WO2015114874A1 - 車両用シートおよび車両用シートの製造方法 - Google Patents
車両用シートおよび車両用シートの製造方法 Download PDFInfo
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- WO2015114874A1 WO2015114874A1 PCT/JP2014/074001 JP2014074001W WO2015114874A1 WO 2015114874 A1 WO2015114874 A1 WO 2015114874A1 JP 2014074001 W JP2014074001 W JP 2014074001W WO 2015114874 A1 WO2015114874 A1 WO 2015114874A1
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- Prior art keywords
- seat
- vehicle seat
- cushion
- fabric
- manufacturing
- Prior art date
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Images
Classifications
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- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
- B60N2/58—Seat coverings
- B60N2/5816—Seat coverings attachments thereof
- B60N2/5883—Seat coverings attachments thereof by sewing, stitching or threading
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
- B60N2/58—Seat coverings
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- B60N2/5866—Seat coverings attachments thereof by thermal welding
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- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
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- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B2038/0052—Other operations not otherwise provided for
- B32B2038/008—Sewing, stitching
Definitions
- the present invention relates to a vehicle seat and a method for manufacturing the same.
- Vehicle seats such as automobile seats are required to have various functions such as safety, holdability and ease of getting on and off (ease of getting on and off), and at the same time there are many demands for improving passenger comfort such as sitting comfort and vibration absorption performance .
- passenger comfort such as sitting comfort and vibration absorption performance .
- it is a large part among interior parts of automobiles, and there are various demands on its appearance and design.
- trim covers that greatly affect the appearance and design of vehicle seats, that is, trim covers, account for a large percentage of the total cost of the vehicle seats together with the frame, and reducing the cost of trim covers in vehicle seats is also an important issue. ing.
- Patent Document 1 discloses a quilting sheet material for automobile cushions, in which a nonwoven fabric layer made of thermoplastic fibers is laminated on the back side of an automobile cushion sheet skin material layer, and the nonwoven fabric layer includes the skin material.
- a quilting sheet material for an automobile cushion capable of exhibiting a quilting effect is disclosed, wherein at least the outer layer surface side opposite to the surface facing the layer is a hardened surface.
- the quilting sheet material for automobile cushions as a cushion sheet material for automobiles, it can be made into a material configuration that facilitates its recyclability. It becomes a quilting sheet material provided with irregularities, and can provide a useful and highly useful cushion sheet material for automobiles.
- Patent Document 2 As another background art of this technical field, there is JP-A-2006-130715 (Patent Document 2).
- Patent Document 2 a skin material in which a fabric, a cushion layer, and a back base fabric are laminated from the front side is set in a mold, and a molten thermoplastic resin is injected to integrally mold the skin material and the thermoplastic resin. It is an interior material, and the fabric has a difference in the vertical and horizontal heat shrinkage rates, and the fabric and the back base fabric form two or more dots in a direction in which the heat shrinkage rate is large via the cushion layer.
- the surface of the skin material is heat-received from the molten resin when molten thermoplastic resin is injected into the mold so that the thermal contraction rate of the fabric increases in the direction between the dot-shaped welded portions.
- the fabric has a difference in heat shrinkage in length and breadth, and the fabric and the back base fabric have two or more dots in the direction of large heat shrinkage through the cushion layer.
- the fabric is shrunk in the direction where the thermal contraction rate of the fabric is large between the dotted welds due to the heat received from the molten resin. Since the dent streaks are formed on the surface of the skin material, it is possible to integrally form an undulating shape of an arbitrary design on the surface of the skin material without post-processing as in the prior art.
- a technique for forming gathers that is, folds that are gathered by shrinking a cloth by sewing a skin material together is used.
- This gathering process is advantageous in terms of comfort, such as ensuring a sufficient stroke of the skin material when seated, but it is difficult to control gathering such as unevenness and position, and in some cases it gives a loose impression, and the product As a result, there is a problem that the variation will increase.
- the surface of the laminated fabric with the thick wadding that is used as the skin material and cushioning material is processed with unevenness by pattern stitching using a computer sewing machine. It is difficult to obtain a sufficient three-dimensional shape (uneven shape) that meets the requirements.
- an object of the present invention is to provide a vehicle seat that has an extraordinary three-dimensional effect on the surface layer of the vehicle seat, brings about a new design and at the same time improves the soft feeling, and is excellent in comfort and design. There is to do.
- Another object of the present invention is to form a three-dimensional pattern on the surface layer of the vehicle seat to provide a new design and at the same time ensure a sufficient stroke of the skin material when seated, thereby improving comfort and design.
- An object of the present invention is to provide an excellent vehicle seat.
