WO2013030666A2

WO2013030666A2 - Seat backboard, vehicle seat provided with this seat backboard, and attaching structure for vehicle interior component

Info

Publication number: WO2013030666A2
Application number: PCT/IB2012/001938
Authority: WO
Inventors: Shinji Awata; Hisaya Mori
Original assignee: Toyota Jidosha Kabushiki Kaisha
Priority date: 2011-08-29
Filing date: 2012-08-29
Publication date: 2013-03-07
Also published as: JP2013047076A; WO2013030666A8; JP5387635B2; WO2013030666A3

Abstract

A seat backboard includes a backboard portion and a lower panel portion. The backboard portion is formed by a resin plate, and is arranged on a back surface side of a seat back frame and fixed to the seat back frame; The lower panel portion is provided built-in, or integrally provided, on a lower edge side of the backboard portion, and has an engagable portion with which a lower terminal portion of a cover that covers a surface of a seat back pad engages.

Description

SEAT BACKBOARD, VEHICLE SEAT PROVIDED WITH THIS SEAT

BACKBOARD, AND ATTACHING STRUCTURE FOR VEHICLE INTERIOR

COMPONENT

· BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] The invention relates to a seat backboard, a vehicle seat provided with this seat backboard, and an attaching structure for vehicle interior component.

2. Description of Related Art

[0002] A terminal (i.e., an end) of a seat back cover is typically fixed by a hog ring to a hanging wire provided on a seat back frame. However, with a fixation structure that uses a hog ring, the number of parts is very large and the work involved is also troublesome, which leads to an increase in cost.

[0003] Taking this into account, Japanese Patent Application Publication No. 08-323073 (JP 08-323073 A) describes a structure in which a terminal of a seat back cover is fixed using a seat backboard. In brief, with this related art, resin hooks are sewn onto three peripheral edge portions other than a lower edge portion of an open peripheral edge portion of a bag-shaped cover that is open on a back surface side. In addition, flanges that are bent toward a vehicle front side are formed on three peripheral edge portions other than the lower edge portion of the seat backboard. Then after the hooks are fastened to the flanges, the seat backboard is fitted from the back surface of a seat back pad and fixed to a seat back frame.

[0004] However, with this related art, it is necessary to form the flanges that are bent toward the vehicle front side on the three peripheral edge portions other than the lower edge portion of the seat backboard in order to fasten the hooks. Therefore, not only must the shape of the seat backboard be drastically changed, but wasted portions are created, which leads to an increase in cost.

SUMMARY OF THE INVENTION

[0005] The invention thus provides a seat backboard in which the cost necessary to fix a cover is able to be reduced, a vehicle seat provided with this seat backboard, and an attaching structure for vehicle interior component.

[0006] A first aspect of the invention relates to a seat backboard that includes a backboard portion and a lower panel portion. The backboard portion is formed by a resin plate, and is arranged on a back surface side of a seat back frame and fixed to the seat back frame. The lower panel portion is provided built-in, or integrally provided, on a lower edge side of the backboard portion, and has an engagable portion with which a lower terminal portion of a cover that covers a surface of a seat back pad engages.

[0007] According to this seat backboard, the lower panel portion that has the engagable portion is provided built-in, or integrally provided, on a lower edge side of the backboard portion of the seat backboard. A lower terminal portion of a cover that covers a surface of a seat back pad engages with the engagable portion of this lower panel portion, and as a result, the lower terminal portion of the cover is fixed to the seat backboard.

[0008] In this way, with the seat backboard described above, the lower panel portion that has the engagable portion is provided built-in, or integrally provided, on a lower edge side of the backboard portion, and the lower terminal portion of the cover engages with this engagable portion. Thus, there is no need for the retaining structure of the related art that uses a wire and a hog ring. Therefore, the number of parts is able to be reduced compared with the retaining structure of the related art. Furthermore, the lower panel portion that has the engagable portion need only be built-in or integrally provided on the lower edge side of the backboard portion, so it is not necessary to drastically change the shape of the seat backboard, and wasted portions also less apt to be produced.

[0009] As described above, the seat backboard according to the first aspect of the invention has a beneficial effect in which the cost necessary to fix the cover is able to be reduced.

[0010] In the seat backboard according to the mode of the invention described above, the seat back frame may include a pair of left and right side frames, and each side portion of the backboard portion may be supported on a front side of the corresponding side frame.

[0011] According to this seat backboard, each side portion of the backboard portion is supported on a front side of the corresponding left or right side frame, so the support rigidity of the backboard portion itself is also increased. Therefore, it is not necessary to employ a structure in which a lower panel extends between the lower end portions of the left and right side frames, and the lower terminal portion of the cover is engaged with the lower panel. Rigidity is still able to be ensured if the lower terminal portion of the cover is directly engaged with the backboard portion. Therefore, the lower panel of the seat back frame may also be omitted.

[0012] The seat backboard according to this mode of the invention has a beneficial effect in which the weight of the seat back frame, and thus the weight of the vehicle seat, is able to be reduced.

[0013] In the seat backboard according to the mode of the invention described above, the lower panel portion may be formed built-into and continuous with the lower edge of the backboard portion, and form a portion of the backboard portion.

[0014] With the seat backboard described above, the lower panel portion is formed built-into and continuous with the lower edge of the backboard portion, and forms a portion of the backboard portion. Therefore, the manufacturing cost is able to be less than when the lower panel portion is formed separately from the backboard portion, and the two are thermally welded together.

