JP6482391B2 - Cushion member manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a cushion member used in a vehicle seat.

  In recent years, some seats of automobiles or the like are equipped with an occupant detection sensor that detects whether or not an occupant is sitting. Such an occupant detection sensor is used to detect the presence or absence of an occupant in order to operate a seat belt reminder or an occupant restraint device. For example, in Patent Document 1, a pressure-sensitive switch (occupant detection sensor) is disposed below the cushion pad, and when the occupant sits down, the seat device is turned on when the occupant detection sensor is pressed against the cushion pad. Is disclosed.

JP, 2014-210554, A

  By the way, if there is a wrinkle on the surface of the cushion pad that presses the occupant detection sensor, the occupant detection sensor cannot be operated stably, and the detection accuracy may be reduced.

Then, an object of this invention is to provide the manufacturing method of the cushion member which can operate a passenger | crew detection sensor stably.
Another object of the present invention is to make a member remaining on a cushion member less noticeable or to suppress interference between the member and another member of a vehicle seat.

  In order to achieve the above object, the cushion member manufacturing method of the present invention is used for a vehicle seat configured to detect the presence or absence of an occupant by operating an occupant detection sensor when the occupant sits down. The pad material and a seat material disposed on the surface opposite to the occupant side of the pad material, the seat material being a part that can contact the occupant detection sensor, and when the occupant sits Cushion member having a sensor operating portion that contacts the occupant detection sensor to operate the occupant detection sensor, and a plurality of positioning portions that are provided around the sensor operating portion and position the sheet material with respect to the mold. The sheet material is set in the mold in a state in which the positioning portion is aligned with the mold-side positioning portion of the mold and the sensor operating portion is stretched, and the pad material is placed on the mold. Wherein the hardened by pouring.

  According to such a method, since it can suppress that a sensor operation part of a cushion member can be wrinkled, an occupant detection sensor can be operated stably.

  In the manufacturing method of the cushion member described above, each mold-side positioning part is based on the corresponding positioning part as viewed from the direction orthogonal to the sensor operating part in a state before the positioning part is aligned with the mold-side positioning part. It can arrange | position on the opposite side to the said sensor operation part side.

  According to this, the sheet | seat material can be set to a type | mold in the state which tensioned the sensor operation part by matching a positioning part with a type | mold side positioning part. Thereby, it can suppress that a sensor action part of a cushion member can be wrinkled.

  In the cushion member manufacturing method described above, the center of each mold-side positioning portion is the center of the corresponding positioning portion when viewed from the direction orthogonal to the sensor operating portion in a state before the positioning portion is aligned with the mold-side positioning portion. The sensor can be disposed on the side opposite to the sensor operating unit side with respect to the center.

  According to this, the sheet | seat material can be set to a type | mold in the state which tensioned the sensor operation part by matching a positioning part with a type | mold side positioning part. Thereby, it can suppress that a sensor action part of a cushion member can be wrinkled.

  In the manufacturing method of the cushion member described above, each mold-side positioning portion is positioned at the center of the corresponding positioning portion when viewed from the direction orthogonal to the sensor operating portion in a state before the positioning portion is aligned with the mold-side positioning portion. They can be placed in overlapping positions.

  According to this, since it becomes easy to match the positioning portion with the die-side positioning portion, the sheet material can be easily set on the die in a state where the sensor operation portion is stretched. Thereby, it is possible to easily manufacture a cushion member that is difficult to wrinkle the sensor operating portion.

  In the above-described cushion member manufacturing method, the positioning portion can be made smaller than the mold-side positioning portion when viewed from a direction orthogonal to the sensor operating portion.

  According to this, the positioning part remaining on the cushion member can be made inconspicuous, or interference between the positioning part and other members of the vehicle seat when the cushion member is attached to the vehicle seat can be suppressed.

  In the above-described method for manufacturing the cushion member, it is preferable that the mold-side positioning portion is a magnet, and the positioning portion includes a ferromagnetic material.

  According to this, it is possible to easily set the sheet material on the mold in a state where the sensor operating portion is stretched using magnetic force. Thereby, it is possible to easily manufacture a cushion member that is difficult to wrinkle the sensor operating portion.

  According to the present invention, since it is possible to suppress wrinkling of the sensor operating portion of the cushion member, the occupant detection sensor can be stably operated.

  Moreover, according to this invention, it can suppress that a sensor operation part of a cushion member can be wrinkled by arrange | positioning each type | mold side positioning part on the opposite side to a sensor operation part side on the basis of a corresponding positioning part. .

  Further, according to the present invention, the center of each mold side positioning portion is arranged on the side opposite to the sensor operating portion side with respect to the center of the corresponding positioning portion, thereby suppressing the sensor operating portion of the cushion member from being wrinkled. can do.

  Moreover, according to this invention, the cushion member which cannot wrinkle a sensor operation part easily can be manufactured by arrange | positioning each type | mold side positioning part in the position which overlaps with the center of a corresponding positioning part.

  In addition, according to the present invention, by positioning the positioning portion smaller than the mold side positioning portion, the positioning portion can be made inconspicuous, or interference between the positioning portion and other members of the vehicle seat can be suppressed. it can.

  In addition, according to the present invention, the mold-side positioning portion is a magnet, and the positioning portion includes a ferromagnetic body, whereby a cushion member that is difficult to wrinkle the sensor operating portion can be easily manufactured.

It is a perspective view of a vehicle seat as a vehicle seat according to an embodiment. It is a perspective view of the cushion frame which comprises a seat frame. It is a top view of a cushion frame, a seat spring, and a connecting member. It is AA sectional drawing (a) of FIG. 3, and the expanded sectional view (b) of a connection member. It is BB sectional drawing of FIG. It is a perspective view of a connecting member, a leaf spring member, an occupant detection sensor, and a clip. It is a disassembled perspective view of a passenger detection sensor. It is sectional drawing of the seat cushion equivalent to CC cross section of FIG. It is sectional drawing of the seat cushion corresponding to FIG. 8 which shows a state when a passenger | crew sits down. It is the figure which looked at the seat spring, the connection member, the occupant detection sensor, and the cushion member from the lower side. It is figure (a)-(c) explaining the manufacturing method of a cushion member. It is Z arrow line view of Fig.11 (a). It is a figure which shows the sensor action part periphery of a cushion member. It is a figure which shows the connection member and passenger | crew detection sensor which concern on a 1st modification. It is a figure which shows the connection member which concerns on a 2nd modification. It is figure (a), (b) which shows the passenger | crew detection sensor which concerns on a 3rd modification.