- Another object of the present invention is to provide a method for manufacturing a vehicle seat that satisfies comfort and design while suppressing manufacturing costs.
- the present invention is a vehicle seat having a seat cushion that serves as a seat surface portion of a seat, a seat back that serves as a seat back portion, and a headrest that protects the head and neck of an occupant, the seat cushion and At least one of the seat backs includes a cover formed by a cloth including a skin material, a cushion material, and a heat shrink material on the surface, and the cover has a plurality of irregularities formed on the surface by stitching. It is characterized by being.
- the present invention also provides a vehicle seat having a seat cushion that serves as a seating surface portion of the seat, a seat back that serves as a backrest portion of the seat, and a headrest that protects the head and neck of the occupant.
- a seat cushion that serves as a seating surface portion of the seat
- a seat back that serves as a backrest portion of the seat
- a headrest that protects the head and neck of the occupant.
- At least one of the cushion and the seat back is provided with a cover formed on the surface thereof by a cloth containing a skin material, a cushion material, and a rubber material, and the cover has a plurality of irregularities formed on the surface by stitch processing. It is characterized by.
- the present invention also includes (a) a step of superposing at least three layers of a skin material, a cushion material, and a heat shrink material to make a laminated fabric, (b) a step of performing pattern stitching on the laminated fabric, c) A method of manufacturing a vehicle seat, including a step of heat-treating the laminated fabric.
- the present invention provides (a) a process of making a laminated fabric by superimposing at least three layers of a skin material, a cushion material, and a rubber material, and (b) the laminated material in a state where the rubber material is mechanically stretched.
- a method of manufacturing a vehicle seat comprising: a step of performing pattern stitch processing on the fabric of (c); and a step of releasing elongation of the rubber material.
- an extraordinary three-dimensional effect is formed on the surface layer, and a new design is brought about, and at the same time, a soft feeling is improved, and a vehicle seat excellent in comfort and design is realized. Can do.
- a three-dimensional pattern is formed on the surface layer to provide a new design, and at the same time, a sufficient stroke of the skin material is ensured at the time of sitting, so that comfort and design are excellent.
- a vehicle seat can be realized.
- FIG. 1 shows an overall outline of a vehicle seat used in an automobile or the like according to an embodiment of the present invention.
- the vehicle seat 1 according to the first embodiment includes, as main parts, a seat cushion 2 that serves as a seat surface portion of a seat, a seat back 3 that serves as a seat back portion, a head portion and a neck portion of an occupant.
- a headrest 4 for protecting the head.
- side supports 5 are provided to support the side portions of the seat surface portion.
- a lattice-like pattern is applied to the surfaces of the seat cushion 2 and the seat back 3 in FIG. 1 by pattern stitching.
- the lattice pattern on the seat cushion 2 and the lattice pattern on the seat back 3 are formed into a three-dimensional pattern by forming a plurality of irregularities on the surface of the fabric by accurate stitching using a computer sewing machine or a multi-axis sewing machine. Is provided.
- FIGS. 2 and 3 show another example of a three-dimensional pattern formed on the surface of the seat cushion 2 or seat back 3 of the vehicle seat in the first embodiment.
- a plurality of patterns extending radially from the center point in three directions are provided at regular intervals.
- a plurality of patterns in which other hexagons are in contact with each side of the hexagon are continuously provided.
- FIG. 4 shows a partial cross section of the seat cushion 2 or the seat back 3 of the vehicle seat in the first embodiment.
- the seat cushion 2 or the seat back 3 according to the first embodiment is a seat cover or trim using a cloth including three layers of a skin material 6, a thick wadding 8 serving as a cushion material, and a heat shrink material 9 thermally contracted by heating. A cover is used.
- the thick wading 8 uses, for example, a highly cushioning urethane material or cotton.
- a polyester raw material can be used, for example.
- the fabric including three layers of the skin material 6, the thick wadding 8, and the heat shrink material 9 is subjected to pattern stitch processing by the stitch yarn 7, and the above-described three-dimensional pattern is formed on the surface of the skin material 6.
- the heat-shrinkable material 9 is heat-treated (heated) after the three layers of the skin material 6, the thick wadding 8 and the heat-shrinkable material 9 are overlaid, and shrinks due to heat shrinkage. Large irregularities (steps) are formed.
- FIG. 6 shows an outline of the manufacturing process of the vehicle seat in the first embodiment.
- step a the raw material of the skin material of the seat cover, that is, the trim cover is cut. Subsequently, each piece of the cut skin material is sewn (step b).
- step c a frame is formed by molding and processing a metal material or the like (step c), and assembly of seat mechanism parts such as a reclining adjuster and a seat lever is performed (step d).
