Vehicle seat

A vehicle seat includes: a pad including: a first pad part; a second pad part; a step portion formed along at least a part of the boundary; and a groove portion extending from the step portion into between the first and second pad parts over the whole length of the step portion; and a trim cover formed by sewing multiple skin pieces together, the skin pieces including: a first body configured to cover the surface of the first pad part following the surface of the step portion; a first gore configured to cover the surface of the step portion; a second body configured to cover the surface of the second pad part following the surface of the step portion; and a second gore jointed to the second body, wherein an edge of the first gore and an edge of the second gore are respectively stored in the groove portion.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2016-142522, filed on Jul. 20, 2016, the entire contents of which are incorporated herein by reference.

BACKGROUND

1. Field of the Invention

The invention relates to a vehicle seat.

2. Description of the Related Art

A vehicle seat typically includes a pad and a trim cover for covering the pad. The trim cover is formed by sewing multiple skin pieces. For example, a trim cover for covering a pad of a seat cushion includes, as the skin piece thereof, a body for covering the seat surface of the pad and a gore for covering the side surfaces of the pad (see, for example, JP-UM-A-S59-75351).

The gore is also applied to covering the surface of the step portion of the pad. A vehicle seat61shown inFIG. 8is a seat to be installed on the passenger seat side of the rear of a vehicle. A seat back63includes an auxiliary seat back63aformed integrally therewith which is to be interposed between the seat back63and a driver's seat side seat (not shown). In the auxiliary seat back63a, there is stored a pull-out type armrest65tiltable toward to the seat cushion side.

As shown inFIG. 9, a pad66of the seat back63includes a first pad part71and a second pad part72disposed adjacent to the first pad part72. The second pad part72constitutes a pad of the auxiliary seat back63a(seeFIG. 8), while the first pad part71constitutes a pad of the seat back63(seeFIG. 8) except for the auxiliary seat back63a. The first and second pads71and72are integrally formed. The upper end of the second pad part72is positioned lower than the upper end of the first pad part71and is formed concave with respect to the upper end of the first pad part71; and, a step portion73is formed along at least a part of the boundary between the upper ends of the first and second pad parts71and72.

A trim cover67of the vehicle seat61integrally covers the first and second pads71and72and includes, as the skin pieces thereof, a first body67afor covering the upper end face of the first pad part71following the surface of the step portion73, a second body67cfor covering the upper end face of the second pad part72following the surface of the step portion73, and a gore67bjointed to the first and second bodies67aand67cfor covering the surface of the step portion73.

In the vehicle seat61shown inFIGS. 8 and 9, a seam allowance68abetween the first body67aand gore67bof the trim cover67and a seam allowance68bbetween the second body67cand gore67care both brought down on the gore67bside and are superimposed on the surface of the step portion73.

The step height H of the step portion73is set, for example, according to a seat design. When the width of the seam allowances68aand68bwith respect to the step height H is excessively large, the seam allowances68aand68bare superimposed on each other on the surface of the step portion73. For example, supposing the width of the seam allowances68aand68bis typically set to 7˜8 mm in consideration of the workability or the like of sewing, when the step height H is 15 mm or less, the seam allowances68aand68bare superimposed on each other on the surface of the step portion73. When the seam allowances68aand68bare superimposed, there is a fear that wrinkles or sags can occur in the gore67bcovering the seam allowances68aand68b, thereby impairing the appearance of the vehicle seat61.

There is a limit to reducing the width of the seam allowances68aand68band, due to this, reduction of the step height H of the step portion73is also restricted, thereby restricting the design of the seat.

SUMMARY

The invention is made in view of the above circumstances and thus it is an object of the invention that, in a vehicle seat with a pad including a step portion, occurrence of wrinkles or sags in a trim cover for covering the step portion can be suppressed and also the freedom of the design of the seat can be enhanced.

According to an aspect of the invention, there is provided a vehicle seat including: a pad including: a first pad part; a second pad part arranged adjacent to the first pad part and formed concave with respect to the first pad part along at least a part of the boundary with the first pad; a step portion formed along at least a part of the boundary; and a groove portion extending from the step portion into between the first and second pad parts over the whole length of the step portion; and a trim cover configured to cover the pad integrally, the trim cover formed by sewing multiple skin pieces together, the skin pieces including: a first body configured to cover the surface of the first pad part following the surface of the step portion; a first gore, jointed to the first body, configured to cover the surface of the step portion; a second body configured to cover the surface of the second pad part following the surface of the step portion; and a second gore jointed to the second body, wherein an edge of the first gore and an edge of the second gore are respectively stored in the groove portion.

According to the invention, in a vehicle seat with a pad including a step portion, occurrence of wrinkles or sags in a trim cover for covering the step portion can be suppressed and also the freedom of the design of the seat can be enhanced.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1shows an example of a vehicle seat in order to explain a first embodiment of the invention.

