusion is covered with the through hole. It is attached to the back surface of the seat pad in a state where it is unfolded in the plane direction. In the present invention, the carpet member is held at the tip of the protrusion in the bonding step. Therefore, from the viewpoint of simplifying the manufacturing process, even if the carpet member is attached to the seat cover in advance, a part of the seat cover is placed on the inner surface of the through hole by the protrusion without being disturbed by the carpet member as much as possible. It will be glued. Therefore, it is possible to prevent the deterioration of the finish of the seat cover caused by the interference between the carpet member and the protrusion as much as possible. Further, by arranging the carpet member on the back surface side of the seat pad by inserting the protrusion, the carpet member can be smoothly attached to the back surface of the seat pad during the covering work.

In the method for manufacturing a vehicle seat of the second invention, in the method for manufacturing a vehicle seat of the first invention, the carpet member is provided at the tip of the protrusion in a state of being bent and deformed so as to reduce the dimension in the plane direction. It is pushed into the recessed housing and held. In the present invention, by pushing the carpet member into the accommodating portion and holding it stably, it is possible to more reliably prevent the deterioration of the finish of the seat cover caused by the carpet member.

In the method for manufacturing a vehicle seat of the third invention, in the method for manufacturing a vehicle seat of the second invention, the carpet member is provided with a promoting portion for promoting bending and deformation. In the present invention, the promoting portion allows the carpet member to be pushed into the accommodating portion while being appropriately bent.

The method for manufacturing a vehicle seat of the fourth invention is the frame shape in which the carpet member is fixed so as to surround the main body portion covering the through hole and the peripheral edge of the main body portion in the method for manufacturing the vehicle seat of the third invention. The mounting portion is attached to the back surface of the seat pad in the coating process. The main body and the mounting portion are each provided with a notch that defines a relative positional relationship with each other, and the notch functions as a facilitating portion. In the present invention, the carpet member can be pushed into the accommodating portion while being appropriately bent by a simple configuration in which the notched portion functions as a facilitating portion.

The method for manufacturing a vehicle sheet according to the fifth invention is the method for manufacturing a vehicle sheet according to any one of the first to fourth inventions, wherein the carpet member surrounds the main body portion covering the through hole and the peripheral edge of the main body portion. It has a frame-shaped mounting portion fixed to the seat pad, and the mounting portion is mounted on the back surface of the seat pad in the coating process. The mounting portion is provided with a protruding portion that protrudes outward in the surface direction of the carpet member and a mounting hole that penetrates the protruding portion in the thickness direction. In the covering process, the mounting portion is inserted into the mounting hole. Attach it to the back of the seat pad via the fastener. In the present invention, in the coating process, the attachment portion of the carpet member can be stably attached to the back surface of the seat pad via the fastener.

The method for manufacturing a vehicle seat according to the sixth invention is an accessory member in which the vehicle seat is arranged in a state of being inserted through a through hole in any one of the first to fifth inventions for manufacturing a vehicle seat. The main body of the carpet member that covers the through hole is provided with a notched slit portion that allows the accessory member to be inserted into the through hole. The slit portion has a first slit portion that expands by passing an accessory member and a second slit portion that is connected to the first slit portion, and the second slit portion is on the end side of the first slit portion. It extends in a direction intersecting the extension direction of the first slit portion. In the present invention, when the accessory member is inserted into the through hole through the slit portion, the expansion of the first slit portion can be promoted at the second slit portion intersecting the slit portion.

The vehicle seat of the seventh invention is adhered to a seat pad that can elastically support an occupant, a through hole that penetrates the seat pad in the thickness direction, and a portion of the seat pad from the seating surface to the inner surface of the through hole. It is provided with a seat cover and a planar carpet member covering a through hole on the back surface side of the seat pad opposite to the seating surface. The carpet member has a main body portion that covers the through hole and a frame-shaped mounting portion that is fixed along the peripheral edge of the main body portion, and the mounting portion is arranged on the back surface side of the seat pad through the through hole. It is attached to the seat cover part. Therefore, in the present invention, the mounting portion is mounted on the back surface side of the seat pad in a state where the seat cover portion arranged on the back surface side of the seat pad is pressed against the seat pad. In the present invention, the mounting portion is used to press the seat cover portion arranged on the back surface side of the seat pad against the seat pad to prevent a gap between them as much as possible. By doing so, it is possible to prevent air from flowing into the through hole as much as possible through the space between the back surface of the seat pad and the seat cover.

The vehicle seat of the seventh invention, the carpet member, and the first carpet member, with being used a second carpet member disposed at different locations from the first carpet member, the first carpet member , Has an erroneous assembly prevention part that looks different from the second carpet member. In the present invention, the difference between the first carpet member and the second carpet member can be visually confirmed by the misassembly prevention unit. Therefore, in the present invention, the first carpet member and the second carpet member can be mounted at appropriate positions without being mistaken for each other as much as possible.

According to the first invention according to the present invention, the seat cover and the carpet member can be attached to the appropriate place of the seat pad with good performance by a simpler configuration. Further, according to the second invention, the seat cover can be attached to a suitable place of the seat pad more reliably and with good finish. Further, according to the third invention, the seat cover can be attached to the appropriate position of the seat pad more reliably and with good finish. Further, according to the fourth invention, the seat cover can be attached to the appropriate place of the seat pad with a simpler configuration more reliably and with good finish. Further, according to the fifth invention, the carpet member can be stably attached to the appropriate position of the seat pad. Further, according to the sixth invention, the carpet member can be conveniently attached to the appropriate position of the seat pad. Further, according to the seventh invention, the seat cover and the carpet member can be attached to the appropriate place of the seat pad with good performance by a simpler configuration. According to the seventh invention, a plurality of carpet members can be more reliably attached to the appropriate positions of the seat pad.