[0015] The seat backboard according to this mode of the invention has a beneficial effect in which the cost is able to be even further reduced.

[0016] In the seat backboard according to the mode of the invention described above, the engagable portion may be a peripheral edge portion of an opening formed in the lower panel portion, and a hook that is attached to the lower terminal portion of the cover may engage with the peripheral edge portion of the opening.

[0017] According to this seat backboard, a structure is employed in which an opening is formed in the lower panel portion, a hook is attached to the lower terminal portion of the cover, and this hook engages with the peripheral edge portion of the opening. Therefore, appropriate tension is able to be applied to the cover by a simple structure.

[0018] The seat backboard according to this mode of the invention has a beneficial effect in which wrinkles are able to be inhibited from forming in the cover.

[0019] In the seat backboard according to the mode of the invention described above, the opening may be a long hole that is long in a seat width direction, and the hook may be formed in a long shape in the seat width direction in a range within which the hook is able to engage with the long hole.

[0020] According to this seat backboard, the lower terminal portion of the cover is able to be drawn in at a long segment corresponding to the width of the hook, by the long-shaped hook being engaged with the peripheral edge portion of the long hole that is long in the seat width direction.

[0021] The seat backboard according to this mode of the invention has a beneficial effect in which the design lines of the cover can be accurately reproduced.

[0022] In the seat backboard according to the mode of the invention described above, an upper end portion of a carpet that covers a lower end portion of a seat back from a vehicle rear side may be fixed to the backboard portion at a position above the opening in the backboard portion.

[0023] According to this seat backboard, the upper end portion of the carpet is fixed to the backboard portion at a position above the opening in the backboard portion, and the lower end portion of the seat back is covered from the vehicle rear side by this carpet. Therefore, the attaching portion of the lower terminal portion of the cover is not exposed inside the vehicle cabin.

[0024] The seat backboard according to this mode of the invention has a beneficial effect in which the external appearance quality of the lower end portion of the vehicle seat is able to be improved.

[0025] In the seat backboard according to the mode of the invention described above, the carpet may include an extending portion that extends upward in a seat height direction, and a folded-back portion that is folded back downward in the seat height direction from an upper end of the extending portion and is fixed to the backboard portion. Further, the seat backboard according to the mode of the invention described above may also include a protruding portion in the backboard portion, that is formed in a position adjacent to an upper end of the folded-back portion, and that protrudes toward a seat rear side so as to be continuous with the folded-back portion.

[0026] According to this seat backboard, the folded-back portion of the carpet that is folded back from the upper end of the extending portion is fixed to the backboard portion. Therefore, the fixing portion where the carpet is fixed to the backboard portion is not exposed inside the vehicle cabin, but a step of the folded-back portion of the carpet is exposed on the lower portion side of the seat backboard. However, in this mode, the protruding portion is formed in the backboard portion and is formed continuous with the folded-back portion in a position adjacent to the upper end of the folded-back portion, so the step of the folded-back portion does not stand out.

[0027] The seat backboard according to this mode of the invention has a beneficial effect in which the external appearance quality of the lower end portion of the vehicle seat, including the carpet, is able to be improved.

[0028] A second aspect of the invention relates to a vehicle seat that may include a seat back frame; the seat backboard according to the mode described above, that is fixed to the seat back frame; a seat back pad that is arranged on a front surface side of the seat backboard; and a cover that covers a surface of the seat back pad.

[0029] According to this vehicle seat, the vehicle seat includes a seat back frame, a seat backboard, a seat back pad, and a cover. Of these, the seat backboard is the seat backboard according to any one of the modes described above, so the operation described above is able to be achieved in the vehicle seat. [0030] The vehicle seat according to the second aspect of the invention has a beneficial effect in which the cost necessary to fix the cover is able to be reduced.

[0031] A third aspect of the invention relates to an attaching structure for vehicle interior component that may include the vehicle seat described above, and a carpet that is attached to the vehicle seat.

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Features, advantages, and technical and industrial significance of exemplary embodiments of the invention will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:

FIG. 1 is an exploded perspective view of a seat back of a vehicle seat according to a first example embodiment of the invention;

FIG. 2 is a perspective view of a resin spring-integrated backboard assembled to a seat back frame shown in FIG. 1;

FIG. 3 is an enlarged top sectional view (i.e., an enlarged top sectional view taken along line III - III in FIG. 2) of the assembled state of the seat back shown in FIG. 1;

FIG. 4A is an enlarged longitudinal sectional view of the assembled state of the seat back shown in FIG. 1;

FIG. 4B is an enlarged view of main portions in FIG. 4A; and

FIG. 5 is a longitudinal sectional view corresponding to FIG. 4B of the main portions of a vehicle seat according to a second example embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

[0033] Hereinafter, a first example embodiment of a vehicle seat according to the invention will be described with reference to FIGS. 1 to 4. In the drawings, arrow FR denotes the front side of the vehicle, arrow UP denotes an upward direction with respect to the vehicle; and arrow IN denotes the inside in the vehicle width direction, as shown appropriately.