Hereinafter, embodiments of the invention will be described in detail with reference to the drawings as appropriate. In the present invention, front and rear, left and right, and top and bottom are based on the direction viewed from the passenger sitting on the vehicle seat.
As shown in FIG. 1, the vehicle seat according to this embodiment is a vehicle seat S used in an automobile, and includes a seat cushion S1, a seat back S2, and a headrest S3.

  The vehicle seat S incorporates a seat frame F as shown in FIG. The seat frame F is mainly composed of a cushion frame F1 constituting the frame of the seat cushion S1 and a seat back frame (not shown) constituting the frame of the seat back S2. The vehicle seat S is configured by covering the seat frame F with a cushion member 60 and an outer skin 70 as shown in FIG. 8 as an example of the seat cushion S1.

  As shown in FIG. 2, the cushion frame F1 constituting the seat frame F includes a pair of side frames 11 that are spaced apart from each other on the left and right sides, and a pan frame 12 that connects the front end portions of the pair of side frames 11; It has a connecting pipe 13 that connects the rear end portions of the pair of side frames 11, and is formed in a frame shape in which these are integrally coupled by welding or the like. The side frame 11 and the pan frame 12 are formed by pressing a metal plate, and the connecting pipe 13 is made of a metal pipe.

  Between the pan frame 12 and the connecting pipe 13 of the cushion frame F1, a plurality of seat springs 20 as wire-like members are installed. More specifically, four (20A to 20D) of the plurality of seat springs 20 are arranged side by side, the front end of each seat spring 20 is hooked on the pan frame 12, and the rear end is the connecting pipe 13. It is constructed in the front-rear direction (direction orthogonal to the left-right direction).

  Each of the plurality of seat springs 20 is a spring that is bent zigzag so as to meander the metal wire to the left and right. Each seat spring 20 includes eight left and right extending portions 21 that extend in the left-right direction (the direction in which the plurality of seat springs 20 are arranged), and a portion that extends in the front-rear direction (the direction in which the seat spring 20 is installed). Two front and rear extending portions 22 and a pipe hooking portion 23 hooked to the connecting pipe 13 are provided. The left and right extending portions 21 are arranged side by side. The foremost left and right extending portion 21 is a hooking portion that is hooked to a hook portion 12 </ b> H formed on the pan frame 12. The front-rear extension portions 22 are provided so as to connect the ends of the adjacent left-right extension portions 21 and are alternately arranged on the left and right sides. The pipe hooking portion 23 extends upward from the end portion of the rearmost left and right extending portion 21 and is formed so that the upper end portion is bent in a hook shape.

  As shown in FIG. 3, adjacent seat springs 20 are formed symmetrically. Specifically, the seat spring 20B (first seat spring) and the seat spring 20C (second seat spring disposed adjacent to the first seat spring) are formed symmetrically, and the seat spring 20A and seat The spring 20B is formed symmetrically, and the seat spring 20C and the seat spring 20D are formed symmetrically.

  The seat spring 20 is connected by a plurality of connecting members 30A to 30F. Each of the connecting members 30A to 30F is made of resin, and is integrally formed with the seat springs 20A to 20D by insert molding.

  The connecting member 30A arranged most recently is a member that connects the rear ends of the seat springs 20A and 20B or the rear ends of the seat springs 20C and 20D. More specifically, the connecting member 30A covers the pipe engaging portions 23 of the seat springs 20A and 20B or the pipe engaging portions of the seat springs 20C and 20D in a state where the portion of the pipe engaging portion 23 that contacts the connecting pipe 13 is covered. It forms so that the parts 23 may be connected. The contact sound between the seat spring 20 and the connecting pipe 13 can be reduced by covering the pipe hooking portion 23 with the resin connecting member 30A.

  The connecting member 30B arranged second from the back is a member that connects the rear ends of the seat springs 20A to 20D. More specifically, the connecting member 30 </ b> B is formed so as to connect the seat springs 20 </ b> A to 20 </ b> D with the rearmost left and right extending portions 21 and the rear end portions of the front and rear extending portions 22 covered. .

  The connecting member 30C disposed at the center in the third horizontal direction from the rear is a member that connects the rear ends of the seat springs 20B and 20C. In more detail, the connecting member 30C is formed so as to connect the front end portions of the rearmost front and rear extending portions 22 of the seat springs 20B and 20C. Further, the connecting member 30C connects the rearmost front / rear extension portion 22 of one seat spring 20B and the second left / right extension portion 21 from the rear, and the rearmost front / rear extension portion of the seat spring 20C. 22 and the second left and right extending portion 21 from the back are formed to be connected.

  The connecting members 30D arranged on the left and right of the connecting member 30C are formed so as to connect the seat spring 20A or the rearmost front / rear extending portion 22 of the seat spring 20D and the second left / right extending portion 21 from the rear. .

  The connecting member 30E arranged fourth from the back is a member that connects the substantially central portions in the front-rear direction of the seat springs 20A to 20D. More specifically, the connecting member 30E includes the third front and rear extension portions 22 from the rear of the seat springs 20B and 20C, the fourth front and rear extension portions 22 from the rear of the seat springs 20A and 20B, and the seat spring 20C. , 20D is formed so as to connect the fourth longitudinally extending portions 22 from the back. Further, the connecting member 30E is formed so as to connect the fourth longitudinally extending portion 22 and the laterally extending portion 21 from the rear of each seat spring 20A to 20D.

