JP6838415B2 - Vehicle seats and their manufacturing methods - Google Patents

Description

The present disclosure relates to vehicle seats.

In vehicle seats such as vehicles, a support bracket for supporting the headrest is attached to the back frame that constitutes the skeleton of the seat back. Both ends of the U-shaped stay of the headrest are inserted into this support bracket.

The support bracket is welded to the upper pipe of the back frame, for example, as disclosed in Patent Document 1. In Patent Document 1, in order to secure the welding strength between the support bracket and the upper pipe, a reinforcing plate is applied to the support bracket and the upper pipe, and the contact surface of the upper pipe with the support bracket is crushed and flattened.

Japanese Unexamined Patent Publication No. 2005-153630

The pitch of the stay in the headrest (ie, the distance between both ends of the stay) may vary depending on the design of the vehicle seat. When the pitch of the stay changes, it is necessary to change the mounting position of the support bracket. However, in the conventional structure, it is necessary to change the position of the flattened portion of the upper pipe according to the mounting position of the support bracket, and there is an inconvenience that the shape of the upper pipe is changed every time the pitch of the stay is changed.

One aspect of the present disclosure is an object of the present invention to provide a vehicle seat that can easily cope with a change in the pitch of a headrest stay.

One aspect of the present disclosure is a vehicle seat including a seat back, a headrest, and a back frame. The back frame constitutes the skeleton of the seat back. The headrest has a headrest main body and a stay. The stay supports the headrest main body, and both ends project toward the back frame side from the headrest main body. The back frame has a plurality of wires, a pair of tubular support brackets, and a pair of reinforcing plates. The plurality of wires extend in the left-right direction of the sheet and are arranged side by side in the up-down direction. Both ends of the stay are inserted into the pair of support brackets. Each pair of stiffeners is placed between the pair of support brackets and the plurality of wires. Further, in each pair of reinforcing plates, a plurality of wires are welded to one surface and one support bracket is welded to the other surface.

According to such a configuration, when changing the pitch of the stay of the headrest, the position of the pair of support brackets can be changed only by correcting the welding position of the pair of reinforcing plates and the plurality of wires. .. That is, it is possible to change the pitch without changing the shape of the back frame. Therefore, it is possible to easily cope with the pitch change of the stay of the headrest while maintaining the fixing strength of the support bracket by the reinforcing plate.

In one aspect of the present disclosure, the pair of reinforcing plates may have the same shape and may have a planar shape that is asymmetric in the vertical direction. Further, of the pair of reinforcing plates, one reinforcing plate may be arranged in a direction in which the other reinforcing plate is rotated by 180 ° when viewed from the front-rear direction of the seat. According to such a configuration, since the reinforcing plates of the same shape can be commonly used in the pair of support brackets, the production cost can be reduced. Further, by making the plane shapes of the left and right reinforcing plates rotationally symmetric, it is possible to prevent the left and right from being mistakenly attached to a plurality of wires with respect to the pair of support brackets in which the pair of reinforcing plates are attached.

In one aspect of the present disclosure, each pair of reinforcing plates may have a length in the left-right direction of the seat that is larger than the length in the left-right direction of the seat of the pair of support brackets. Further, the pair of reinforcing plates has a region in which the length of the region located between the pair of support brackets is located outside the pair of support brackets in the left-right direction of the seat when viewed from the front-rear direction of the seat. It may be larger than the length. According to such a configuration, the amount of protrusion of the reinforcing plate to the outside in the left-right direction of the seat can be reduced as compared with the support bracket, so that the space around the support bracket can be saved while maintaining the fixing strength between the support bracket and the plurality of wires. Can be planned.

In one aspect of the present disclosure, the welding direction of the pair of reinforcing plates and the pair of support brackets may be in the vertical direction. According to such a configuration, welding can be performed while avoiding the central portion in the width direction of the support bracket. As a result, the generation of beads at the central portion in the width direction of the support bracket is suppressed, so that the quality of the support structure of the headrest can be improved.

Another aspect of the present disclosure is a method of manufacturing a vehicle seat including a seat back, a headrest, and a back frame. The back frame constitutes the skeleton of the seat back. The vehicle seats are manufactured by welding a reinforcing plate to a tubular support bracket for inserting a headrest stay, and extending the seats in the left-right direction and arranging them side by side in the vertical direction in the back frame. A process of welding a reinforcing plate welded to a support bracket to a plurality of wires is provided.