[0034] FIG. 1 is an exploded perspective view of a seat back that corresponds to a backrest of a vehicle seat according to the first example embodiment. In FIG. 1, the angles at which the various constituent elements are viewed are shown changed slightly. Also, FIG. 4A is a longitudinal sectional view of a vehicle seat provided with the seat back. As shown in these drawings, the vehicle seat 10 is formed by a seat cushion 11 (see FIG. 4A) upon which an occupant sits, a seat back 12, and a headrest, not shown. The seat back 12 is supported in a reclinable manner on a rear end portion of the seat cushion 11. The headrest is supported so as to be able to be raised and lowered on an upper end portion of the seat back 12.

[0035] As shown in FIG. 1, the seat back 12 is formed by a metal seat back frame 14, a seat backboard 16, a seat back pad 18, a cover 20, vertical attaching members 22, and a transverse attaching member 24. The seat back frame 14 forms a frame member of the seat back 12. The seat backboard 16 is attached to a front surface side of the seat back frame 14, and a resin spring is integrally provided with the seat backboard 16. The seat back pad 18 forms a cushion of the seat back 12 and is attached from the front of the seat backboard 16 so as to be supported by the seat back frame 14. The cover 20 covers mainly the front surface of the seat back pad 18. The vertical attaching members 22 and the transverse attaching member 24 are used to attach the cover 20 to the seat backboard 16. Hereinafter, each of the constituent elements will be described in detail..

[0036] As shown in FIGS. 1 to 4A, the seat back frame 14 is a rectangular frame when viewed from the front. The phrase "when viewed from the front" means when viewed from the front of the vehicle. Hereinafter, the orientation of the vehicle and the orientation of the vehicle seat 10 will be described as one and the same. More specifically, the seat back frame 14 is formed by a pair of left and right side frames 26, an upper frame 28, and a lower panel 30. The pair of left and right side frames 26 is arranged opposing one another in the vehicle width direction. The upper frame 28 has an inverted U-shape that connects upper end portions of the left and right side frames 26 together. The lower panel 30 connects lower end portions of the left and right side frames 26 together in the vehicle width direction. The seat back 12 is made by press-forming all of the four members, including the upper frame 28, but another frame structure may also be employed. For example, only the upper frame may be a pipe member that has been bent in an inverted U-shape, or the upper frame and the pair of left and right side frames may be formed by a single pipe member that has been bent in an inverted U-shape.

[0037] Next, the sectional structure of the left and right side frames 26 will be described. As shown in FIGS. 2 and 3, the side frames 26 each include a side wall portion 26A, a front wall portion 26B, and a rear wall portion 26C. Each side frame 26 is formed in a general L-shape when viewed individually in a top sectional view. When viewed as a left and right pair, the side frames 26 are formed in an open sectional shape in which the insides of the side frames 26 that face each other in the seat width direction in a top sectional view are open. The side wall portion 26A becomes on the whole narrower in width from a lower end portion toward an upper end portion thereof. Also, a plurality of mounting holes 32 (see FIG. 1) are formed vertically separated on a lower portion of the side wall portion 26A. The front wall portion 26B extends toward the inside in the seat width direction and slightly angled toward the rear via an arced surface from a front end of the side wall portion 26A. The rear wall portion 26C extends toward the inside in the seat width direction from a rear end of the side wall portion 26A, and a tip end portion of the rear wall portion 26C is bent at an angle toward the front of the vehicle. The width of the rear wall portion 26C is set to be sufficiently wider than the width of the front wall portion 26B. Also, a mounting hole 34 (see FIG. 1) is also formed on an upper portion side of the rear wall portion 26C.

[0038] Next, the structure of the seat backboard 16 that forms a main portion of the vehicle seat 10 according to the first example embodiment will be described in detail. As shown in FIGS. 1 to 4B, the seat backboard 16 includes a backboard portion 36 and a spring portion 38. The backboard portion 36 is formed by a resin plate member and arranged on a back surface side of the seat back frame 14. The spring portion 38 is made of resin and is built into the backboard portion 36. The spring portion 38 extends between the pair of left and right side frames 26 so as to be directly supported thereby. Moreover, the spring portion 38 is formed so as to be able to bendably deform, in response to a load applied toward the back of the seat back, in the direction in which the load is applied (i.e., toward the rear of the vehicle).

[0039] The backboard portion 36 includes a board main body 40 and a retaining portion 42 that has a U-shaped groove shape. The board main body 40 is formed slightly smaller than the seat back frame 14. The retaining portion 42 is integrally formed on an outer peripheral portion of the board main body 40. More specifically, the board main body 40 is formed slightly smaller than an inner peripheral edge of an open portion of the seat back frame 14 that is formed in a rectangular frame shape. When assembled to the seat back frame 14, the board main body 40 is arranged slightly toward the vehicle rear side, between tip end portions (inner end portions) of the rear wall portions 26C of the left and right side frames 26. Therefore, the board main body 40 is able to be assembled from the vehicle front side of the seat back frame 14 (see FIG. 3). The sectional shape of the retaining portion 42 is U-shaped with the vehicle rear side being open. This retaining portion 42 is used to retain an outer peripheral portion of the cover 20 that will be described later. The retaining portion 42 also serves to reinforce the plate-shaped board main body 40 and increase the surface rigidity of the entire backboard portion 36.

[0040] The spring portion 38 includes a lower spring portion 44 that is formed built-in on a lower portion side of the backboard portion 36, and an upper spring portion 46 that is formed built-in on an upper portion side of the backboard portion 36. The upper spring portion 46 is provided independently in a position separated by a predetermined distance in a seat back height direction from the lower spring portion 44.