  The foremost connecting member 30F is a member that connects the front end portions of the seat springs 20B and 20C. More specifically, the connecting member 30F has a substantially plate-like main body portion 31, and the main body portion 31 is formed so as to connect the second longitudinally extending portions 22 from the front of the adjacent seat springs 20B and 20C. Has been. Further, the main body 31 connects the second and third left and right extending portions 21 from the front of the one seat spring 20B, and the second and third left and right extending portions from the front of the one seat spring 20C. It is formed so that 21 may be connected. With such a configuration, the seat springs 20B and 20C can be firmly connected. For example, the seat springs 20B and 20C can be operated as an integral spring.

  The connecting member 30 </ b> F has a pair of covering portions 32 disposed on the front side of the main body portion 31 so as to be separated from each other on the left and right. The covering portion 32 is formed so as to cover the front left and right extending portions 21 (hanging portions) and the front and rear extending portions 22 of the seat springs 20B and 20C, and is formed integrally with the main body portion 31. In addition, the foremost left and right extension part 21 (holding part) and the front and rear extension part 22 of the seat springs 20A and 20D, the second right and left extension part 21 and the front and rear extension part 22 from the front, and the front 3 The th left and right extending portion 21 is covered with a resin covering portion 30G. The front left and right extending portion 21 (hanging portion) to be hooked on the pan frame 12 is covered with the resin covering portions 32 and 30G, thereby reducing the contact sound between the seat spring 20 and the pan frame 12. can do.

  The connecting member 30F is provided substantially in the center in the left-right direction of the seat cushion S1, and a part thereof contacts the pan frame 12 and is supported by the pan frame 12. Specifically, as shown in FIG. 4 (a), the pan frame 12 has, at its rear end, a support portion 12A as a first portion, and a first extension extending substantially downward from the rear end of the support portion 12A. Part 12B and a second extension part as a second part arranged to be shifted downward (opposite to the passenger side) with respect to support part 12A by extending backward from the rear end of first extension part 12B 12C. The connecting member 30F has a front end portion as one end portion (more specifically, a front end portion of the main body portion 31 and a sandwiching portion 32A, which will be described later of the covering portion 32) contact the support portion 12A from above and contact the support portion 12A. It is supported.

  With such a configuration, the seat springs 20B and 20C are supported in contact with the pan frame 12 via the connecting member 30F. Further, as shown in FIG. 3, the seat springs 20A and 20D are supported by being in contact with the pan frame 12 via the covering portion 30G. Thereby, the contact sound of the seat spring 20 and the pan frame 12 can be reduced. Further, since the connecting member 30F and the covering portion 30G are made of resin, the contact sound between them and the pan frame 12 can also be reduced.

  Returning to FIG. 4A, the rear end portion (rear end portion of the main body portion 31) as the other end portion of the connecting member 30F is separated from the second extension portion 12C and floats from the second extension portion 12C. It is arranged in such a state. Thereby, a gap is formed between the rear end portion of the connecting member 30F and the second extending portion 12C. Since the front end portion of the connecting member 30F is supported by being in contact with the pan frame 12 and the rear end portion is separated from the pan frame 12, the contact area between the connecting member 30F and the pan frame 12 can be reduced. In addition, the contact sound between the connecting member 30F and the pan frame 12 can be reduced.

  As shown in FIG. 5, the pan frame 12 has a protruding portion 12D that protrudes upward (occupant side) from the support portion 12A. Of the pair of covering portions 32, the portion (the sandwiching portion 32 </ b> A) that covers the front-rear extension portion 22 is disposed so as to sandwich the protruding portion 12 </ b> D from the left and right with the connecting member 30 </ b> F supported by the support portion 12 </ b> A. Thereby, the position of the connecting member 30F can be stabilized. As shown in FIG. 6, the main body 31 of the connecting member 30 </ b> F has a concave portion 33 that is recessed toward the rear at the front end portion between the pair of covering portions 32. The recess 33 is formed with a width and depth that can receive the protrusion 12 </ b> D of the pan frame 12. Thereby, since the recessed part 33 is arrange | positioned so that protrusion part 12D may be pinched | interposed from the right and left with 32 A of clamping parts, the position of the connection member 30F can be stabilized more.

  An occupant detection sensor 40 and a leaf spring member 50 as a spring member are attached to the upper surface of the connecting member 30F. That is, the connecting member 30F also functions as a member (sensor support member) that supports the occupant detection sensor 40 from below by attaching the occupant detection sensor 40. Thereby, since the member which connects the seat spring 20 can be utilized as a member which supports the passenger | crew detection sensor 40 etc., size reduction and cost reduction can be achieved. The connecting member 30F is supported by the cushion frame F1 via the seat spring 20 installed on the cushion frame F1.

  The occupant detection sensor 40 is a sensor configured to detect the presence or absence of an occupant by operating when the occupant sits down. The occupant detection sensor 40 includes a base 41 attached to the connecting member 30F and a pair of detection units 42 (first detection unit 42A and second detection unit) provided at both left and right ends of the base 41 so as to be connected to the base 41. 42B). The base 41 has a pair of sensor-side through holes 43 (through holes) provided so as to penetrate vertically in order to attach the occupant detection sensor 40 to the connecting member 30F.

  As shown in FIG. 7, the occupant detection sensor 40 is formed by stacking and bonding a first sheet 40A, a second sheet 40B, and a third sheet 40C having flexibility. Each sheet 40A, 40B, 40C has through-holes 43A, 43B, 43C that form sensor-side through-holes 43 when they are stacked. The first sheet 40A includes two electrodes E1 formed at both left and right end portions of the upper surface, and a pair of wirings W1 extending inward in the left-right direction from each electrode E1 along the rear end portion of the first sheet 40A. Have. An electric wire 44 is drawn out from each wiring W1. In addition, the first sheet 40A has an exhaust port 45 provided in a portion serving as the base portion 41 so as to penetrate vertically between the through holes 43A (the pair of sensor side through holes 43). The third sheet 40C includes two electrodes E2 formed on the left and right ends of the lower surface, and a wiring W2 extending along the front end of the third sheet 40C and electrically connecting the two electrodes E2. have. The second sheet 40B avoids the pair of through holes 46A provided at positions facing the pair of electrodes E1, E2, the through holes 46B provided at positions opposed to the exhaust ports 45, and the through holes 43B. It has an exhaust groove 46C provided so as to connect the left and right through holes 46A and the central through hole 46B.