According to such a configuration, the position of the support bracket can be changed only by correcting the welding position between the reinforcing plate to which the support bracket is welded and the wire. Therefore, it is possible to easily cope with the pitch change of the stay of the headrest while maintaining the fixing strength between the support bracket and the back frame by the reinforcing plate.

FIG. 1 is a schematic perspective view of a vehicle seat according to an embodiment. FIG. 2 is a schematic partial front view of the back frame in the vehicle seat of FIG. FIG. 3A is a schematic front view showing a mounting state of the headrest to the back frame, and FIG. 3B is a schematic front view showing a mounting state in which the stay pitch is different from that of FIG. 3A. 4A is a schematic perspective view of the mounting structure of the wire and the support bracket in the back frame of FIG. 2, and FIG. 4B is a schematic front view of the mounting structure of the wire and the support bracket of FIG. 4A. 4C is a schematic rear view of the mounting structure of the wire and the support bracket of FIG. 4A.

Hereinafter, embodiments to which the present disclosure has been applied will be described with reference to the drawings.
[1. First Embodiment]
[1-1. Constitution]
The vehicle seat 1 shown in FIG. 1 includes a plurality of seat cushions 2, a plurality of seat backs 3 corresponding to the plurality of seat cushions 2, and a plurality of headrests 4.

Each of the plurality of seat cushions 2 is a portion for supporting the buttocks and the like of the seated person. Each of the plurality of seat backs 3 is a portion for supporting the back of the seated person. Each of the plurality of headrests 4 is a portion for supporting the head of the seated person.

Further, the vehicle seat 1 includes a plurality of cushion frames (not shown) constituting the skeletons of the plurality of seat cushions 2 and one back frame 5 (see FIG. 2) constituting the skeletons of the plurality of seat backs 3. To be equipped.

The vehicle seat 1 of the present embodiment is used as a rear seat for an ordinary passenger car. The following description and directions in each drawing mean directions in a state where the vehicle seat 1 is assembled to a vehicle (that is, a vehicle).

<Headrest>
As shown in FIG. 3A, the headrest 4 has a headrest main body 4A in which a cover is attached to a pad that supports the head of a seated person, and a stay 4B that supports the headrest main body 4A.

The stay 4B is a rod-shaped metal member that is bent in an inverted U-shape, that is, a U-shape that is upside down when viewed from the front-rear direction of the seat. Both ends of the stay 4B project below the headrest main body 4A, that is, toward the back frame 5. Both ends of the stay 4B are arranged parallel to each other in the left-right direction of the seat, that is, in the width direction of the seat.

<Back frame>
The back frame 5 has a structure on the upper end side for supporting the plurality of headrests 4. This support structure is provided for each headrest 4. As a support structure corresponding to one headrest 4, the back frame 5 includes a plurality of wires 5A extending in the left-right direction of the seat and arranged side by side in the vertical direction, and both ends of the stay 4B, as shown in FIG. It has a pair of tubular support brackets 5B into which the wires are inserted, and a pair of reinforcing plates 5C arranged between the pair of support brackets 5B and the plurality of wires 5A, respectively.

(Wire)
The plurality of wires 5A are solid round bar-shaped metal members. The back frame 5 is configured by joining a plurality of wires 5A and a plurality of wires 5D extending in the vertical direction by welding.

(Support bracket)
Each pair of support brackets 5B is a square tubular metal member. The direction of the central axis of the pair of support brackets 5B coincides with the insertion direction of the stay 4B of the headrest 4. Headrest supports (not shown) are attached to the inside of the pair of support brackets 5B. The headrest support is provided with a through hole in the center.

By inserting each end of the stay 4B into the through hole of the headrest support, both ends of the stay 4B are inserted into the pair of support brackets 5B, and the headrest 4 is supported by the back frame 5.

The support bracket 5B is formed by bending a plate material into a tubular shape and welding the ends to each other. Each pair of support brackets 5B is fixed to a plurality of wires 5A by a pair of reinforcing plates 5C described later.

(Reinforcing plate)
Each pair of reinforcing plates 5C is a plate-shaped metal member. Each pair of reinforcing plates 5C has a plurality of wires 5A welded to one surface, that is, the rear surface, and one support bracket 5B welded to the other surface, that is, the front surface.