- step e integral foaming of the trim cover and urethane
- step f adhesive molding of the trim cover and urethane pad
- FIG. 7 shows a breakdown of the process (process b) for sewing each piece of the skin material described above.
- a skin material 6, a thick wadding 8 such as a urethane material, and a heat shrink material 9 such as a polyester material are stacked in three layers to form a laminated fabric (step j).
- pattern stitching is accurately performed on the surface of the laminated fabric, that is, the sheet surface, using a computer sewing machine or a multi-axis sewing machine (step k).
- the pattern to be applied by the stitch processing can be arbitrarily selected from a plurality of patterns registered in advance in the computer.
- FIG. 10 shows a cross section of the laminated fabric after the stitching process (step k). Since the laminated fabric at this stage is the same as the state where the conventional pattern stitch processing is performed, the unevenness (step) on the surface of the skin material 6 by the stitch yarn 7 is the same as the conventional unevenness (step). It has become.
- FIG. 11 shows a partial cross section of the laminated fabric at this stage.
- FIG. 11 corresponds to the AA ′ cross section of FIG. 9 showing the overall outline of the vehicle seat.
- Each part of the sheet to be stitched here may use a laminated fabric in which the above-described skin material 6, thick wadding 8 and heat shrinkable material 9 are laminated in three layers, Depending on the portion of the sheet used, a combination of a portion using a laminated fabric and a conventional fabric, for example, a two-layer fabric of a skin material 6 and a thick wadding 8 may be used.
- the laminated fabric including the three layers of the skin material 6, the thick wadding 8 and the heat shrinkable material 9 subjected to the pattern stitching is subjected to heat treatment to heat shrink the heat shrinkable material 9 (step m ).
- the heat-shrinkable material 9 shrinks, and large irregularities (steps) can be formed on the surface of the skin material 6 that has been stitched, that is, the surface of the sheet cover.
- FIG. 8 shows a modification of the step (step b) of sewing each piece of the skin material described above in the first embodiment.
- step m in FIG. 7 can be processed before step l. That is, before sewing each piece of the skin material, heat treatment was performed on the laminated fabric including three layers of the skin material 6, the thick wadding 8, and the heat-shrinkable material 9, and the stitch processing was performed only at the site using the laminated fabric. After forming large irregularities (steps) on the surface of the skin material 6, that is, the surface of the seat cover, each part of the sheet can be sewn to form a seat cover, that is, a trim cover.
- the above-described pattern due to the unevenness (steps) on the surface of the seat cover may be a lattice pattern as described with reference to FIG. 1 or a regular pattern such as a geometric pattern as described with reference to FIGS. Is set according to
- the vehicle seat an extraordinary three-dimensional effect is formed on the surface layer, and a new design property is provided, and at the same time, a soft feeling is improved, and the comfort and design properties are excellent.
- a vehicle seat can be realized.
- the unevenness (steps) formed on the seat surface improves the fit when the occupant is seated, improves the air permeability due to the reliable three-dimensionality, and the stitch yarn is created by eliminating friction between the occupant and the stitch thread when seated. It is possible to improve the durability.
- the vehicle seat manufacturing method by using a heat-shrinkable material as part of the material, a vehicle seat that satisfies comfort and design is manufactured without using a special sewing machine while reducing manufacturing costs. can do.
- FIG. 5 shows a partial cross section of a seat cushion 2 or a seat back 3 of a vehicle seat according to another embodiment of the present invention.
- the same parts as in the first embodiment will be described with the details omitted.
- the seat cushion 2 or the seat back 3 of the vehicle seat 1 is a seat cover using a fabric including three layers of a skin material 6, a cotton 10 serving as a cushion material, and a stretchable rubber 11 from the surface side. That is, a trim cover is used.
- the fabric including the three layers of the skin material 6, the cotton 10, and the face rubber 11 is subjected to pattern stitch processing by the stitch yarn 7, and a three-dimensional pattern is formed on the surface of the skin material 6 as in the first embodiment. Yes.
- the surface rubber 11 is subjected to stitching in a state where the surface rubber 11 is mechanically stretched after the three layers of the skin material 6, cotton 10, and the surface rubber 11 are overlapped.
- FIG. 5 shows a state after the mechanical extension of the face rubber 11 is released after the stitch processing. Since the surface rubber 11 from which the mechanical extension has been released returns to the state before the mechanical extension, a large unevenness (step) is formed on the skin material 6.
- the outline of the manufacturing process of the vehicle seat in the second embodiment is manufactured through the same process as in the first embodiment, that is, the process shown in FIG.