  By overlapping and bonding the first sheet 40A, the second sheet 40B, and the third sheet 40C, the pair of upper and lower electrodes E1 and E2 face each other with a space therebetween through the through hole 46A (second sheet 40B). The through hole 46B and the exhaust port 45 communicate with each other. The detection unit 42 is a portion where a pair of electrodes E1 and E2 are disposed. A filter 40D is attached to the lower surface of the first seat 40A (occupant detection sensor 40) so as to cover the exhaust port 45. The filter 40 </ b> D has air permeability and suppresses water from entering the occupant detection sensor 40 from the exhaust port 45.

  When no pressure is applied to the detection unit 42, the pair of electrodes E1 and E2 are separated from each other, so that the occupant detection sensor 40 is in an OFF state in which no current flows. On the other hand, when pressure is applied to each of the first detection unit 42A and the second detection unit 42B so that the pair of right electrodes E1 and E2 come into contact with each other and the pair of left electrodes E1 and E2 come into contact with each other, an occupant detection sensor 40 becomes an ON state in which a current flows. When the pair of electrodes E1 and E2 come into contact with each other, the air between the pair of electrodes E1 and E2 is pushed out from the space between the pair of electrodes E1 and E2, passes through the exhaust groove 46C and the through hole 46B, and passes through the exhaust port. 45 to the outside of the occupant detection sensor 40.

As shown in FIG. 6, the leaf spring member 50 is a plate-like spring that extends in the left-right direction (the direction in which the base portion 41 and the detection portion 42 are arranged), and faces the occupant detection sensor 40 below the occupant detection sensor 40. Are arranged. The leaf spring member 50 includes left and right pressing portions 51 and a connecting portion 52 that integrally connects the left and right pressing portions 51 (the first pressing portion 51A and the second pressing portion 51B).
The connecting portion 52 is a portion (base facing portion) that faces the base portion 41 of the occupant detection sensor 40, and includes a pair of first through holes 53 (through holes) that communicate with the pair of sensor side through holes 43, and an exhaust port 45. And a second through-hole 55 as an air flow channel facing the.

  The pressing part 51 includes a first pressing part 51A that faces the first detection part 42A and a second pressing part 51B that faces the second detection part 42B. Each pressing portion 51 is provided with a through hole 56 as an opening facing the detection portion 42. The through hole 56 has a substantially circular shape, and is provided so that the detection unit 42 faces the leaf spring member 50 and the occupant detection sensor 40 when viewed from below. Since the opening provided in the pressing portion 51 is the through hole 56, for example, the rigidity of the leaf spring member 50 can be ensured as compared with the case where the opening is notched.

  The main body portion 31 of the connecting member 30F has an attachment portion 34, opposing portions 35 provided on the left and right sides of the attachment portion 34, and a cushion support portion 36 provided so as to surround the attachment portion 34 and the opposing portion 35. doing.

  The attachment portion 34 is a portion to which the base portion 41 of the occupant detection sensor 40 and the connecting portion 52 of the leaf spring member 50 are attached. The attachment portion 34 is provided at a position facing the pair of sensor side through holes 43 and the pair of first through holes 53, and includes two attachment holes 34 </ b> A for attaching the base portion 41 and the connecting portion 52, and two attachment holes. An air vent hole 34B provided at a position facing the exhaust port 45 and the second through hole 55 between 34A. Both the attachment hole 34A and the air vent hole 34B are provided so as to penetrate vertically. Further, as shown in FIG. 4 (b), the attachment portion 34 has an inclined surface 34C that inclines downward (in the direction away from the occupant side) from the front to the rear in the horizontal center of the rear end portion of the upper surface. have. The inclined surface 34C is a surface that guides the electric wire 44 extending from the occupant detection sensor 40 toward the lower side of the connecting member 30F. By having such an inclined surface 34 </ b> C, the handling performance of the electric wire 44 can be improved, and the load applied to the electric wire 44 from the cushion member 60 when an occupant sits down can be reduced.

  As shown in FIG. 4A, the electric wire 44 is disposed under the pan frame 12, and a midway portion is held by the clip 91. As for the electric wire 44, the clip 91 engages with the through-hole 12E formed in the 2nd extension part 12C, and the middle part is attached to the 2nd extension part 12C. Since a gap is formed between the connecting member 30F and the second extending portion 12C, the claw portion of the clip 91 for attaching the electric wire 44 can be arranged using the gap, and thus the electric wire 44 is attached to the clip 91. Can be easily attached to the pan frame 12. In addition, the electric wire itself can also be arrange | positioned in the clearance gap between the connection member 30F and the 2nd extension part 12C. The end of the electric wire 44 is connected to a connector 92 with a clip. The pan frame 12 includes a third extending portion 12K that extends substantially downward from the front end of the support portion 12A, and a fourth extending portion 12L that extends forward from the front end of the third extending portion 12K. The end of the electric wire 44 is attached to the pan frame 12 by the connector 92 engaging with the through hole 12M formed in the fourth extending portion 12L.

Returning to FIG. 6, the facing portion 35 is a portion facing the detecting portion 42, and includes a first facing portion 35 </ b> A facing the first detecting portion 42 </ b> A and a second facing portion 35 </ b> B facing the second detecting portion 42 </ b> B. Contains. A convex portion 37 as a pressurizing portion that protrudes upward toward the detection portion 42 is provided at a portion of each facing portion 35 that faces the detection portion 42.
The cushion support part 36 is an edge part of the main body part 31. The connecting member 30F is formed integrally with the seat springs 20B and 20C so that the cushion support portion 36 covers the seat springs 20B and 20C (wire-like members).