[0041] The lower spring portion 44 includes three lower spring main body portions 48 as well as lower connecting portions 50. The three lower spring main body portions 48 are arranged parallel to each other in the seat width direction and arranged separate to each other in the seat back height direction. The lower connecting portions 50 are connected in the seat back height direction, one to each end portion 48B in the seat width direction (i.e., the length direction) of each of these three lower spring main body portions 48, and are also connected to the backboard portion 36, and are fixed to the side frames 26. The left and right lower connecting portions 50 correspond to both side portions of the backboard portion. Also, the number of lower spring main body portions 48 that form the lower spring portion 44 is arbitrary and may be changed appropriately according to the relationship between the lower spring portion 44 and the required cushion performance. Therefore, a single lower spring portion that is wide in the vertical direction may be provided, or conversely, a plurality, i.e., two or four or more, may be provided.

[0042] A top sectional shape of the lower spring main body portions 48 is wavy. A wavy portion 48A expands by a load being applied toward the backboard portion 36 side (i.e., the vehicle rear side) to the lower spring main body portions 48, and as a result, the wavy portion 48A bendably deforms (elastically deforms) toward the backboard portion 36 side that is the direction in which the load is applied. Vertical resin pawl portions 58, that will be described later, for attaching the cover 20 are formed built-in near both end portions 48B in the seat width direction of the upper, middle, and lower lower spring main body portions 48. The vertical resin pawl portions 58 extend in the seat height direction. The wavy portion 48A is not formed in the areas where the vertical resin pawl portions 58 are formed on these lower spring main body portions 48.

[0043] As shown in FIG. 3, the backboard portion 36 described above is arranged in a position separated by a predetermined distance to the vehicle rear side from the lower spring portion 44. That is, a predetermined gap 52 is formed between the lower spring portion 44 and the backboard portion 36. The lower spring main body portions ^*48 are able to elastically deform within the area of this gap 52. In other words, the backboard portion 36 also serves as a restricting member that restricts the bending amount of the lower spring portion 44 to a predetermined amount or less. ,

[0044] The lower connecting portions 50 are formed having generally inverted U-shapes in a top sectional view. Each lower connecting portion 50 includes an inside wall 50A, an outside wall 50B, a front wall 50C, and a rear wall 50D. The end portion 48B in the seat width direction of the lower spring main body portion 48 is connected to the inside wall 50A. The outside wall 50B is parallel to the inside wall 50A, and is retained in a state surface-contacting an outside surface of the side wall portion 26A of the side frame 26. The front wall 50C connects a front end of the inside wall 50A with a front end of the outside wall 50B in the vehicle width direction, and is supported in a state partially surface-contacting the front wall portion 26B of the side frame 26. The rear wall 50D is parallel to the end portion 48B in the seat width direction of the lower spring main body portion 48, and is a portion that connects to the backboard portion 36 from a rear end portion of the inside wall 50A.

[0045] Both end portions 48B in the seat width direction of each of the three lower spring main body portions 48 described above are formed as flat portions where the wavy portion 48A is not formed. Each end portion 48B of the lower spring main body portions 48 is connected to the corresponding one of the pair of left and right lower connecting portions 50. That is, a plurality of the lower spring main body portions 48 are provided in the seat back height direction, and each end portion 48B in the seat width direction of these lower spring main body portions 48 is connected to the corresponding one of the pair of left and right lower connecting portions 50, such that the lower spring portion 44 is integrated with the backboard portion 36. The longitudinal dimension of the lower connecting portions 50 is set to include an area from an upper edge of the highest lower spring main body portion 48 to a lower edge of the lowest lower spring main body portion 48.

[0046] The outside wall 50B of the lower connecting portion 50 is fixed to the side frame 26 by being fixed from the outside in the seat width direction by fixing means, not shown, to the mounting holes 32 of the side wall portion 26A of the side frame 26. As the fixing means, any of various modes may be applied, such as a structure in which resin clips are formed built-in on the outside wall 50B and engage , with the mounting holes 32, a structure that fastens with a fastener such as a rivet, and a screw, or bolt and a weld nut, or a structure that adheres with a structural adhesive or the like. When the lower connecting portion 50 is fixed to the side frame 26, the rear wall 50D is also arranged parallel to the rear wall portion 26C of the side frame 26. As a result, the end portions 48B in the seat width direction of the lower spring main body portions 48 are arranged inserted into sectional inner portion of the side frame 26.

[0047] The upper spring portion 46 has basically the same structure as the lower spring portion 44. More specifically, the upper spring portion 46 includes an upper spring main body portion 54 and upper connecting portions 56. Also, a wavy portion 54A is formed, so as to expand and bendably deform (elastically deform) when a load is applied toward the backboard portion 36 side (i.e., the vehicle rear side), on the upper spring main body portion 54. Furthermore, a vertical resin pawl portion 58 is formed built-in on both end portions 54B in the seat width direction of the upper spring main body portion 54. Moreover, a transverse resin pawl portion 60 that extend in the seat width direction is integrally formed on a center portion 54C and on both end portions 54B in the seat width direction of the upper spring main body portion 54. Also, the upper connecting portions 56 have shapes that extend out toward the outside in the seat width direction, and are set to longitudinal dimensions that fit between the side wall portions 26A of the left and right side frames 26 described above. Also, the upper connecting portions 56 are fixed to the side frames 26 by being fixed in the seat front-back direction by fixing means, not shown, to the mounting holes 34 in the rear wall portions 26C.