It is a perspective view of a vehicle seat. It is a perspective view of a part of a seat cushion which exposed a seat pad. It is a top view of a part of a seat pad. It is an exploded perspective view of a seat cover and a first carpet member. It is a front view of the first carpet member. It is a front view of the 2nd carpet member. It is a perspective view of a part of an adhesive device. It is sectional drawing of a part of a seat cushion at the time of a bonding process. It is sectional drawing of a part of a seat cushion at the time of a coating process. It is sectional drawing of a part of a seat cushion in a state where an accessory member is arranged. It is a back view of a part of a seat cushion in a state where an accessory member is arranged.

Hereinafter, embodiments for carrying out the present invention will be described with reference to FIGS. 1 to 11. For convenience, each figure may appropriately show arrow lines indicating the front-rear direction, the up-down direction, and the left-right direction of the vehicle seat. Further, in FIG. 2, for convenience, the seat cover is partially broken to expose a part of the seat pad. Further, in FIGS. 4 and 8 to 10, since the vertical direction of each member is determined based on the state of being arranged on the vehicle seat, the vertical direction is opposite to that of the other drawings.

The vehicle seat 2 of FIG. 1 is a horizontally long seat on which a plurality of occupants can be seated, and includes a seat cushion 4 and a seat back 6. The lower portion of the upright seat back 6 that serves as a backrest is connected to the rear portion of the seat cushion 4 that serves as the seat surface so as to be able to fold up. The vehicle seat 2 can be divided at the center in the left-right direction, and is divided into a first seat cushion portion 4a and a first seatback portion 6a on the left side and a second seat cushion portion 4b and a second seatback portion 6b on the right side. Each occupant can be seated. Further, electrical components (not shown) are arranged on the back side (lower side) of at least one of the seat cushion portions 4a and 4b, and these electrical components are attached to a suitable place in the vehicle interior such as the vehicle seat 2 or the floor surface of the passenger compartment. Has been done. As this type of electrical component, various components that operate electrically to dissipate heat can be assumed, and various batteries such as HV batteries, motors, sensors, and their accessories can be exemplified.

[Seat cushion / buckle member (accessory member)]
The seat cushion 4 has a seat pad 4P, a seat cover 4S, a pair of left and right through holes 11 and 12, and a pair of carpet members 31 and 32 (each member), referring to FIGS. 1 and 2. Details will be described later as appropriate). Buckle members BM1 and BM2 corresponding to the accessory members of the present invention are arranged in the pair of left and right through holes 11 and 12 (details will be described later), respectively. The buckle members BM1 and BM2 are cubic members having the same shape and the same size, and can lock tongue members of seat belts (not shown) arranged on the left and right sides of the vehicle seat 2. One of the buckle members BM1 is arranged in the first through hole 11 provided at the rear right side of the first seat cushion portion 4a. The other buckle member BM2 is arranged in the second through hole 12 provided at the left rear portion of the second seat cushion portion 4b.

In this embodiment, the seat cover 4S is adhesively fixed to a portion of the seat pad 4P from the upper surface serving as the seating surface SS to the inner surfaces of the through holes 11 and 12. Further, a pair of carpet members 31 and 32 are attached to the lower surface of the seat pad 4P shown in FIG. 11 which is the back surface RS and cover the corresponding through holes 11 and 12. In this type of seat configuration, it is desirable to attach the carpet members 31 and 32 to the seat cover 4S prior to bonding the seat pad 4P and the seat cover 4S, which will be described later, from the viewpoint of simplifying the seat manufacturing process. .. However, in that case, when the seat pad 4P and the seat cover 4S are adhered, there is a concern that the seat cover 4S cannot be adhered neatly due to the carpet members 31 and 32, and the finish quality deteriorates. Therefore, in this embodiment, in the bonding process and the coating process described later, the seat cover 4S and the carpet members 31 and 32 are attached to the appropriate places of the seat pad 4P with good performance by a simpler configuration. Hereinafter, each configuration will be described in detail.

[Seat pad / through hole]
The seat pad 4P is a member having a substantially rectangular shape in a top view forming the outer shape of the seat, with reference to FIGS. 1 and 2, and has a first through hole 11 and a second through hole 12. The material of this type of seat pad 4P is not particularly limited, and examples thereof include foamed resins such as polyurethane foam (density: 10 kg / m ^{3 to} 60 kg / m ³ ). Further, the first through hole 11 is a substantially rectangular hole portion that penetrates the seat pad 4P in the thickness direction with reference to FIGS. 3 and 10, and is opened in the seating surface SS and the back surface RS of the seat pad 4P, respectively. doing. The seating side opening of the first through hole 11 is arranged in a recessed portion 4Pa which is one step lower than the seating surface SS of the first seat cushion portion 4a, and the recessed portion 4Pa is substantially L-shaped when viewed upward. It is in shape. The first through hole 11 has four inner surfaces (front inner surface 11a, rear inner surface 11b, left inner surface 11c, right inner surface 11d) arranged on the front, rear, left and right sides, and the left inner surface 11c and the right inner surface 11d are formed. It is longer than the front inner surface 11a and the rear inner surface 11b. The opening size of the first through hole 11 is set to be slightly larger than the external size of one buckle member BM1. Therefore, when one of the buckle members BM1 is inserted into the first through hole 11, a gap through which air can pass in the vertical direction is formed between them.