  As shown in FIG. 8, the occupant detection sensor 40 and the leaf spring member 50 are configured such that a clip 93 as a fixing member is inserted into the sensor side through hole 43 and the first through hole 53 and engaged with the mounting hole 34A. Thus, it is fixed to the connecting member 30F. The occupant detection sensor 40 and the leaf spring member 50 are positioned on the connecting member 30F by being fixed to the connecting member 30F. Further, in a state where the occupant detection sensor 40 and the leaf spring member 50 are fixed to the connecting member 30F, the second through hole 55 and the air vent hole 34B communicate with each other, and the exhaust port 45 of the occupant detection sensor 40 has a second position. It arrange | positions facing the through-hole 55 and the air vent hole 34B.

  In the seat cushion S <b> 1, the connecting member 30 </ b> F (opposing member), the occupant detection sensor 40, and the leaf spring member 50 are disposed below the cushion member 60. The left and right detection portions 42 of the occupant detection sensor 40 are respectively disposed between the cushion member 60 and the convex portion 37 (connecting member 30F) facing each other through the through hole 56 of the leaf spring member 50. .

  The attachment portion 34 of the connecting member 30F is provided so as to protrude above the opposing portion 35 (on the cushion member 60 side), and a step 38 is formed between the attachment portion 34 and the opposing portion 35. Yes. On the other hand, the lower surface of the attachment portion 34 and the facing portion 35 is formed as a substantially flat surface. For this reason, the attachment portion 34 is formed such that the thickness in the vertical direction (the direction facing the cushion member 60) is larger than the thickness of the facing portion 35 in the vertical direction. Thereby, the rigidity of the attachment portion 34 to which the occupant detection sensor 40 or the like of the connecting member 30F is fixed can be secured, and the occupant detection sensor 40 or the like can be stably attached. The cushion support part 36 is provided so that the upper part protrudes above the upper surface of the attachment part 34, and supports the cushion member 60. The convex portion 37 has a substantially spherical shape, and is formed such that its diameter D1 (maximum diameter) is larger than the diameter D2 of the detection portion 42 of the occupant detection sensor 40.

  The leaf spring member 50 is formed so that the length in the left-right direction is longer than that of the occupant detection sensor 40. For this reason, the end portion 50E on the outer side in the left-right direction of the pressing portion 51 (on the detection portion 42 side of the leaf spring member 50) is located farther from the base 41 (center of the occupant detection sensor 40) than the detection portion 42 in the left-right direction. Specifically, it is arranged at a position outside the detection unit 42. The through hole 56 provided in the leaf spring member 50 is formed such that its diameter D3 is larger than the diameter D2 of the detection unit 42. Further, the diameter D3 of the through hole 56 is formed to be larger than the diameter D1 of the convex portion 37. Thereby, the convex portion 37 can easily enter the through hole 56.

  The leaf spring member 50 is formed in a shape in which each pressing portion 51 (an end portion facing the detection portion 42) is smoothly curved so as to go upward as it goes from the inner side to the outer side in the left-right direction. For this reason, the occupant detection sensor 40 arranged on the leaf spring member 50 is fixed to the connecting member 30F at the center in the left-right direction via the connecting portion 52, and both left and right end portions are supported from below by the pressing portion 51. In this state, in a state where the occupant shown in FIG. 8 is not sitting, the detection unit 42 is curved upward as it goes from the inner side to the outer side in the left-right direction so as to be separated from the convex portion 37. The plate spring member 50 may be formed in a shape that is curved as a whole before being attached to the connecting member 30F, or the shape in which the connecting portion 52 is flat and only the pressing portion 51 is bent. It may be formed.

  The leaf spring member 50 forms a gap between the cushion member 60 and the facing portion 35 by pressing the cushion member 60 upward. More specifically, the first pressing portion 51A presses the cushion member 60 upward to form a gap between the cushion member 60 and the first facing portion 35A, and the second pressing portion 51B is a cushion. By pressing the member 60 upward, a gap is formed between the cushion member 60 and the second facing portion 35B.

  When the occupant is not sitting, the occupant detection sensor 40 is in the OFF state because the leaf spring member 50 is provided with the through hole 56 so that the detection unit 42 is not strongly pressed against the cushion member 60.

  The cushion member 60 of the seat cushion S1 used for the vehicle seat S includes a pad material 61 made of urethane foam and a sheet material 62 made of nonwoven fabric. The sheet material 62 is brought into contact with the seat spring 20 installed so as to face the sheet material 62, the connecting member 30F arranged to face the sheet material 62, the leaf spring member 50, and the like. It is provided to suppress damage and is arranged so as to cover substantially the entire lower surface of the pad material 61.

  As shown in FIG. 9, when the occupant sits on the vehicle seat S (seat cushion S <b> 1), the skin 70 and the cushion member 60 are pushed downward by the occupant's thigh T, so that the lower side of the cushion member 60 is The surface presses the left and right detection units 42 and the pressing unit 51 downward. Then, the left and right detection portions 42 are sandwiched between the cushion member 60 and the facing portion 35 of the connecting member 30F, more specifically, the convex portion 37 that has entered the through hole 56 of the leaf spring member 50. Pressure is applied to the detection unit 42 from the convex portion 37 between the cushion member 60 and the facing portion 35, and the pair of electrodes E1 and E2 (see FIG. 7) come into contact with each other. Accordingly, the occupant detection sensor 40 is turned on and detects that the occupant is sitting.

  Since the connecting member 30F includes the convex portion 37 (pressurizing portion), in addition to the configuration in which the detecting portion is sandwiched between the cushion member and the flat surface when the occupant sits, the connecting member 30F is added to the detecting portion 42. Since the applied pressure increases, the pair of electrodes E1 and E2 can be brought into contact with each other more reliably. Thereby, when a passenger | crew sits down, the passenger | crew detection sensor 40 can be operated favorably. On the other hand, since the convex portion 37 has a substantially spherical shape, it can be suppressed that a large load is locally applied to the detection portion 42.