As shown in FIGS. 3A and 3B, the pair of reinforcing plates 5C have the same shape. Further, each pair of reinforcing plates 5C has a planar shape that is asymmetric in the vertical direction. Specifically, the planar shape of the pair of reinforcing plates 5C is a substantially trapezoidal shape in which the lengths of the opposing sides (that is, the upper base and the lower base) are different. The upper bottom and the lower bottom extend in the left-right direction of the sheet, respectively. Further, the upper bottom is shorter than the lower bottom, one end of the upper bottom and the lower bottom is connected by a side perpendicular to the left-right direction (hereinafter, referred to as "vertical side"), and the other end is in the left-right direction of the seat. And the sides inclined in the vertical direction (hereinafter referred to as "inclined sides") are connected.

The length of each pair of reinforcing plates 5C in the left-right direction of the seat is larger than the length (that is, diameter) of the pair of support brackets 5B in the left-right direction of the seat. As shown in FIG. 2, the pair of reinforcing plates 5C has a region length L1 located between the pair of support brackets 5B when viewed from the front-rear direction of the seat, which is larger than that of the pair of support brackets 5B. It is larger than the length L2 of the region located on the outside in the left-right direction. In the present embodiment, the inclined sides of the pair of reinforcing plates 5C are arranged between the pair of support brackets 5B, and the vertical sides of the pair of reinforcing plates 5C are located outside the pair of support brackets 5B. Have been placed. The vertical length of the pair of reinforcing plates 5C is smaller than the vertical length of the pair of support brackets 5B.

As shown in FIGS. 4A, 4B, and 4C, the pair of reinforcing plates 5C each have a first through hole 6 for weight reduction and a second through hole 7 for inserting a pin at the time of positioning. The first through hole 6 and the second through hole 7 are arranged in a region located between a pair of support brackets 5B of the reinforcing plate 5C, that is, a region sandwiched between the inclined side and the lower bottom.

Of the pair of reinforcing plates 5C, one reinforcing plate is arranged in a direction in which the other reinforcing plate is rotated by 180 ° when viewed from the front-rear direction of the seat. That is, when the reinforcing plate 5C on the left side is rotated by 180 ° about the midpoint of the line segment connecting the centers of gravity of the pair of reinforcing plates 5C, it completely overlaps the reinforcing plate 5C on the right side. In the present embodiment, of the pair of reinforcing plates 5C, the reinforcing plate 5C on the right side is arranged so that the upper bottom comes to the upper side, and the reinforcing plate 5C on the left side is arranged so that the lower bottom comes to the upper side. There is.

Further, the welding direction of the pair of reinforcing plates 5C and the pair of support brackets 5B is the vertical direction. That is, weld lines along the vertical direction are formed in the welded portions of the pair of reinforcing plates 5C and the pair of support brackets 5B.

The welding position of the pair of reinforcing plates 5C and the pair of support brackets 5B may be the end portion (that is, the corner portion) in the left-right direction of the seat. By welding the corners in this way, it is possible to suppress the generation of beads in the pair of support brackets 5B and improve the quality.

Further, in the present embodiment, as shown in FIGS. 4A, 4B, and 4C, one wire 5A is welded to the upper end and one lower end of one reinforcing plate 5C. In other words, the pitch of the two wires 5A (that is, the distance between the centers) is designed according to the vertical length of one reinforcing plate 5C.

[1-2. Manufacturing method of vehicle seat]
Hereinafter, a method for manufacturing the vehicle seat 1 will be described.
The vehicle seat is manufactured by first welding the reinforcing plate 5C to the tubular support bracket 5B for inserting the stay 4B of the headrest 4, and extending the seat in the left-right direction in the back frame 5. In addition, a second welding step of welding the reinforcing plate 5C welded to the support bracket 5B to a plurality of wires 5A arranged side by side in the vertical direction is provided.

<First welding process>
In this step, one reinforcing plate 5C is welded to one surface of one support bracket 5B to obtain a part (hereinafter, referred to as "support bracket with reinforcing plate") in which the reinforcing plate 5C is attached to the support bracket 5B. The welding direction is the vertical direction (that is, the central axis direction of the support bracket 5B) as described above.