Further, the second through hole 12 is a substantially rectangular hole portion penetrating the seat pad 4P in the thickness direction with reference to FIG. 3, and has four inner surfaces (front inner surface 12a, rear inner surface 12b, left inner surface 12c, right). It has an inner surface 12d). The second through hole 12 has substantially the same basic configuration as the first through hole 11 except that the second through hole 12 is slightly shorter in the front-rear direction than the first through hole 11. The seating side opening of the second through hole 12 is arranged in another recessed portion 4Pb that is one step lower than the seating surface SS of the second seat cushion portion 4b, and the other recessed portion 4Pb is upward. It has a substantially triangular shape visually.

[Seat Cover]
As shown in FIG. 2, the seat cover 4S is a face material constituting the design surface of the seat, and can be formed of, for example, a cloth (woven fabric, knitted fabric, non-woven fabric) or leather (natural leather, synthetic leather). With reference to FIG. 4, the seat cover 4S includes a first cover portion 21 that covers the seating surface SS of the seat pad 4P, and second cover portions 22a to 22d that cover the inner surfaces of the corresponding through holes 11 and 12. It has (in FIG. 4, for convenience, only the second cover portion covering the inner surface of the first through hole is shown). The first cover portion 21 is a planar seat cover portion that follows the seating surface shape of the seat pad 4P, and can be formed by, for example, suturing a plurality of skin pieces.

Here, the second cover portions 22a to 22d covering the inner surface of the first through hole 11 and the second cover portion (not shown) covering the inner surface of the second through hole 12 shown in FIG. 3 have substantially the same basic configuration. ing. Therefore, the details will be described by taking as an example the second cover portions 22a to 22d that exclusively cover the inner surface of the first through hole 11. The second cover portions 22a to 22d are seat cover portions that cover the corresponding inner surfaces 11a to 11d of the first through hole 11, respectively, with reference to FIG. 4, so as to be connected to the first cover portion 21. It is connected. The second cover portions 22a to 22d are slightly longer than the vertical (depth direction) dimensions of the first through hole 11. Therefore, the corresponding inner surfaces 11a to 11d can be covered by arranging the second cover portions 22a to 22d in a square tube shape along the inner surfaces 11a to 11d of the first through hole 11. Further, in this covered state, the ends E1 to E4 of the second cover portions 22a to 22d are arranged on the back side of the seat pad 4P through the first through hole 11. That is, in this embodiment, the second cover portions 22a to 22d correspond to a part of the seat cover of the present invention, and the end portions E1 to E4 are the seat cover portions arranged on the back surface side of the seat pad of the present invention. Corresponds to.

The ends E1 to E4 of the second cover portions 22a to 22d are arranged in a cross shape around the first through hole 11 so as to be arranged facing the back surface RS of the seat pad 4P. .. That is, the end E1 of the second cover portion 22a covering the front inner surface 11a of the first through hole 11 bends forward from the lower edge of the front inner surface 11a, and the end E2 of the second cover portion 22b covering the rear inner surface 11b , It is arranged so as to be bent rearward from the lower edge of the rear inner surface 11b. Further, the end E3 of the second cover portion 22c covering the left inner surface 11c bends to the left from the lower edge of the left inner surface 11c, and the end E4 of the second cover portion 22d covering the right inner surface 11d is the right inner surface 11d. It is arranged so as to bend to the right from the lower edge.

[First carpet member (main body)]
Here, the first carpet member 31 and the second carpet member 32 shown in FIG. 2 have substantially the same basic configuration. Therefore, the details of each configuration will be described below, using the first carpet member 31 as an example. The first carpet member 31 is a face material capable of covering the first through hole 11 from the back surface side of the seat pad 4P with reference to FIGS. 4 and 5, and has a main body portion 40 and a mounting portion 50. ing. The main body 40 is a face material having a substantially rectangular shape in a deployed state covering the first through hole 11, and is larger than the opening on the back side of the first through hole 11. The main body portion 40, together are composed of air-impermeable or low air permeability of the surface material (e.g. air permeability ^{0cc / cm 2 · sec~10cc / cm} 2 · sec surface material), moderate flexibility It can be flexed and deformed so that the dimension in the plane direction becomes smaller. Examples of the material of the main body 40 of this type include a non-woven fabric, leather, a fiber laminate such as felt, a resin film material, and a slab urethane mat material.

[Notch (promoting part)]
The main body portion 40 is provided with a plurality of first notch portions 46, a first overhanging convex portion 47, and a slit portion 42 described later, with reference to FIGS. 4 and 5. The plurality of first cut portions 46 are portions that serve as marks for positioning with the mounting portion 50, which will be described later, and are provided at appropriate intervals along the outer peripheral edge of the main body portion 40. Further, when the first carpet member 31 is flexed and deformed, which will be described later, the main body portion 40 is smoothly flexed and deformed with each first notch portion 46 as a base point. That is, each notch 46 functions as a facilitating portion PM that promotes bending deformation of the main body 40 in the surface direction (in FIGS. 4 and 5, for convenience, only a part of the notches is designated by a reference numeral PM indicating the facilitating portion. ). In this embodiment, three first notches 46 are provided on the front side, the rear side, and the left side of the main body 40, and two first notches 46 are provided on the right side (the part excluding the center) of the main body 40. It is provided. Each first notch 46 can be formed by cutting out the outer peripheral edge of the main body 40 at an appropriate position in a substantially triangular shape. Most of the plurality of first cut portions 46 are arranged at the same positions as the corresponding second cut portions 56 of the mounting portion 50 described later, and some of the first cut portions 46 correspond to the mounting portions 50 described later. It is arranged at the same position as the positioning hole portion 57. Further, the first overhanging convex portion 47 is a portion where the outer peripheral edge of the main body portion 40 is projected in a triangular shape, and is provided at the center of the right side of the main body portion 40. Then, when the first carpet member 31 is attached, the tip of the first overhanging convex portion 47 is directed to the right, so that the first carpet member 31 can be attached to the seat pad side in an appropriate direction.