A vehicle seat1shown inFIG. 1is a seat which is to be installed on the passenger side seat of the rear part of a vehicle and includes a seat cushion2constituting a seat surface part of the seat, a seat back3constituting a back rest part of the seat, and a headrest4for supporting the head of a passenger seated on the seat. The seat back3includes an auxiliary seat back3aformed integrally therewith to be interposed between the seat1and a seat (not shown) on the driver's seat side; and, in the auxiliary seat back3a, there is stored a pull-out type armrest5tillable toward the seat cushion2.

The seat cushion2, seat back3, headrest4and armrest5respectively include a pad formed of foam material such as urethane foam and a frame for supporting the pad. The respective pads of the seat cushion2, seat back3, headrest4and armrest5are covered by a trim cover.

The trim cover is formed by sewing multiple skin pieces together. As the skin piece, there is used, for example, leather (natural leather, synthetic leather) or cloth (woven fabric, knitted fabric, unwoven fabric). The skin piece may have a single layer structure of leather or cloth, or may have a multilayer structure in which leather or cloth is used as an outer layer and wadding (for example, resin foam such as elastically deformable flexible polyurethane foam) is laminated thereon. And, the trim cover may be formed of the same kind of skin pieces or may be formed of multiple kinds of skin pieces different depending on the locations of the trim cover.

FIG. 2shows the section of the upper end part of the seat back3.

A pad6of the seat back3includes a first pad part11and a second pad part12arranged adjacent to the first pad part11. The second pad part12constitutes a pad of the auxiliary seat back3a(seeFIG. 1), and the first pad part11constitutes a pad of the seat back3except for the auxiliary seat back3a. The first and second pads11and12are integrally formed.

The upper end of the second pad part12is situated lower than the upper end of the first pad part11and is formed convex with respect to the upper end of the first pad part11, while a step portion13is formed along at least a part of the boundary between the upper ends of the first and second pad parts11and12. And, in the pad6, there is formed a groove portion14which extends from the step portion13into between the first and second pad parts11and12in the vertical direction over the whole length of the step portion13.

The trim cover7for covering the pad6includes, as the skin pieces thereof, a first body7afor covering the upper end face of the first pad part11following the surface of the step portion13, a first gore7bjointed to the first body7afor covering the surface of the step portion13, a second body7cfor covering the upper end face of the second pad part12following the surface of the step portion13, and a second gore7djointed to the second body7c.

The respective edges of the first and second gores7band7dare sewn together in a superimposed state and are stored in the groove portion14of the pad6.

A seam allowance8aof the first body7aand first gore7bis brought down to the first gore7bside and is superimposed on the surface of the step portion13. A seam allowance8bof the second body7cand second gore7dis brought down to the second gore7dside but is inserted into the groove portion14. Thus, the seam allowance8bwill not be superimposed on the seam allowance8aon the surface of the step portion13.

Since the seam allowances8aand8bare not superimposed on each other on the surface of the step portion13, it is possible to suppress occurrence of wrinkles or sags in the first gore7bwhich is superimposed on the surface of the step portion13and appears on the external surface of the vehicle seat1. This makes it possible to suppress the deteriorated appearance of the vehicle seat1caused by such wrinkles or sags. And, the width of the seam allowances8aand8bcan be set properly in consideration of sewing workability etc. regardless of the size of the step height H of the step portion13. The above configuration can ease the constraints of the step height H of the step portion13, thereby enabling enhancement in the freedom of design of the vehicle seat1.

The above configuration of the pad6and trim cover7is particularly useful when the maximum value of the step height H of the step portion13is relatively small, for example, 15 mm or less.

FIGS. 3 and 4respectively shows modifications of the vehicle seat1.

In a modification shown inFIG. 3, the respective edges of the first and second gores7band7dof the trim cover7stored in the groove portion14of the pad6are sewn together integrally with a reinforcing member15. This configuration can enhance the rigidity of the first gore7bappearing on the external surface of the vehicle seat1, thereby enabling more positive suppression of wrinkles or sags in the first gore7b. The reinforcing member is not limited particularly but, for example, it may be a sheet member made of resin, or the end portion of leather or cloth forming the trim cover7.

Also, in a modification shown inFIG. 4, the respective edges of the first and second gores7band7dof the trim cover7stored in the groove portion14of the pad6are sewn together by multiple rows (in the illustrated example, two rows) of mutually parallel arranged seams16. This configuration can enhance the rigidity of the first gore7bappearing on the external surface of the vehicle seat1, thereby enabling more positive suppression of wrinkles or sags in the first gore7b.

FIG. 5is an explanatory view of a second embodiment of the vehicle seat of the invention.

A vehicle seat21shown inFIG. 5is a seat to be installed in the front part of a vehicle, and includes a seat cushion22, a seat back23and a headrest24. The seat cushion22, a seat back23and a headrest24respectively include a pad, while the respective pads of the seat cushion22, seat back23and headrest24are covered by a trim cover.

FIG. 6shows a section of the upper end part of the seat back23.

The pad26of the seat back23includes a first pad part31and a second pad part32arranged adjacent to the first pad part31. The first pad part31constitutes the pads of shoulder parts23a(seeFIG. 5) arranged on the two sides of the seat back23in the width direction, while the second part32is situated between the width-direction two sides shoulder parts23aand constitutes the pad of the central part23b(seeFIG. 5) on which the headrest24will be mounted. The first and second pad parts31and32are integrally formed.