[0048] In this example embodiment the spring portion 38 is divided into the lower spring portion 44 and the upper spring portion 46 as described above, but the invention is not limited to this. That is, both of these may be connected and integrated together. That is, a structure in which the lower connecting portions 50 extend toward the seat back upper side and are connected to both end portions in the seat width direction of the upper spring main body portion 54 may also be employed.

[0049] Also in this example embodiment, only one upper spring portion 46 is provided, but the invention is not limited to this. That is, a plurality of the upper spring portions 46 may also be provided, or a structure in which a plurality of spring portions are provided at equidistant intervals from the upper portion to the lower portion of the backboard portion 36 may be employed. [0050] As shown in FIG. 1, the seat back pad 18 is mainly formed by a pad center upper portion 62, a pad center lower portion 64, and a pair of left and right pad side portions 66. The seat back pad 18 is made of urethane foam or the like.

[0051] As shown in FIG. 4A, the longitudinal sectional shape of the pad center upper portion 62 is formed in a general J-shape that is upside down and left-right reversed. This pad center upper portion 62 is engaged from the seat back upper side with the upper frame 28 of the seat back frame 14. The longitudinal sectional shape of the pad center lower portion 64 is formed in a general J-shape that is left-right reversed. Also, a lower portion of the pad center lower portion 64 has a shape that bulges out in a shape that curves outward toward the front of the vehicle from an upper portion of the pad center lower portion 64. This pad center lower portion 64 is engaged from the seat back lower side with a connecting rod 68 that connects lower end portions of the side frames 26 together in the seat width direction. The connecting rod 68 is arranged parallel to a front side of the lower panel 30 of the seat back frame 14.

[0052] Also^", as shown in FIG. 3, the transverse sectional shape of each pad side portion 66 is formed in a general C-shape. This pad side portion 66 is attached so as to wrap around the side frame 26 with the lower connecting portion 50 attached. A lower portion of the pad side portion 66 forms a shape that bulges out in a shape that curves outward toward the front of the vehicle from an upper portion of each pad side portion 66. The pad side portions 66 bulge out toward the front of the vehicle more than the pad center upper portion 62 and the pad center lower portion 64 do, and are shaped to ensure side supportability with respect to an occupant.

[0053] Returning to FIG. 4 A, the seat backboard 16 described above is arranged extending from a back surface side lower end portion 62A of the pad center upper portion 62 to a back surface side upper, end portion 64A of the pad center lower portion 64. More accurately, the back surface side upper end portion 64A of the pad center lower portion 64 is formed thinner than the back surface side lower end portion 62A, and a lower end portion of the backboard portion 36 is arranged overlapping in the front-back direction with the thin portion. [0054] Also, a transverse slit 70 that extends in the seat back width direction is formed, as a through-groove for pulling the cover over, between the pad center upper portion 62 and the pad center lower portion 64 described above. Further, a pair of left and right vertical slits 72 is formed, as through-grooves for pulling the cover over, one between the pad center upper portion 62 and the pad center lower portion 64, and one pad side portion 66, and the other between the pad center upper portion 62 and the pad center lower portion 64, and the other pad side portion 66. The slit widths of the transverse slit 70 and the vertical slits 72 are set to lengths that enable the vertical attaching members 22 and the transverse attaching member 24 that will be described later to be inserted. Also, the transverse slit 70 and the vertical slits 72 are all formed linearly and pass through the seat back pad 18 in the thickness direction of the seat back pad 18 (i.e., in the longitudinal direction of the vehicle).

[0055] As shown in FIG. 1, the cover 20 is formed large enough to be able to cover the seat back pad 18 from the front of the seat back pad 18. Also, the cover 20 includes a cover center upper portion 74, a cover center lower portion 76, and a pair of left and right cover side portions 78, matching the split construction of the seat back pad 18 described above.

[0056] The entire cover 20 is attached by the vertical attaching members 22, the transverse attaching member 24, the vertical resin pawl portions 58, the transverse resin pawl portions 60, and an outer peripheral retaining portion 80 and the like.

[0057] As shown in FIG. 1, each of the vertical attaching members 22 includes an attaching member main body 22A that is formed in a band-shape, and a resin engaging portion 22B. The engaging portion 22B is provided on one side edge of the attaching member main body 22A and is formed in a wedge-shape. The other side edge of the attaching member main body 22A is attached in advance to the cover center upper portion , 74, the cover center lower portion 76, and the cover side portions 78 by sewing. In FIG. 1, the vertical attaching members 22 and the transverse attaching member 24 are shown separated from the cover 20, but the vertical attaching members 22 and the transverse attaching member 24 are attached to the cover 20 in advance. Corresponding to this, the vertical resin pawl portions 58 are formed built-in farther to the outside on both sides in the seat width direction of the wavy portions 48A of the lower spring main body portions 48. The engaging portions 22B of the vertical attaching members 22 are able to elastically engage with the vertical resin pawl portions 58. Also, the center portion of the cover 20 is attached to the seat backboard 16 in the vertical direction by elastically engaging the engaging portions 22B of the pair of left and right vertical attaching members 22 with the corresponding vertical resin pawl portions 58 of the lower spring main body portions 48.