[Slit part]
Further, the slit portion 42 is a substantially H-shaped cut formed in the main body portion 40 with reference to FIGS. 4 and 5, and is formed by a first slit portion 44 and a pair of second slit portions 45a and 45b. It is configured. The first slit portion 44 is a relatively long portion extending in the front-rear direction of the seat, and extends along the long direction of one buckle member BM1 as shown in FIG. Further, the pair of second slit portions 45a and 45b are relatively short portions extending in the left-right direction of the seat, respectively, and are arranged so as to be symmetrical in the front-rear direction with the first slit portion 44 interposed therebetween. The second slit portion 45a on the front side is connected to the front end of the first slit portion 44 and extends so as to be symmetrical, and the second slit portion 45b on the rear side is connected to the rear end of the first slit portion 44. It is connected and extended so that it is symmetrical.

[Mounting part]
Further, the mounting portion 50 is a substantially rectangular frame in the unfolded state with reference to FIGS. 4 and 5, and includes a window portion 52, a plurality of projecting portions 54, a plurality of second notch portions 56, and a positioning hole. It has a portion 57 and a second overhanging convex portion 58. The mounting portion 50 is made of a non-breathable or low-breathable face material, has appropriate flexibility, and can be flexed and deformed so as to have a small size in the plane direction. As the material of this type of mounting portion 50, the example material can be exemplified in the main body portion 40, and it is preferable to use a resin face material having superior rigidity as compared with the main body portion 40. The outer shape of the mounting portion 50 excluding the protruding portion 54 is substantially the same as the outer shape of the main body 40, and these are stacked in a state where the outer peripheral edge of the mounting portion 50 is aligned with the outer peripheral edge of the main body 40. Can be placed. The window portion 52 is a through hole that penetrates the mounting portion 50 in the thickness direction, is provided substantially in the center of the mounting portion 50, and has a shape and dimensions that imitate the opening of the first through hole 11. There is.

[Protruding part]
Further, the plurality of projecting portions 54 are semicircular portions projecting outward in the surface direction from the outer peripheral edge of the mounting portion 50. A substantially circular mounting hole 54H penetrating the protruding portion 54 in the thickness direction is provided in the substantially center of each of the protruding portions 54, and the fastener HG of FIG. 11 to be described later is inserted into each mounting hole 54H. be able to. In this embodiment, the left end of the front side, the rear part of the right side, the center of the left side, and the front corner of the left side of the mounting portion 50 are provided with protrusions 54, respectively.

Further, the plurality of second notches 56 are substantially triangular notches provided on the outer peripheral edge of the mounting portion 50 at positions different from those of the protruding portions 54. Each of the second cut portions 56 is provided on the outer peripheral edge of the mounting portion 50 at appropriate intervals, generally following the arrangement position of the corresponding first cut portion 46. Then, when the first carpet member 31 is flexed and deformed, which will be described later, the mounting portion 50 is smoothly flexed and deformed with each second notch 56 as a base point. That is, each second notch 56 functions as a facilitating portion PM that promotes bending deformation of the main body 40 in the surface direction (in FIGS. 4 and 5, for convenience, the reference numeral PM indicating the facilitating portion only to a part of the notch portion). With). Further, the positioning hole portion 57 is a substantially circular hole portion provided in the center of the left side of the mounting portion 50 so as to overlap the corresponding protruding portion 54, and is a position overlapping the first cut portion 46 in the center of the left side of the main body portion 40. It is located in. The second overhanging convex portion 58 is a portion where the outer peripheral edge of the mounting portion 50 is projected in a triangular shape, and is arranged at a position corresponding to the first overhanging convex portion 47 of the main body portion 40. Then, in the mounting work of the first carpet member 31, the main body portion 40 and the mounting portion 50 can be overlapped in an appropriate direction by aligning the first protruding convex portion 47 and the second protruding convex portion 58. it can.

[Installation work of seat cover and first carpet member]
In this embodiment, the first carpet member 31 is attached to an appropriate position of the seat cover 4S prior to the bonding step of the seat cover 4S described later. At this time, referring to FIGS. 4 and 11, the four second cover portions 22a to 22d are arranged in a square tubular shape so as to reproduce the state of being arranged in the first through hole 11. The square tubular second cover portions 22a to 22d can be sutured in advance between these edges. Then, the ends E1 to E4 of the second cover portions 22a to 22d, the mounting portion 50, and the main body portion 40 developed in a planar shape are overlapped in this order. At this time, by aligning each first notch 46 of the main body 40 with the corresponding second notch 56 and the positioning hole 57 of the mounting 50, the main body 40 and the mounting 50 are overlapped with each other. Both parts 40 and 50 can be appropriately overlapped and arranged. Then, the ends E1 to E4, the attachment portion 50, and the main body portion 40 of the second cover portions 22a to 22d are integrated by four suture lines SEW provided on the front, back, left, and right sides, respectively, with reference to FIG. In this state, the outer peripheral edges of the main body 40, the mounting portion 50, and the ends E1 to E4 are arranged at substantially the same positions, and the protruding portions 54 of the mounting portion 50 are arranged so as to project outward in the surface direction. .. Then, the main body portion 40 is exposed from the window portion 52 of the mounting portion 50 and is arranged at a position where it can face the first through hole 11.