- the same parts as in the first embodiment will be described with the details omitted.
- FIG. 13 shows a breakdown of the sewing process in Example 2, that is, a process of sewing each piece of the skin material in FIG. 6 (process b).
- the skin material 6, the cotton 10 serving as a cushion material, and the elastic rubber 11 having elasticity are superimposed on three layers to form a laminated fabric (step n).
- the surface rubber 11 is kept stretched by mechanical means, and pattern stitching is accurately performed on the surface of the laminated fabric, that is, the sheet surface, using a computer sewing machine or a multi-axis sewing machine (step o).
- the pattern to be applied by the stitch process can be arbitrarily selected from a plurality of patterns registered in advance in the computer, as in the first embodiment.
- step o shows a cross section of the laminated fabric after the stitching process (step o).
- the surface rubber 11 is maintained in a mechanically stretched state and is the same as the state in which the conventional pattern stitch processing is performed.
- the unevenness (step) is an unevenness (step) having the same size as the conventional one.
- each part of the seat formed in step a of FIG. 6 is stitched to form a vehicle seat cover (step p).
- FIG. 15 shows a partial cross section of the laminated fabric at this stage.
- FIG. 15 corresponds to the AA ′ cross section of FIG. 9 showing the overall outline of the vehicle seat.
- each part of the sheet to be sewn may be a laminated fabric in which the above-described skin material 6, cotton 10, and face rubber 11 are laminated in three layers, and the part of the sheet to be used.
- a combination of a two-layer fabric of a portion using a laminated fabric and a conventional fabric, for example, the skin material 6 and the cotton 10 may be used.
- the face rubber 11 is subjected to a stress, that is, a contraction force to return to the state before being stretched, and the stitched skin is processed.
- a stress that is, a contraction force to return to the state before being stretched
- Large irregularities can be formed on the surface of the material 6, that is, the surface of the sheet cover.
- seat cover surface mentioned above is the pattern with the regularity as demonstrated in FIG. 2 and FIG. That is, a geometric pattern or the like is set according to a request.
- a three-dimensional pattern is formed on the surface layer to provide a new design, and at the same time, ensure a sufficient stroke of the skin material when seated, thereby improving comfort.
- Vehicle seats with excellent design can be realized.
- the unevenness (steps) formed on the seat surface improves the fit when the occupant is seated, improves the air permeability due to the reliable three-dimensionality, and the stitch yarn is created by eliminating friction between the occupant and the stitch thread when seated. It is possible to improve the durability.
- the vehicle seat manufacturing method by using a surface rubber as a part of the material, a vehicle seat that satisfies comfort and design characteristics is manufactured without using a special sewing machine while suppressing manufacturing costs. be able to.
- this invention is not limited to the above-mentioned Example, Various modifications are included.
- the above-described embodiments have been described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described.
- a part of the configuration of one embodiment can be replaced with the configuration of another embodiment, and the configuration of another embodiment can be added to the configuration of one embodiment.
- SYMBOLS 1 Vehicle seat, 2 ... Seat cushion, 3 ... Seat back, 4 ... Headrest, 5 ... Side support, 6 ... Skin material, 7 ... Stitch thread, 8 ... Thick wadding, 9 ... Heat shrink material, 10 ... Cotton, 11 ... rubber.