[0058] Similarly, the transverse attaching member 24 includes an attaching member main body 24A that is formed in a band-shape, and a resin engaging portion 24B. The engaging portion 24B is provided on one side edge of the attaching member main body 24A and is formed in a wedge-shape. The other side edge of the attaching member main body 24A is attached in advance to the cover center upper portion 74 and the cover center lower portion 76 by sewing. Corresponding to this, the transverse resin pawl portions 60 are formed built-in in a center portion in the seat width direction and in two outer locations, one on each side. The engaging portion 24B of the transverse attaching member 24 is able to elastically engage with the transverse resin pawl portions 60. Also, the center portion of the cover 20 is attached to the seat backboard 16 in the transverse direction by elastically engaging the engaging portion 24B of the transverse attaching member 24, that is provided in three locations, with the transverse resin pawl portions 60 of the uppermost lower spring main body portion 48.

[0059] Further, the outer peripheral retaining portion 80 that is arrowhead-shaped is attached by sewing to an appropriate position on an outer peripheral portion of the cover 20. The outer peripheral retaining portion 80 is retained by being inserted from the vehicle rear side into the retaining portion 42 of the backboard portion 36. As a result, the outer peripheral portion of the cover 20 is engaged in a removable manner with the backboard portion 36.

[0060] Next, the lower portion attaching structure of the cover 20 that is a main portion of this example embodiment will be described in detail. As shown in FIGS. 1 and 2 and 4A and 4B, a lower panel portion 100 is formed built-in on a lower edge side of the board main body 40 of the backboard portion 36 of the seat backboard 16 described above. In addition, a plurality of long holes 102 are formed in the lower panel portion 100. That is, ordinarily, a lower end portion of the board main body 40 is positioned above the position shown in FIG. 2, but in this example embodiment, the lower end portion of the board main body 40 is extended by a predetermined length so that it is lower than normal, and this portion is the lower panel portion 100. Therefore, the lower panel portion 100 is an element that may be understood to be a plate that extends in the seat width direction. Accordingly, the lower panel portion 100 may be formed built-into and continuous with a lower edge of the board main body 40 as in this example embodiment, or the backboard portion may be formed built-into, but away from, the lower edge of the board main body 40. Moreover, the lower panel portion and the board main body 40 may be made as separate parts and then integrated by thermal welding. The meaning of the phrase "...integrally provided, on a lower edge side of the backboard portion" also includes this type of structure.

[0061] Also, the long holes 102 are formed as long openings in the seat width direction. The plurality of long holes 102 (three in this example embodiment) are arranged in a straight line in the seat width direction.

[0062] Meanwhile, as shown in FIG. 4B, a lower band 104 that serves as a lower terminal portion of the cover is sewn to a lower end portion of the cover center lower portion 76 described above. More specifically, the lower band 104 is formed in a band-shape, and is arranged adjacent to the lower end portion of the cover center lower portion 76 such that the seat width direction becomes the length direction. Also, a lower end portion 104A of the lower band 104 is sewn to the lower end portion of the cover center lower portion 76. Base end portions 106A of-resin hooks 106, each of which is formed in a J-shape when viewed from the side of the seat, are attached by sewing to an upper end portion 104B of the lower band 104. The hooks 106 are formed in long shapes in the seat width direction. The length dimension of the hooks 106 is set to be slightly shorter than the length dimension of the long holes 102. Also, tip end portions 106B of the hooks 106 are inserted into the long holes 102 from the back surface side of the lower panel portion 100 and engaged with peripheral edge portions 108 that serve as engagable portions. That is, the width dimension of the lower band 104 (i.e., the dimension in the vertical direction of the seat in FIG. 4B) is set to a length whereby the lower end portion of the cover center lower portion 76 can be connected to the peripheral edge portions 108 of the long holes 102 in the lower panel portion 100 via the hooks 106. Also, when the tip end portions 106B of the hooks 106 are engaged with the peripheral edge portions 108 of the long holes 102, the tip end portions 106B abut in line contact against inner peripheral surfaces of the long holes 102.

[0063] Also, a carpet 110 that covers a lower end portion of the seat back 12 from the vehicle rear side is arranged on the seat rear side of the lower panel portion 100 described above. The vehicle seat 10 and the carpet 110 that is attached to the vehicle seat 10 are included in vehicle interior component. As shown in FIG. 4B, the carpet 110 includes an extending portion 110A and a folded-back portion HOB. The extending portion 110A extends upward in the seat height direction. The folded-back portion HOB folds back downward in the seat height direction from an upper end of the extending portion 110A. The folded-back portion HOB is fixed using clips 112 and spacers 114 to the board main body 40 at a position above the long holes 102 in the board main body 40. Also, a lower end portion of the extending portion 110 A is retained below the seat cushion 11.

[0064] Next, the operation and effects of this example embodiment will be described.

[0065] The vehicle seat 10 having the structure described above is provided with the seat backboard 16 in which the resin spring portion 38 is formed built-into the resin backboard portion 36. Also, this seat backboard 16 is fitted from the vehicle front side to the metal seat back frame 14. More specifically, the left and right lower connecting portions 50 are fitted from the vehicle front side to the left and right side frames 26, and in this state, the outside walls 50B of the lower connecting portions 50 are fixed from the outside in the seat width direction to the side frames 26. Then, the seat back pad 18 is attached from the vehicle front side to the seat back frame 14, and the cover 20 is put over the seat back pad 18. The vertical attaching members 22 and the transverse attaching member 24 are fixed by sewing to the cover 20 in advance, and while covering the seat back pad 18 with the cover 20, are inserted into the vertical slits 72 and the transverse slit 70 that correspond to the vertical attaching members 22 and the transverse attaching member 24, respectively, and fixed to the vertical resin pawl portions 58 and the transverse resin pawl portions 60, respectively. Further, the outer peripheral retaining portion 80 of the cover 20 is engaged with the retaining portion 42 of the backboard portion 36, and the hooks 106 that are attached to the lower band 104 engage with the peripheral edge portions 108 of the long holes 102 in the lower panel portion 100. Then, the folded-back portion HOB of the carpet 110 attaches to the board main body 40 using the clips 112 and the spacers 114.