[Second carpet member]
The second carpet member 32 shown in FIG. 2 is a face material that covers the second through hole 12 from the back surface side of the seat pad 4P, and is attached to the seat cover 4S by the method exemplified by the first carpet member 31. The second carpet member 32 has a main body portion 40a and a mounting portion 50a with reference to FIG. 6, and these portions 40a and 50a are abbreviated as corresponding portions of the first carpet member 31 shown in FIG. It has the same basic configuration. Therefore, the configuration peculiar to the second carpet member 32 will be described in detail below, and the configuration substantially the same as that of the first carpet member 31 is designated by a corresponding reference numeral and detailed description thereof will be omitted.

The main body portion 40a of the second carpet member 32 is a substantially square face material having a size larger than the opening on the back side of the second through hole 12 shown in FIG. 3, and the slit portion 42a and the slit portion 42a are referred to with reference to FIG. It has a plurality of first notch portions 46a and a first overhanging convex portion 47a. In the main body portion 40a, the first notch portion 46a and the first overhanging convex portion 47a have a unique configuration (formation position and number of formations). That is, one first notch 46a is provided in the center of the front side of the main body 40a, and three are provided on the rear side, the left side, and the right side of the main body 40a. Further, the first overhanging convex portion 47a is provided at the rear portion on the left side of the main body portion 40a.

Further, the mounting portion 50a of the second carpet member 32 includes a window portion 52a, a plurality of projecting portions 54a, a plurality of second notch portions 56a, a plurality of positioning hole portions 57a, and a second, with reference to FIG. It has an overhanging convex portion 58a. In the mounting portion 50a, a plurality of projecting portions 54a, a plurality of second notch portions 56a, a plurality of positioning hole portions 57a, and a second overhanging convex portion 58a have a unique configuration. That is, the protruding portion 54a is provided at the front right portion, the front left portion, the left side center, the left side rear portion, and the right side center of the mounting portion 50a, respectively. Further, the plurality of second cut portions 56a are provided on the outer peripheral edge of the mounting portion 50a at a position different from that of the protruding portion 54a and at the same position as the corresponding first cut portion 46a. Further, the positioning hole portion 57a is provided on the right side and the left side of the mounting portion 50a so as to overlap the corresponding protruding portion 54a. A second overhanging convex portion 58a is provided on the left side (between the protruding portions) of the mounting portion 50a corresponding to the first overhanging convex portion 47a.

[Difference between the first carpet member and the second carpet member (misassembly prevention part)]
Here, referring to FIG. 2, since the first carpet member 31 and the second carpet member 32 are attached to different positions of the seat pad 4P, it is necessary to avoid assembling them by mistake (misassembling) as much as possible. Is. Therefore, in this embodiment, the outer shape of the first carpet member 31 shown in FIG. 5 is different from the outer shape of the second carpet member 32 shown in FIG. 6 in appearance. Therefore, the outer shape of the first carpet member 31 itself functions as an erroneous assembly prevention unit WAM, and erroneous assembly due to misassembly with the second carpet member 32 can be avoided as much as possible. In particular, in the present embodiment, the difference in appearance from the second carpet member 32 is obvious due to each protruding portion 54 protruding from the first carpet member 31. Therefore, the outer shape of the first carpet member 31 (wrong assembly prevention portion WAM) makes it possible to clearly distinguish the first carpet member 31 and the second carpet member 32, and these can be appropriately attached.

[Installation work of seat cover and carpet member (adhesive device)]
With reference to FIGS. 8 and 9, the seat cover 4S and the carpet members 31 and 32 are attached to appropriate positions on the seat pad 4P in the bonding step and the coating step described later. Here, in this embodiment, since the first carpet member 31 and the second carpet member 32 are attached in substantially the same process, the details of each process will be described below, using the first carpet member 31 as an example. Then, in the bonding step, the seat cover 4S can be bonded and fixed at an appropriate position on the seat pad 4P by using the bonding device XM shown in FIG. This adhesive device XM has a heating main body portion 2x that can be pressed against the first cover portion 21 applied to the seating surface SS of the seat pad 4P of FIG. 8, and a protrusion 4x that can be inserted into the first through hole 11. Have. The protrusion 4x is a columnar portion protruding from the heating main body 2x, and a recessed accommodating portion 6x is provided on the tip surface of the protrusion 4x.