  The air discharged from the exhaust port 45 of the occupant detection sensor 40 when the pair of electrodes E1 and E2 come into contact with each other passes through the second through hole 55 and the air vent hole 34B and is discharged below the connecting member 30F. By having the second through hole 55 and the air vent hole 34B, air discharged from the occupant detection sensor 40 can be released well. In particular, since the second through hole 55 and the air vent hole 34B are provided between the pair of first through holes 53 or the pair of mounting holes 34A for fixing, the occupant detection sensor 40 and the leaf spring member 50 are provided. When attached to the connecting member 30F, these can be brought into close contact with the exhaust port 45, the second through hole 55, and the air vent hole 34B, so that the air discharged from the occupant detection sensor 40 can be released more favorably.

Next, the cushion member 60 of the seat cushion S1 will be described in more detail.
As shown in the state viewed from the lower side in FIG. 10, the sheet material 62 of the cushion member 60 includes a sensor operating portion 63 and a plurality of positioning portions 64.
The sensor operating unit 63 is a part of the surface of the sheet material 62 that can contact the detection unit 42 of the occupant detection sensor 40. When the occupant sits down, the sensor operating unit 63 comes into contact with the detection unit 42 of the occupant detection sensor 40 from above, and sandwiches the detection unit 42 with the connecting member 30F (convex portion 37), thereby occupant detection sensor 40. Is activated (turned on).

  The positioning part 64 is a part for positioning the sheet material 62 with respect to a mold for molding the cushion member 60. The positioning part 64 is provided by, for example, attaching a ferromagnetic material such as iron formed in a disk shape to the nonwoven fabric constituting the sheet material 62. Among the plurality of positioning portions 64, in particular, the positioning portion 64 </ b> A is provided around the sensor operating portion 63 and in the vicinity of the sensor operating portion 63. More specifically, four positioning portions 64 </ b> A are provided and are disposed at positions that surround the two sensor operating portions 63. In addition, two positioning portions 64A (first positioning portion and second positioning portion) arranged on a diagonal diagonal line formed by the four positioning portions 64A are arranged with one sensor operating portion 63 interposed therebetween. ing. As an example, the positioning portion 64A is desirably disposed at a position of 40 mm to 50 mm from the nearest sensor operating portion 63.

  The four positioning portions 64A are arranged at positions that surround the occupant detection sensor 40, more specifically, so as to avoid the connecting member 30F to which the occupant detection sensor 40 is attached. The four positioning portions 64A are arranged at a position between the seat spring 20A and the seat spring 20B so as to avoid the seat springs 20A to 20D, and the remaining two are between the seat spring 20C and the seat spring 20D. Placed in position. That is, the four positioning portions 64A are arranged so as to be visible without being hidden by the connecting member 30F or the seat springs 20A to 20D when the seat cushion S1 is viewed from below. Thereby, contact with positioning part 64A, crew member detection sensor 40, connecting member 30F, and seat springs 20A-20D can be controlled, for example, generation of contact sound can be controlled.

Next, an example of a method for manufacturing the cushion member 60 will be described.
As shown in FIG. 11A, the cushion member 60 sets the sheet material 62 to the first mold 81, and as shown in FIG. The molding die 80 having a cavity 60C for assembling and molding the cushion member 60 is assembled, and the material of the pad material 61 is poured into the molding die 80 and solidified as shown in FIG.

  When setting the sheet material 62 on the first mold 81, the sheet material 62 is set in a state of being positioned with respect to the first mold 81. Specifically, as shown in FIG. 11A, the first mold 81 is provided with a plurality of mold-side positioning portions 84 made of permanent magnets at locations corresponding to the plurality of positioning portions 64 of the sheet material 62. It has been. Then, by aligning each positioning part 64 with the corresponding mold-side positioning part 84 and setting the sheet material 62 on the first mold 81, the positioning part 64 is attracted to the mold-side positioning part 84 by a magnetic force. Thus, the sheet material 62 can be positioned with respect to the first mold 81.

  The mold side positioning portion 84 has four mold side positioning portions 84A corresponding to the four positioning portions 64A, as shown in FIG. 12 viewed from the direction of the arrow in FIG. The center 84C of each mold side positioning part 84A is the center of the corresponding positioning part 64A as seen from the direction orthogonal to the sensor operating part 63 in a state before the positioning part 64A is aligned with the mold side positioning part 84A shown in FIG. With reference to 64C, it is arranged on the side opposite to the sensor operating part 63 side (region 62A side). More specifically, the center 84C of each mold-side positioning portion 84A is located in the diagonal direction of the substantially rectangular region 62A surrounded by the four positioning portions 64A, rather than the center 64C of the corresponding positioning portion 64A. It is shifted from the position far away. Each mold side positioning portion 84A is disposed at a position overlapping the center 64C of the corresponding positioning portion 64A when viewed from the direction orthogonal to the sensor operating portion 63 in a state before the positioning portion 64A is aligned with the mold side positioning portion 84A. Has been. That is, each mold-side positioning portion 84A is arranged so that the center 64C of the corresponding positioning portion 64A is positioned inside the contour before the positioning portion 64A is positioned.

  Therefore, when each positioning portion 64A is aligned with the corresponding mold side positioning portion 84A, each positioning portion 64A moves away from the center 62C of the region 62A toward the center 84C of the corresponding mold side positioning portion 84A. The sheet material 62 is set in the first mold 81 with the region 62A (sensor operating portion 63) stretched. The mold-side positioning portion 84 is a permanent magnet, and the positioning portion 64 includes a ferromagnetic material. Therefore, the sheet material 62 is placed on the first die 81 in a state where the sensor operating portion 63 is stretched using magnetic force. Can be set easily. Each positioning portion 64 (including 64A) has substantially the same diameter (size) as viewed from the direction orthogonal to the sensor operating portion 63 and is provided with a smaller diameter (size) than the mold side positioning portion 84A. ing.