[0066] The seat cushion 11 and the headrest, not shown, are attached to the seat back 12 that is assembled as described above to obtain the vehicle seat 10. When an occupant sits in the vehicle seat 10, a load toward the seat back rear side is input to the spring portion 38 via the cover 20 and the seat back pad 18. Therefore, the lower spring main body portions 48 and the upper spring main body portion 54 bendably deform toward the seat back rear side that is the direction in which the load is applied. Also, the load at this time is transmitted to the left and right side frames 26 by the lower connecting portions 50, so reaction force toward the vehicle front side is generated by the side frames 26.

[0067] When a load is input to the spring portion 38 from an occupant in this way, the spring portion 38 bendably deforms, which contributes to ensuring the cushion performance of the seat back 12, and the load itself is transmitted to the left and right side frames 26 and supported . by the left and right side frames 26. As a result, cushion performance of the seat back 12 is sufficiently ensured. Also, the spring portion 38 is made of resin and provided built-into the backboard portion 36, so the number of parts and the number of assembly processes are able to be reduced compared with a case in which the spring portion 38 is formed by a metal seat back spring. As a result, according to this example embodiment, cushion performance of the seat back 12 is able to be sufficiently ensured, and moreover, both weight and cost are able to be reduced.

[0068] Here, in this example embodiment, the lower panel portion 100 in which the long holes 102 are formed is formed built-in on the lower edge side of the backboard portion 36 of the seat backboard 16, and the lower band 104 to which the hooks 106 are attached is sewn to the lower end portion of the cover center lower portion 76. Therefore, the lower terminal portion (i.e., the lower band 104) of the cover 20 is able to be fixed to the lower end portion of the seat backboard 16 when the hooks 106 are engaged with the peripheral edge portions 108 of the long holes 102. This obviates the need for the retaining structure of the related art that uses a wire and a hog ring. Accordingly, the number of parts is able to be reduced compared with the retaining structure of the related art. Furthermore, the lower panel portion 100 in which the long holes 102 are formed need only be provided built-in on the lower edge side of the backboard portion 36,_. so it is not necessary to drastically change the shape of the seat backboard 16, and wasted portions are less apt to be produced. As a result, according to this example embodiment, the cost necessary to fix the cover is able to be reduced.

[0069] Also, in this example embodiment, the left and right lower connecting portions 50 that correspond to both side portions of the backboard portion 36 are supported on the front side of the left and right side frames 26, so support rigidity of the backboard portion 36 itself is also increased. Therefore, with the related art, a structure is employed in which the lower panel extends between the lower end portions of the left and right side frames, and the lower terminal portion of the cover is retained by the lower panel. However, rigidity is still able to be ensured if the lower band 104 of the cover 20 is directly retained by the backboard portion 36. Therefore, the lower frame (i.e., the lower panel) 30 of the seat back frame 14 is also able to be omitted, so the weight the seat back frame 14, and thus the weight of the vehicle seat 10, is able to be reduced.

[0070] Moreover, in this example embodiment, the lower panel portion 100 is formed built-into and continuous with the lower edge of the backboard portion 36, and forms a portion of the backboard portion 36. Therefore, the manufacturing cost is able to be less than when the lower panel portion 100 is formed separately from the backboard portion 36, and the two are thermally welded together. As a result, the cost is able to be even further reduced.

[0071] Also, in this example embodiment, the long holes 102 are formed in the lower panel portion 100, and the hooks 106 are attached to the upper end portion 104B of the lower band 104 that forms the lower terminal portion of the cover 20. Also, a structure is employed in which the tip end portions 106B of these hooks 106 engage with the peripheral edge portions 108 of the long holes 102. Therefore, appropriate tension is able to be applied to the cover 20 by a simple structure. As a result, wrinkles are able to be inhibited from forming in the cover 20.

[0072] Furthermore, in this example embodiment, the lower band 104 of the cover 20 is drawn in at long segments corresponding to the widths of the hooks 106, by the long hooks 106 being engaged with the peripheral edge portions 108 of the long holes 102 that are long in the seat width direction. As a result, the design lines of the cover 20 can be accurately reproduced.

[0073] Also, in this example embodiment, the folded-back portion HOB of the carpet 110 is fixed to the backboard portion 36 at a position above the long holes 102 in the backboard portion 36, and the lower end portion of the seat back 12 is covered from the vehicle rear side by this carpet 110. Therefore, the attaching portion of the lower band 104 is not exposed inside the vehicle cabin. Thus, the external appearance quality of the lower end portion of the seat back 12 of the vehicle seat 10 is able to be improved.

[0074] Next, a second example embodiment of the vehicle seat according to the invention will be described with reference to FIG. 5. Component parts that are the same as those in the first example embodiment described above will be denoted by the same reference characters and descriptions of those parts will be omitted.._..