[Adhesion process]
In the bonding step, the parts 21, 22a to 22d of the seat cover 4S shown in FIG. 4 are bonded from the seating surface SS of the seat pad 4P shown in FIG. 3 to the inner surfaces 11a to 11d of the first through hole 11. A planar adhesive (not shown) is attached to the back surface RS of the seat cover 4S in advance, and the seat cover 4S is adhesively fixed to the seat pad 4P by being melted by heat and then cured. To. In this bonding step, with reference to FIG. 8, after each portion 21, 22, 22d, 22d, etc. of the seat cover 4S is applied to an appropriate position on the seat pad 4P, the heating main body portion 2x of the bonding device XM is attached to the first cover portion 21. It is pressed (in FIG. 8, for convenience, only a part of the left and right second cover parts and the left and right inner surfaces are shown). Further, the protrusion 4x of the adhesive device XM is inserted into the first through hole 11 from the seating surface side while pressing the second cover portions 22c, 22d and the like against the corresponding inner surfaces 11c, 11d and the like of the first through hole 11. In the bonding process, in consideration of the finish of the seat cover 4S, it should be avoided as much as possible that the first carpet member 31 pre-attached to each of the second cover portions 22c, 22d, etc. interferes with the protrusion 4x. is there.

Therefore, in this embodiment, referring to FIG. 8, the protrusion 4x is inserted into the first through hole 11 with the first carpet member 31 held at the tip of the protrusion 4x, so that the first carpet member Interference between 31 and the protrusion 4x is preferably avoided. That is, when the protrusion 4x is inserted, the first carpet member 31 is pushed into the accommodating portion 6x at the tip of the protrusion 4x and held in a state of being bent and deformed so that the dimension in the surface direction becomes smaller. At this time, the first carpet member 31 can be flexed and deformed so as to be smoothly reduced in the surface direction with the notches 46 and 56 as the promoting portions PM shown in FIG. 5 as base points. Then, the protrusion 4x is inserted into the first through hole 11 while pressing the second cover portions 22c, 22d, etc. against the corresponding inner surfaces 11c, 11d, etc. By inserting the protrusion 4x, the first carpet member 31 is arranged on the back surface side of the seat pad 4P together with the ends E3, E4 and the like of the second cover portion while being pushed into the accommodating portion 6x. By heating the seat cover 4S with the adhesive device XM in this state, each part 21, 22, 22d, 22d, etc. of the seat cover 4S is adhered and fixed at an appropriate position on the seat pad 4P. In this way, the second cover portions 22c, 22d, etc. can be neatly adhered to the corresponding inner surfaces 11c, 11d, etc. without being disturbed by the first carpet member 31 as much as possible.

[Coating process]
In the coating step, the first carpet member 31 is attached to the back surface RS of the seat pad 4P with reference to FIGS. 9 and 11. In this coating step, referring to FIG. 9, the first carpet member 31 removed from the tip of the protrusion 4x in FIG. 8 is developed in the plane direction so as to cover the first through hole 11 of the seat pad 4P. Attach to the back RS. For example, by removing the protrusion 4x from the first through hole 11, the first carpet member 31 is removed from the tip of the protrusion 4x, and the seat pad 4P is removed together with the ends E3, E4, etc. of the second cover portion. Placed on the back side. Therefore, the fastener HG is inserted from the mounting holes 54H of each protruding portion 54 while pulling the mounting portion 50 together with the main body portion 40 outward in the surface direction. Then, by fixing the fastener HG to the back surface RS of the seat pad 4P while forming a ring shape, the attachment portion 50 of the first carpet member 31 can be stably attached to the back surface RS of the seat pad 4P via the fastener HG. it can. In the state where the first carpet member 31 is attached in this way, the opening on the back surface side of the first through hole 11 is closed by the main body 40 with reference to FIG. Further, referring to FIG. 9, the end portions E3 and E4 of each second cover portion are pressed against the back surface RS of the seat pad 4P by the pressing from the mounting portion 50. By pressing the ends E3, E4, etc. of each second cover portion against the back surface RS of the seat pad 4P in this way to bring them into close contact with each other, it is possible to prevent the formation of a gap between them as much as possible.

[Buckle member placement work]
Then, with reference to FIGS. 2 and 3, buckle members BM1 and BM2 corresponding to the seat cushion portions 4a and 4b are attached. For example, one buckle member BM1 is inserted into the first through hole 11 through the slit portion 42 of the first carpet member 31. At this time, referring to FIGS. 10 and 11, for example, one buckle member BM1 is inserted from the first slit portion 44 of the first carpet member 31. By pressing from one of the buckle members BM1, the first slit portion 44 is gradually expanded to the left and right, and the carpet member portion divided by the portion 44 is pushed back to the left and right. Then, in this embodiment, the second slit portions 45a and 45b extending to the left and right are provided at the front and rear ends of the first slit portion 44, respectively. Therefore, the carpet member portions divided by the first slit portions 44 can be smoothly pushed away by the second slit portions 45a and 45b. Then, the other buckle member BM2 is inserted into the second through hole 12 in the same procedure as the above-mentioned work.

Then, referring to FIGS. 10 and 11, in the state where one buckle member BM1 is inserted into the first through hole 11, the gap between them is closed by the main body 40 of the first carpet member 31. Has been done. Similarly, when the other buckle member BM2 shown in FIG. 2 is inserted into the second through hole 12, the gap between them is closed by the main body portion 40a of the second carpet member 32. Therefore, even when the electrical components on the back side of the seat pad 4P are operated, the carpet members 31 and 32 preferably prevent air from leaking from the first through hole 11 and the second through hole 12 to the seating side. can do. In particular, in this embodiment, the seat cover portions (E1 to E4 and the like shown in FIG. 11) arranged on the back surface side of the seat pad 4P are pressed against the seat pad 4P by the mounting portions 50 and 50a. By doing so, it is possible to prevent air from flowing into the through holes 11 and 12 through between the back surface RS of the seat pad 4P and the seat cover 4S as much as possible.