  After the sheet material 62 is set on the first mold 81, the molding die 80 is assembled as shown in FIG. 11B, and the material of the pad material 61 is placed on the molding die 80 as shown in FIG. 11C. The cushion member 60 can be manufactured by pouring and hardening, and then removing the mold from the mold 80. As described above, the cushion member 60 is manufactured by pouring the material of the pad material 61 into the molding die 80 in a state in which the region 62A of the sheet material 62 is stretched, and thus the cushion member 60 is manufactured. The region 62A (particularly the sensor operating portion 63) has a configuration in which the tension of the sheet material 62 is stronger (the tension is higher) than the outside of the region 62A. Further, as shown in FIG. 13, the region 62A (sensor operating portion 63) has a structure in which the wrinkles 62B formed on the surface of the sheet material 62 are less than the outside of the region 62A. Since the tension of the sheet material 62 can be considered as the unevenness of the surface (region 62A) of the cushion member 60, the surface (region 62A) of the cushion member 60 is three-dimensionally measured after the cushion member 60 is molded. By measuring with the instrument, it can be measured as the degree of unevenness of the region 62A.

  Since the two positioning portions 64A are arranged with the one sensor operating portion 63 interposed therebetween, the sheet material 62 is set on the first mold 81 in a state where the two positioning portions 64A are pulled in the direction of widening the interval between the two positioning portions 64A. Thus, the one sensor operating portion 63 can be stretched, and the formation of wrinkles 62B on the sensor operating portion 63 can be suppressed. Further, since the four positioning portions 64A are arranged at a position surrounding the sensor operating portion 63, the sheet material 62 is moved to the first mold 81 in a state where the positioning portions 64A are pulled away from each other at the time of manufacturing. By setting to, the entire sensor operating part 63 can be stretched, and the formation of wrinkles 62B on the sensor operating part 63 can be further suppressed.

  According to the present embodiment described above, even when the elasticity of the cushion member 60 is reduced due to aging degradation or the like, for example, when it is deformed so as to hang down on the facing portion 35 side, as shown in FIG. A gap can be formed between the cushion member 60 and the facing portion 35 by the spring member 50. Accordingly, it is possible to suppress erroneous detection of the occupant detection sensor 40 due to the detection unit 42 being sandwiched between the cushion member 60 and the facing portion 35 when the occupant is not sitting.

  Further, since the occupant detection sensor 40 and the leaf spring member 50 are positioned on the connecting member 30F (the same member), the positional accuracy of the occupant detection sensor 40 and the leaf spring member 50 can be improved. Thereby, a clearance gap can be favorably formed in the location where the detection part 42 is arrange | positioned between the cushion member 60 and the opposing part 35, and a misdetection can be suppressed more.

  Further, since the occupant detection sensor 40 and the leaf spring member 50 can be collectively attached to the connecting member 30F by the clip 93, the number of parts can be reduced and the positional accuracy of the occupant detection sensor 40 and the leaf spring member 50 can be increased. Further improvement can further suppress false detection.

  In addition, since the end portion 50E of the leaf spring member 50 is disposed on the outer side in the left-right direction with respect to the detection portion 42, the entire portion overlapping the detection portion 42 of the cushion member 60 is moved upward by the leaf spring member 50 as viewed from above. Can be pressed. Also by this, a gap can be formed between the cushion member 60 and the facing portion 35 where the detection unit 42 is disposed, so that erroneous detection can be further suppressed.

  As shown in FIG. 9, when the occupant sits down, the detection unit 42 detects the occupant by being sandwiched between the cushion member 60 and the convex portion 37 provided on the facing portion 35. The accuracy of detection by the occupant detection sensor 40 can be improved as compared with a configuration in which it is sandwiched between flat surfaces.

  Moreover, since the diameter D1 of the convex part 37 is larger than the diameter D2 of the detection part 42, the convex part 37 can contact the detection part 42 stably and can apply a pressure to the detection part 42 favorably. The accuracy can be further improved.

  On the other hand, as shown in FIG. 8, since the attachment portion 34 protrudes above the facing portion 35, it is difficult for a load to be applied to the detection portion 42 when an occupant is not sitting, so a small load is applied to the cushion member 60. It is not detected that there is an occupant only by doing so, and the detection accuracy as a whole can be further improved.

  Further, since the step 38 is formed between the attachment portion 34 and the facing portion 35, the amount of movement (play) of the detection portion 42 in the vertical direction can be secured, so that a small load is applied to the cushion member 60. This alone does not detect the presence of an occupant, and the detection accuracy can be further improved.

  In addition, the occupant detection sensor 40 is curved so that the detection unit 42 is separated from the convex portion 37 in a state where no occupant is sitting, so that a space can be secured between the detection unit 42 and the convex portion 37. . Also by this, if only a small load is applied to the cushion member 60, it is not detected that there is an occupant, and the detection accuracy can be further improved.

  Further, since the cushion support portion 36 protrudes above the attachment portion 34, a space can be secured between the cushion member 60 and the attachment portion 34 or the facing portion 35 when the occupant is not sitting. Thereby, it is not detected that there is an occupant only by applying a small load to the cushion member 60, and the detection accuracy can be further improved.

  As shown to Fig.4 (a), since the passenger | crew detection sensor 40 is supported by the pan frame 12 via the connection member 30F, the passenger | crew detection sensor 40 can be stably supported with a simple structure. Thereby, since the passenger | crew detection sensor 40 can be operated stably, the precision of the detection by the passenger | crew detection sensor 40 can be improved.

  Further, as shown in FIG. 5, the holding member 32 </ b> F is supported by the pan frame 12, and thus the holding part 32 </ b> A is arranged with the protruding part 12 </ b> D interposed therebetween, so that the position of the connecting member 30 </ b> F can be stabilized. The occupant detection sensor 40 can be supported more stably.

  Further, as shown in FIG. 6, since the connecting member 30F has the recess 33 that can receive the protruding portion 12D, the holding portion 32A and the recessed portion 33 sandwich the protruding portion 12D from the left and right, thereby changing the position of the connecting member 30F. The occupant detection sensor 40 can be supported more stably.