Further, in this step, a support bracket with a reinforcing plate in which the upper bottom in the planar shape of the reinforcing plate 5C is on the upper side and a support bracket with a reinforcing plate in which the lower bottom in the planar shape of the reinforcing plate 5C is on the upper side are manufactured. These two types of support brackets with reinforcing plates are combined one by one and used for one seat back 3.

Here, the reinforcing plate 5C can be formed by punching the plate material with a mold. It should be noted that burrs are generated by punching on the surface of the reinforcing plate 5C opposite to the side to which the mold is applied. Therefore, by using this surface as the welding surface with the support bracket 5B, it is possible to suppress injuries when the reinforcing plate 5C is welded to the plurality of wires 5A. In the present embodiment, the pair of left and right reinforcing plates 5C have the same shape, and one reinforcing plate is arranged in a direction in which the other reinforcing plate is rotated by 180 ° when viewed from the front-rear direction of the seat. Therefore, in both the left and right reinforcing plates 5C, the surface where burrs are generated can be the welded surface with the support bracket 5B.

<Second welding process>
In this step, one support bracket with a reinforcing plate obtained in the first welding step is welded to a plurality of wires 5A. As a result, the support bracket 5B is fixed to the plurality of wires 5A via the reinforcing plate 5C. This welding work is performed twice, one pair on each side, for one seat back 3.

After fixing the support bracket 5B to the plurality of wires 5A, the headrest 4 is supported by the back frame 5 by inserting both ends of the stay 4B into the pair of support brackets 5B.

[1-3. effect]
According to the embodiment described in detail above, the following effects can be obtained.
(1a) The support bracket 5B is fixed to a plurality of wires 5A constituting the back frame 5 via a reinforcing plate 5C. Therefore, when changing the pitch of the stay 4B of the headrest 4 from the pitch shown in FIG. 4A to the pitch shown in FIG. 4B, for example, the support bracket only needs to correct the welding position between the reinforcing plate 5C and the plurality of wires 5A. The fixed position of 5B can be shifted. The same applies when the pitch is increased from FIG. 4B to FIG. 4A. Therefore, it is possible to easily cope with the pitch change of the stay 4B of the headrest 4 while maintaining the fixing strength of the support bracket 5B by the reinforcing plate 5C.

(1b) Welding of the support bracket 5B and the reinforcing plate 5C and welding of the reinforcing plate 5C and the plurality of wires 5A can be performed under better conditions than directly welding the support bracket 5B to the plurality of wires 5A. Therefore, the generation of beads is suppressed and the quality is improved. Further, in the present embodiment, there is no need to flatten the pipe as in the prior art.

(1c) Since the pair of reinforcing plates 5C have the same shape, the pair of support brackets 5B can commonly use the reinforcing plates 5C having the same shape. Therefore, the production cost can be reduced. Further, by making the plane shapes of the left and right reinforcing plates 5C rotationally symmetric, the left and right sides are mistakenly attached to a plurality of wires 5A with respect to the pair of support brackets 5B in which the pair of reinforcing plates 5C are attached. Can be suppressed.

(1d) In one reinforcing plate 5C, the length L1 of the region located between the pair of support brackets 5B is from the length L2 of the region located outside the pair of support brackets 5B in the left-right direction of the seat. Is also large, so that the amount of protrusion of the reinforcing plate 5C to the outside in the left-right direction of the seat can be reduced as compared with the support bracket 5B. As a result, it is possible to save space around the support bracket 5B while maintaining the fixing strength between the support bracket 5B and the plurality of wires 5A.

(1e) Since the welding direction of one reinforcing plate 5C and the pair of support brackets 5B is in the vertical direction, welding can be performed while avoiding the central portion in the width direction of the support brackets 5B. As a result, the generation of beads at the central portion of the support bracket 5B in the width direction is suppressed, so that the quality of the support structure of the headrest 4 can be improved.

[2. Other embodiments]
Although the embodiments of the present disclosure have been described above, it goes without saying that the present disclosure is not limited to the above-described embodiments and can take various forms.

(2a) In the vehicle seat 1 of the above embodiment, the shape of the pair of reinforcing plates 5C described above is an example, and the shape of the reinforcing plate 5C is not limited to this.
Therefore, the pair of reinforcing plates 5C does not necessarily have to have the same shape, and may have different shapes on the left and right. Further, even if the shape is the same, it does not have to be a plane shape that is asymmetric in the vertical direction, and further, it does not have to be a rotationally symmetric shape.