[0075] As shown in FIG. 5, this second example embodiment is characteristic in that a protruding portion 120 is formed built-into a lower portion (in a position adjacent to the upper end of the folded-back portion HOB) of the board main body 40 of the backboard portion 36. The longitudinal sectional shape of the protruding portion 120 is a generally right-angled triangular shape, and the protruding portion 120 includes a lower surface 120A and an inclined surface 120B. Also, the protruding portion 120 is formed parallel to the long holes 102, and is formed across the entire length in the width direction of the board main body 40. Furthermore, the protruding height of the protruding portion 120 is set to substantially match the height of the folded-back portion HOB of the carpet 110. The inclined surface 120B is formed so as to be continuous with a surface on the seat rear side of the folded-back portion HOB.

[0076] With this structure as well, operation and effects similar to those of the first example embodiment described above are able to be obtained. In addition, with this example embodiment, the operation and effects described below are able to be obtained. That is, as described above, the carpet 110 is fixed to the seat backboard 16 by the folded-back portion HOB that is folded back from the upper end of the extending portion HOA being fixed to the backboard portion 36. Therefore, the fixing portion where the carpet 110 is fixed to the backboard portion 36 is not exposed inside the vehicle cabin, but a step of the folded-back portion HOB of the carpet 110 is exposed on the lower portion side of the seat backboard 16. However, in this example embodiment, the protruding portion 120 is formed continuous with the folded-back portion HOB in a position adjacent to the upper end of the folded-back portion HOB of the backboard portion 36, so the step of the folded-back portion 110B does not stand out. As a result, with this example embodiment, the external appearance quality of the lower end portion of the vehicle seat 10, including the carpet 110, is able to be improved.

[0077] In the example embodiment described above, the resin spring portion 38 is formed built-into the resin backboard portion 36, but the invention is not limited to this. That is, the resin spring portion may be integrally provided with the resin backboard portion. That is, the back support portion-and the spring portion may be made separately, and then the two may be integrated together by welding or the like. Furthermore, the spring main body portion that forms the spring portion and a connecting portion may be made as separate parts and then integrated together by welding or the like. In addition, in the example embodiment described above, the connecting portions 50 are described as constituent elements of the spring portion 38, but the connecting portions 50 may also be construed without any problem whatsoever as constituent elements of the backboard portion 36. This is because when the seat backboard is a finished product, it simply is a matter of whether the constituent elements that are the connecting portions are categorized as being included in the spring portion or included the backboard portion.

[0078] Also, in the example embodiment described above, a structure is employed in which the long holes 102 are formed in the lower panel portion 100 and the hooks 106 are attached to the lower band 104, but the invention is not limited to this. That is, other structures may also be employed. For example, hook-shaped portions may be set on the lower panel portion, long holes may be formed in the lower band, and the long holes may engage with hook portions of the hook-shaped portions. Also, the hooks do not have to be formed in long shapes that follow the long holes, and each hook may also be divided into a plurality of individual hooks.

[0079] Furthermore, in the example embodiment described above, the backboard portion 36 is supported on the front side of the side frames 26, but the invention also includes a structure in which the backboard portion is not supported on the front side of the side frames.

[0080] In the example embodiment described above, the carpet 110 is provided, but the invention may also include a structure in which the carpet is omitted.

Claims

CLAIMS:

1. A seat backboard comprising:

a backboard portion that, is formed by a resin plate, and is arranged on a back surface side of a seat back frame and fixed to the seat back frame; and

a lower panel portion that is provided built-in, or integrally provided, on a lower edge side of the backboard portion, and has an engagable portion with which a lower terminal portion of a cover that covers a surface of a seat back pad engages.

2. The seat backboard according to claim 1, wherein the seat back frame includes a pair of left and right side frames; and each side portion of the backboard portion is supported on a front side of the corresponding side frame.

3. The seat backboard according to claim 1 or 2, wherein the lower panel portion is formed built-into and continuous with the lower edge of the backboard portion, and forms a portion of the backboard portion.

4. The seat backboard according to any one of claims 1 to 3, wherein the engagable portion is a peripheral edge portion of an opening formed in the lower panel portion, and a hook that is attached to the lower terminal portion of the cover engages with the peripheral edge portion of the opening.

5. The seat backboard according to claim 4, wherein the opening is a long hole that is long .in a seat width direction; and the hook is formed in a long shape in the se_.at width. direction in a range within which the hook is able to engage with the long hole.

6. The seat backboard according to claim 4 or 5, wherein an upper end portion of a carpet that covers a lower end portion of a seat back from a vehicle rear side is fixed to the backboard portion at a position above the opening in the backboard portion.

7. The seat backboard according to claim 6, wherein the carpet includes an extending portion that extends upward in a seat height direction, and a folded-back portion that is folded back downward in the seat height direction from an upper end of the extending portion and is fixed to the backboard portion,

the seat backboard further comprising:

a protruding portion in the backboard portion, that is formed in a position adjacent to an upper end of the folded-back portion, and that protrudes toward a seat rear side so as to be continuous with the folded-back portion.

8. A vehicle seat comprising:

a seat back frame;

the seat backboard according to any one of claims 1 to 7, the seat backboard being fixed to the seat back frame;

a seat back pad that is arranged on a front surface side of the seat backboard; and a cover that covers a surface of the seat back pad.

9. An attaching structure for vehicle interior component, comprising:

the vehicle seat according to claim 8, and

a carpet that attaches to the vehicle seat.