The upper end of the second pad part32is situated lower than the upper end of the first pad part31and is formed convex with respect to the upper end of the first pad part31, while a step portion33is formed along at least a part of the boundary between the upper ends of the first and second pad parts31and32. And in the pad26, there is formed a groove portion34which extends from the step portion33into between the first and second pad parts31and32vertically along the whole length of the step portion33.

The trim cover27for covering the pad26includes, as the skin pieces thereof, a first body27afor covering the upper end face of the first pad part31following the surface of the step portion33, a first gore27bjointed to the first body27afor covering the surface of the step portion33, a second body27cfor covering the upper end face of the second pad part32following the surface of the step portion33, and a second gore27djointed to the second body27c.

The respective edges of the first and second gores27band27dare sewn together in a superimposed state and are stored in the groove portion34of the pad26.

A seam allowance28aof the first body27aand first gore27bis brought down to the first gore7bside and is superimposed on the surface of the step portion33. A seam allowance28bof the second body27cand second gore27dis brought down to the second gore27dside but is inserted into the groove portion34. Thus, the seam allowance28bwill not be superimposed on the seam allowance28aon the surface of the step portion33.

Since the seam allowances28aand28bare not superimposed on each other on the surface of the step portion33, it is possible to suppress occurrence of wrinkles or sags in the first gore27bwhich is superimposed on the surface of the step portion33and appears on the external surface of the vehicle seat21. This configuration can suppress the deteriorated appearance of the vehicle seat21caused by such wrinkles or sags. And, the width of the seam allowances28aand28bcan be set properly in consideration of sewing workability etc. regardless of the size of the step height H of the step portion33. This configuration can ease the constraints of the step height H of the step portion33, thereby enabling enhancement in the freedom of design of the vehicle seat21.

Here, in order to suppress the occurrence of wrinkles or sags in the first gore27bby enhancing the rigidity of the first gore27bappearing on the external surface of the vehicle seat21, the respective edges of the first and second gores27band27dto be stored into the groove portion34of the pad26, as shown inFIG. 3, may be sewn together integrally with the reinforcing member, or, as shown inFIG. 4, may be sewn together by multiple rows of seams.

FIG. 7shows a section of the front end part of the seat cushion22.

The pad46of the seat cushion22includes a first pad part51and a second pad part52arranged adjacent to the first pad part51. The first pad part51constitutes a pad of a thigh support22a(seeFIG. 5) formed in the central portion of the seat cushion22in the width direction, while the second pad part52constitutes pads of two side supports22b(seeFIG. 5) arranged on both sides of the thigh support22a. The first and second pad parts51and52are integrally formed.

The front end of the second pad part52is situated backward of the front end of the first pad part51and is formed concave with respect to the front end of the first pad part51, while a step portion53is formed along at least a part of the boundary between the front ends of the first and second pad parts51and52. And, in the pad46, there is formed a groove portion54which extends from the step portion53into between the first and second pad parts51and52vertically along the whole length of the step portion53.

The trim cover47for covering the pad46includes, as the skin pieces thereof, a first body47afor covering the upper end face of the first pad part51following the surface of the step portion53, a first gore47bjointed to the first body47afor covering the surface of the step portion53, a second body47cfor covering the upper end face of the second pad part52following the surface of the step portion53, and a second gore47djointed to the second body47c.

The respective edges of the first and second gores47band47dare sewn together in a superimposed state and are stored in the groove portion54of the pad46.

A seam allowance48aof the first body47aand first gore47bis brought down to the first gore47bside and is superimposed on the surface of the step portion53. A seam allowance48bof the second body47cand second gore47dis brought down to the second gore47dside but is inserted into the groove portion54. Thus, the seam allowance48bwill not be superimposed on the seam allowance48aon the surface of the step portion53.

Since the seam allowances48aand48bare not superimposed on each other on the surface of the step portion53, it is possible to suppress occurrence of wrinkles or sags in the first gore47bwhich is superimposed on the surface of the step portion53and appears on the external surface of the vehicle seat21. This configuration can suppress the deteriorated appearance of the vehicle seat21caused by such wrinkles or sags. And, the width of the seam allowances48aand48bcan be set properly in consideration of sewing workability etc. regardless of the size of the step height H of the step portion53. Thus, this configuration can ease the constraints of the step height H of the step portion53, thereby enabling enhancement in the freedom of design of the vehicle seat21.

Here, in order to suppress the occurrence of wrinkles or sags in the first gore47bby enhancing the rigidity of the first gore47bappearing on the external surface of the vehicle seat21, the respective edges of the first and second gores47band47dto be stored into the groove portion54of the pad46, as shown inFIG. 3, may be sewn together integrally with the reinforcing member, or, as shown inFIG. 4, may be sewn together by multiple rows of seams.

Although the invention has been described heretofore with reference to the step portion13of the seat back3, the step portion33of the seat back23, and the step portion53of the seat cushion22, the invention can also be applied to the step portions of the other parts of a vehicle seat.