Further, the reinforcing plate 5C does not necessarily have to be longer in the left-right direction of the seat than the support bracket 5B as long as the welding length can be secured. On the contrary, the reinforcing plate 5C may partially project above or below the support bracket 5B when viewed from the front-rear direction of the seat. Further, the first through hole 6 and the second through hole 7 have an arbitrary configuration and can be omitted.

(2b) In the vehicle seat 1 of the above embodiment, the welding direction of the pair of reinforcing plates 5C and the pair of support brackets 5B does not have to be the vertical direction. However, as described above, the welding direction is preferably the vertical direction from the viewpoint of suppressing the bead.

(2c) In the vehicle sheet 1 of the above embodiment, the number of wires 5A welded to one reinforcing plate 5C is not limited to two. One reinforcing plate 5C may be welded to three or more wires 5A.

(2d) The vehicle seat 1 of the above embodiment can be applied to a seat for an automobile other than a seat for a rear seat of an ordinary passenger car, and a seat used for a vehicle such as a railroad vehicle, a ship, an aircraft other than an automobile.

(2e) The functions of one component in the above embodiment may be dispersed as a plurality of components, or the functions of the plurality of components may be integrated into one component. Further, a part of the configuration of the above embodiment may be omitted. Further, at least a part of the configuration of the above embodiment may be added or replaced with the configuration of the other embodiment. It should be noted that all aspects included in the technical idea specified from the wording described in the claims are embodiments of the present disclosure.

1 ... Vehicle seat, 2 ... Seat cushion, 3 ... Seat back, 4 ... Headrest,
4A ... headrest body, 4B ... stay, 5 ... back frame, 5A ... wire,
5B ... Support bracket, 5C ... Reinforcing plate, 5D ... Wire, 6 ... First through hole,
7 ... Second through hole.

Claims (5)

A vehicle seat including a seat back, a headrest, and a back frame constituting the skeleton of the seat back.
The headrest
Headrest body and
A stay that supports the headrest body and has both ends protruding toward the back frame from the headrest body.
Have,
The back frame is
A plurality of wires extending in the left-right direction of the sheet and arranged side by side in the up-down direction,
A pair of tubular support brackets into which both ends of the stay are inserted, and
A pair of reinforcing plates arranged between the pair of support brackets and the plurality of wires, respectively.
Have,
Each of the pair of reinforcing plates has a flat plate shape, and the plurality of wires are welded to one surface and one support bracket is welded to the other surface. The vehicle seat according to claim 1.
The pair of reinforcing plates has the same shape, and each has an asymmetric plane shape in the vertical direction.
Of the pair of reinforcing plates, one reinforcing plate is a vehicle seat arranged in a direction in which the other reinforcing plate is rotated by 180 ° when viewed from the front-rear direction of the seat. A vehicle seat including a seat back, a headrest, and a back frame constituting the skeleton of the seat back.
The headrest
Headrest body and
A stay that supports the headrest body and has both ends protruding toward the back frame from the headrest body.
Have,
The back frame is
A plurality of wires extending in the left-right direction of the sheet and arranged side by side in the up-down direction,
A pair of tubular support brackets into which both ends of the stay are inserted, and
A pair of reinforcing plates arranged between the pair of support brackets and the plurality of wires, respectively.
Have,
Each of the pair of reinforcing plates has the plurality of wires welded to one surface and one support bracket welded to the other surface.
The length of each of the pair of reinforcing plates in the left-right direction of the seat is larger than the length of the pair of support brackets in the left-right direction of the seat, and they are located between the pair of support brackets when viewed from the front-rear direction of the seat. A vehicle seat in which the length of the region to be used is larger than the length of the region located outside the pair of support brackets in the left-right direction of the seat. The vehicle seat according to any one of claims 1 to 3.
A vehicle seat in which the welding direction of the pair of reinforcing plates and the pair of support brackets is in the vertical direction. A method for manufacturing a vehicle seat including a seat back, a headrest, and a back frame constituting the skeleton of the seat back.
The process of welding the reinforcing plate to the tubular support bracket for inserting the stay of the headrest, and
In the back frame, a step of welding a reinforcing plate welded to the support bracket to a plurality of wires extending in the left-right direction of the sheet and arranged side by side in the vertical direction.
A method of manufacturing a vehicle seat.

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