As described above, in the present embodiment, the carpet members 31 and 32 are held at the tips of the protrusions 4x in the bonding step. Therefore, from the viewpoint of simplifying the manufacturing process, even if the carpet members 31 and 32 are attached to the seat cover 4S in advance, the seat cover 4S collides with the carpet members 31 and 32 as much as possible without being disturbed. It is adhered to the inner surface of each of the through holes 11 and 12 by the portion 4x. Therefore, it is possible to prevent the deterioration of the finish of the seat cover 4S caused by the interference between the carpet members 31 and 32 and the protrusion 4x as much as possible. In particular, by pushing the carpet members 31 and 32 into the accommodating portion 6x and holding them stably, it is possible to more reliably prevent the deterioration of the finish of the seat cover 4S caused by the carpet members 31 and 32. Can be done. At this time, the promoting portion PM can push the carpet members 31 and 32 into the accommodating portion 6x while appropriately bending them. Further, with a simple configuration in which the cut portions 46, 56 and the like function as the promoting portion PM, the carpet members 31 and 32 can be pushed into the accommodating portion 6x while being appropriately bent.

Further, in this embodiment, by arranging the carpet members 31 and 32 on the back side of the seat pad 4P by the insertion work of the protrusion 4x, it is possible to smoothly attach the carpet members 31 and 32 to the back surface RS of the seat pad 4P during the covering work. it can. In this coating step, the mounting portions 50 and 50a of the carpet members 31 and 32 can be stably mounted by the back surface RS of the seat pad 4P via the fastener HG. Further, in this embodiment, the buckle members BM1 and BM2 are inserted into the through holes 11 and 12 through the slit portions 42 and 42a. At this time, the expansion of the first slit portion 44 can be promoted by the second slit portions 45a and 45b intersecting the first slit portion 44.

Further, in this embodiment, the seat cover portions (E1 to E4, etc.) arranged on the back surface side of the seat pad 4P are pressed against the seat pad 4P by using the mounting portions 50 and 50a, and a gap is generated between them. Prevent things as much as possible. By doing so, it is possible to prevent air from flowing into the through holes 11 and 12 as much as possible through between the back surface RS of the seat pad 4P and the seat cover 4S. Further, in this embodiment, the difference between the first carpet member 31 and the second carpet member 32 can be visually confirmed by the misassembly prevention unit WAM. Therefore, in this embodiment, the first carpet member 31 and the second carpet member 32 can be mounted at appropriate positions without being mistaken for each other as much as possible. Therefore, according to this embodiment, the seat cover 4S and the carpet members 31 and 32 can be attached to the seat pad 4P in a suitable position with a simpler configuration.

The vehicle seat of the present embodiment is not limited to the above-described embodiment, and various other embodiments may be adopted. In this embodiment, the procedures of the bonding process and the coating process are illustrated, but the procedure of each process is not limited. For example, the adhesive device may be configured to simply press the seat cover (a configuration that does not heat) until the adhesive applied between the seat pad and the seat cover is cured. Further, the method of holding the carpet member at the tip of the protrusion may take various forms in addition to the example of pushing it into the accommodating portion. In addition to suturing, various members such as bolts, clips, and staples can be used to attach the end, body, and attachment of the seat cover, and methods such as adhesion, attachment, and fusion should be used. You can also. The end portion of the second cover portion, the main body portion, and the mounting portion may be overlapped in this order so that the mounting portion is arranged on the backmost side.

Further, in the present embodiment, the configurations (shape, dimensions, mounting position, constituent parts, etc.) of the carpet members 31 and 32 are illustrated, but the configuration of the carpet members is not limited. For example, the carpet member may have a configuration in which the main body portion and the mounting portion are integrated, and the mounting portion may be omitted if necessary. Further, as the facilitating portion, a configuration in which the notch portion is also used is exemplified, but as the facilitating portion, a hole portion, a notch or a slit provided at an appropriate position of the carpet member can be exemplified, and the facilitating portion and the notch portion can be provided separately. .. The shape of the notch can be changed as appropriate, and various shapes such as a polygonal shape such as a triangular shape, a semicircular shape, and a semi-elliptical shape can be obtained. Further, as the erroneously assembled portion, a part of the shape of the first carpet member or the colored portion attached to the member can be used, and the erroneously assembled portion can be omitted if necessary. In addition, the shape of the slit portion can be changed as appropriate. For example, in addition to the H shape when viewed from above, various shapes such as L shape, T shape, and cross shape can be taken, and each slit portion is also linear. , May be curved or tilted in an appropriate direction. For example, the second slit portion may be arranged so as to intersect with the first slit portion, and the slit portions can be intersected in an arrow shape, for example.

Further, as a method of attaching the attachment portion to the seat pad, in addition to the case of using a fastener, a method such as adhesion, attachment or fusion can be exemplified. Further, as the fastener, in addition to the ring-shaped wire material, various members such as bolt materials, clips and staples can be used. The configuration of the protruding portion can also be changed as appropriate. For example, the protruding portion can be provided on all (or most of) the outer peripheral edge of the mounting portion. In this case, the protruding portion to be mounted on the seat pad can be provided as needed. Can be selected.

Further, in the present embodiment, the configurations (shape, size, formation position, number of formations, etc.) of the through holes 11 and 12 are illustrated, but the configuration of each through hole is not limited. Through holes can be provided at appropriate positions on the sheet. Further, as an accessory member, various members that can be inserted into the through hole can be assumed.