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Abstract
Description
ここで縫合するシート各部位は、その全ての部位において、上述の表皮材6、厚手ワディング8、熱収縮材9を三層に重ね合わせた積層生地を用いてもよく、また、
使用されるシートの部位により、積層生地を用いる部位と従来の生地、例えば表皮材6、厚手ワディング8の二層の生地の組み合わせであってもよい。
表皮材6、綿10、面ゴム11の三層を含む生地は、ステッチ糸7によりパターンステッチ加工が施され、実施例1と同様に、表皮材6の表面に立体的な模様が形成されている。ここで、面ゴム11は、表皮材6、綿10、面ゴム11の三層を重ね合わせた後に、面ゴム11を機械的に伸長した状態でステッチ加工が施されている。図5はステッチ加工後に、面ゴム11の機械的な伸長が解放された後の状態を示している。機械的な伸長が解放された面ゴム11は機械的に伸長させる前の状態に戻るため、表皮材6に大きな凹凸(段差)が形成されている。
ここで縫合するシート各部位は、その全ての部位において、上述の表皮材6、綿10、面ゴム11を三層に重ね合わせた積層生地を用いてもよく、また、使用されるシートの部位により、積層生地を用いる部位と従来の生地、例えば表皮材6、綿10の二層の生地の組み合わせであってもよい。
Claims (17)
- シートの座面部となるシートクッションと、
シートの背もたれ部となるシートバックと、
乗員の頭部および頸部を保護するヘッドレストと、を有する車両用シートであって、
前記シートクッションおよび前記シートバックのうち、少なくとも一方において、その表面に、表皮材、クッション材、熱収縮材を含む生地により形成されたカバーを備え、
前記カバーはステッチ加工によりその表面に複数の凹凸が形成されていることを特徴とする車両用シート。 - 前記カバーは、前記複数の凹凸により、その表面に立体的な模様が施されていることを特徴とする請求項1に記載の車両用シート。
- 前記表面の立体的な模様は幾何学模様であることを特徴とする請求項2に記載の車両用シート。
- 前記熱収縮材は、ポリエステル素材であることを特徴とする請求項1から3のいずれかに記載の車両用シート。
- 前記クッション材は、ウレタンまたは綿であることを特徴とする請求項1から4のいずれかに記載の車両用シート。
- シートの座面部となるシートクッションと、
シートの背もたれ部となるシートバックと、
乗員の頭部および頸部を保護するヘッドレストと、を有する車両用シートであって、
前記シートクッションおよび前記シートバックのうち、少なくとも一方において、その表面に、表皮材、クッション材、ゴム材を含む生地により形成されたカバーを備え、
前記カバーはステッチ加工によりその表面に複数の凹凸が形成されていることを特徴とする車両用シート。 - 前記カバーは、前記複数の凹凸により、その表面に立体的な模様が施されていることを特徴とする請求項6に記載の車両用シート。
- 前記表面の立体的な模様は幾何学模様であることを特徴とする請求項7に記載の車両用シート。
- 前記クッション材は、ウレタンまたは綿により形成されていることを特徴とする請求項6から8のいずれかに記載の車両用シート。
- 以下の工程を含む車両用シートの製造方法
(a)少なくとも、表皮材、クッション材、熱収縮材の三層を重ね合わせて積層の生地を作る工程、
(b)前記積層の生地にパターンステッチ処理を行う工程、
(c)前記積層の生地に熱処理を施す工程。 - 前記(b)工程および前記(c)工程の間に、以下の工程を有する請求項10に記載の車両用シートの製造方法
(d)前記積層の生地と、前記積層の生地と異なる生地とを縫合することにより前記車両用シートのトリムカバーを形成する工程。 - 前記(c)工程の後、以下の工程を有する請求項10に記載の車両用シートの製造方法
(d)前記積層の生地と、前記積層の生地と異なる生地とを縫合することにより前記車両用シートのトリムカバーを形成する工程。 - 前記熱収縮材は、ポリエステル素材であることを特徴とする請求項10から12のいずれかに記載の車両用シートの製造方法。
- 前記クッション材は、ウレタンまたは綿であることを特徴とする請求項10から13のいずれかに記載の車両用シートの製造方法。
- 以下の工程を含む車両用シートの製造方法
(a)少なくとも、表皮材、クッション材、ゴム材の三層を重ね合わせて積層の生地を作る工程、
(b)前記ゴム材を機械的に伸長した状態で、前記積層の生地にパターンステッチ処理を行う工程、
(c)前記ゴム材の伸長を解放する工程。 - 前記クッション材は、ウレタンまたは綿であることを特徴とする請求項15に記載の車両用シートの製造方法。
- シートの座面部となるシートクッションおよびシートの背もたれ部となるシートバックのうち、少なくとも一方において、前記積層の生地を用いることを特徴とする請求項10から16のいずれかに記載の車両用シートの製造方法。
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US15/112,190 US10414305B2 (en) | 2014-01-31 | 2014-09-10 | Vehicle seat and method of manufacturing vehicle seat |
KR1020167020853A KR20160124090A (ko) | 2014-01-31 | 2014-09-10 | 차량용 시트 및 차량용 시트의 제조 방법 |
EP14880472.7A EP3100905A4 (en) | 2014-01-31 | 2014-09-10 | Vehicle seat and method of manufacturing vehicle seat |
CN201480074452.2A CN105939891A (zh) | 2014-01-31 | 2014-09-10 | 车辆用座椅及车辆用座椅的制造方法 |
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JP2014016951A JP2015143067A (ja) | 2014-01-31 | 2014-01-31 | 車両用シートおよび車両用シートの製造方法 |
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US20160368405A1 (en) | 2016-12-22 |
EP3100905A4 (en) | 2017-09-27 |
US10414305B2 (en) | 2019-09-17 |
KR20160124090A (ko) | 2016-10-26 |
JP2015143067A (ja) | 2015-08-06 |
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CN105939891A (zh) | 2016-09-14 |
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