Further, although the configuration (shape, dimensions, constituent members, etc.) of the vehicle seat 2 has been illustrated, it is not intended to limit the configuration of the vehicle seat. For example, in the present embodiment, the electrical components are arranged on the back side of the seat pad, but the configuration of the present invention can be suitably applied to the case where an air flow occurs on the back side of the seat pad regardless of the electrical components. Further, in the present embodiment, the seat cushion has been described as an example, but the configuration of the present invention can be applied to various seat constituent members such as a seat back and a headrest. The configuration of the present embodiment can be applied to all vehicle seats such as vehicles, aircrafts, and trains.

2 Vehicle seat 4 Seat cushion 6 Seat back 4S Seat cover 4P Seat pad 11 First through hole 11a to 11d Inner surface of first through hole 12 Second through hole 12a to 12d Inner surface of second through hole 21 First cover part 22a ~ 22d Second cover part (part of the seat cover of the present invention)
E1 to E4 End of the second cover portion (seat cover portion arranged on the back surface side of the seat pad of the present invention)
31 1st carpet member 32 2nd carpet member 40 Main body 42 Slit 44 1st slit 45a, 45b 2nd slit 46 1st notch 47 1st overhang convex 50 Mounting 52 Window 54 Protruding 54H Mounting hole 56 Second notch 57 Positioning hole 58 Second overhang convex BM1, BM2 Buckle member (accessory member of the present invention)
HG Fastener SEW Suture Line PM Encouragement Part WAM Misassembly Prevention Part SS Seat Pad Seating Surface RS Seat Pad Backside XM Adhesive Device 2x Heating Body 4x Protrusion 6x Storage

Claims (7)

An adhesive step of adhering a planar seat cover from the seating surface of the seat pad that elastically supports the occupant to the inner surface of the through hole of the seat pad that opens to the seating surface, and a planar carpet that covers the through hole. The member is provided with a covering step of attaching the member to the back surface opposite to the seating surface of the seat pad.
In the bonding step, when the bonding device is pressed against the seat cover on the seat pad to bond them, the protrusion of the bonding device presses a part of the seat cover against the inner surface while pressing the seating surface side. In the method for manufacturing a vehicle seat inserted through the through hole from
The carpet member is attached to a seat cover portion arranged on the back surface side of the seat pad through the through hole, and is attached to the seat cover portion.
In the bonding step, the protrusion of the bonding device is inserted into the through hole while holding the carpet member at the tip of the protrusion, and in the coating step, the carpet member removed from the tip of the protrusion. A method for manufacturing a vehicle seat, which is attached to the back surface of the seat pad in a state of being developed in the surface direction so as to cover the through hole. The vehicle according to claim 1, wherein the carpet member is bent and deformed so as to have a smaller dimension in the surface direction, and is pushed and held in a recessed accommodating portion provided at the tip of the protrusion. Sheet manufacturing method. The method for manufacturing a vehicle seat according to claim 2, wherein the carpet member is provided with a promoting portion that promotes bending and deformation. The carpet member has a main body portion that covers the through hole and a frame-shaped mounting portion that is fixed so as to surround the peripheral edge of the main body portion, and in the covering step, the mounting portion is attached to the seat pad. It is configured to be attached to the back side of
The method for manufacturing a vehicle seat according to claim 3, wherein each of the main body portion and the mounting portion is provided with a notch portion that defines a relative positional relationship with each other, and the notch portion functions as the facilitating portion. .. The carpet member has a main body portion that covers the through hole and a frame-shaped mounting portion that is fixed so as to surround the peripheral edge of the main body portion, and in the covering step, the mounting portion is attached to the seat pad. It is configured to be attached to the back side of
The mounting portion is provided with a projecting portion that protrudes outward in the surface direction of the carpet member and a mounting hole that penetrates the protruding portion in the thickness direction. The method for manufacturing a vehicle seat according to any one of claims 1 to 4, wherein the seat pad is attached to the back surface of the seat pad via a fastener inserted into the mounting hole. The vehicle seat has an accessory member that is arranged so as to be inserted through the through hole, and the main body of the carpet member that covers the through hole allows the accessory member to be inserted into the through hole. A cut-shaped slit is provided to make a carpet.
The slit portion has a first slit portion that expands by passing through the accessory member and a second slit portion that is connected to the first slit portion, and the second slit portion is the first slit portion. The method for manufacturing a vehicle seat according to any one of claims 1 to 5, wherein the first slit portion extends in a direction intersecting the extension direction of the first slit portion on the end side. A seat pad that can elastically support an occupant, a through hole that penetrates the seat pad in the thickness direction, a seat cover that is adhered to a portion from the seating surface of the seat pad to the inner surface of the through hole, and the above. In a vehicle seat provided with a planar carpet member covering the through hole on the back surface side of the seat pad opposite to the seating surface.
The carpet member has a main body portion that covers the through hole and a frame-shaped mounting portion that is fixed along the peripheral edge of the main body portion, and the mounting portion is the back surface of the seat pad through the through hole. It is attached to the seat cover part placed on the side,
The mounting portion is mounted on the back surface side of the seat pad in a state where the seat cover portion arranged on the back surface side of the seat pad is pressed against the seat pad .
As the carpet member, a first carpet member and a second carpet member arranged at a position different from the first carpet member are used, and the carpet member is used.
A vehicle seat in which the first carpet member has an erroneous assembly prevention portion having a different appearance from the second carpet member .

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