  As shown in FIG. 4A, since the connecting member 30F for connecting the seat spring 20 is supported by the pan frame 12, excessive bending of the seat spring 20 can be suppressed. Thereby, the sitting comfort of the vehicle seat S can be improved.

  In addition, since the front end portion of the connecting member 30F is supported by being in contact with the support portion 12A and the rear end portion is disposed away from the second extension portion 12C, the excessive deformation of the seat spring 20 is suppressed. The amount of bending of the seat spring 20 can be ensured. Thereby, sitting comfort can be improved more.

  Further, as shown in FIG. 3, since the connecting member 30F connects the left and right extending portions 21 of the seat springs 20B and 20C, the distance between the left and right extending portions 21 can be defined. As a result, the amount of bending of the seat spring 20 can be adjusted, so that the sitting comfort can be further improved.

  Further, since the connecting member 30F is provided in the center in the left-right direction, the connecting member 30F can receive the load with a good balance, and the sitting comfort can be further improved.

  Moreover, since the two seat springs 20 arranged adjacent to each other are symmetrically formed, the seat spring 20 can be flexed in a well-balanced manner with the center in the left-right direction as a reference, and the sitting comfort is further improved. Can be made.

  As shown in FIG. 10, the cushion member 60 has the positioning portion 64A of the sheet material 62 provided around the sensor operating portion 63 and in the vicinity of the sensor operating portion 63. The sheet material 62 is set on the molding die 80 in a state where the sensor actuating portion 63 is stretched in accordance with the mold side positioning portion 84A, and the material of the pad material 61 is poured into the molding die 80 and hardened. Thereby, since it can suppress that wrinkle 62B is made to the sensor operation part 63, the passenger | crew detection sensor 40 can be operated stably by the sensor operation part 63. FIG.

  Further, as shown in FIG. 12, the center 84C of each mold side positioning portion 84A is disposed on the opposite side of the sensor operating portion 63 side with respect to the center 64C of the corresponding positioning portion 64A. By aligning 64 </ b> A with the mold side positioning portion 84 </ b> A, the sheet material 62 can be set in the molding die 80 in a state where the sensor operating portion 63 is stretched. Thereby, it can suppress that the sensor action | operation part 63 of the cushion member 60 can be wrinkled.

  In addition, since each mold side positioning portion 84A is arranged at a position overlapping the center 64C of the corresponding positioning portion 64A, the positioning portion 64A is easily aligned with the mold side positioning portion 84A, and the sensor operating portion 63 is stretched. Thus, the sheet material 62 can be easily set on the mold 80. In particular, in the present embodiment, the mold-side positioning portion 84A is a magnet, and the positioning portion 64A includes a ferromagnetic material. Therefore, the sheet material 62 is molded with the sensor operating portion 63 stretched using magnetic force. 80 can be set easily. Thereby, the cushion member 60 which is hard to be wrinkled in the sensor operation part 63 can be manufactured easily.

  Moreover, since the size of the positioning part 64 is smaller than the size of the mold side positioning part 84A, the positioning part 64 remaining on the cushion member 60 can be made inconspicuous after the cushion member 60 is manufactured. Further, since the positioning portion 64 is small, when the cushion member 60 is attached to the vehicle seat S, the positioning portion 64 and other members of the vehicle seat S, for example, the occupant detection sensor 40, the connecting member 30F, the seat Interference with the springs 20A to 20D can be suppressed.

  Although one embodiment of the invention has been described above, the present invention is not limited to the embodiment. About a concrete structure, it can change suitably in the range which does not deviate from the meaning of invention as follows.

  In the embodiment, the diameter D1 (maximum diameter) of the convex portion 37 provided on the connecting member 30F is larger than the diameter D2 of the detection portion 42 of the occupant detection sensor 40. However, the present invention is not limited to this. Absent. For example, as shown in FIG. 14, the diameter D <b> 1 (maximum diameter) of the convex portion 37 may be smaller than the diameter D <b> 2 of the detection unit 42. According to this, since the diameter of the convex portion 37 (upsizing) can be suppressed, the connecting member 30F and the occupant detection sensor 40 can be made compact.

  In the above-described embodiment, the convex portion 37 has a substantially spherical shape, but is not limited thereto. For example, the convex portion may have a substantially cylindrical shape, and the corner portion may be chamfered into a curved shape.

  In the said embodiment, when the passenger | crew sat down, the convex part 37 integrally provided in the opposing part 35 was illustrated as a pressurization part which applies a pressure to the detection part 42 between the cushion member 60 and the opposing part 35. However, the present invention is not limited to this. For example, the pressurizing part is disposed between the detection part of the occupant detection sensor and the flat opposing part, and is attached to at least one of the occupant detection sensor and the opposing part by attaching the disk-like foamed elastic body. It may be.

  In the embodiment, as shown in FIG. 8, the upper portion of the seat spring 20 and the upper surface of the attachment portion 34 are disposed at substantially the same height, but the present invention is not limited to this. For example, as shown in FIG. 15, the seat spring 20 (wire-like member) may be arranged such that the upper portion protrudes above the upper surface of the attachment portion 34 (on the cushion member 60 side). In this configuration, the cushion support portion 36 that covers the seat spring 20 is also arranged such that the upper portion protrudes above the upper surface of the attachment portion 34. Even in such a configuration, when the occupant is not sitting, a space can be secured between the cushion member 60 and the attachment portion 34 or the facing portion 35. Therefore, the occupant detection (not shown) is not performed only when a small load is applied to the cushion member 60. The presence of an occupant is not detected by the sensor, and the detection accuracy can be improved. Further, since the cushion support portion 36 is provided so as to cover the seat spring 20, the rigidity of the connecting member 30F can be increased.

  In the embodiment, the occupant detection sensor 40 has a flat shape and is supported from below by the leaf spring member 50, so that the detection unit 42 is curved so as to be separated from the convex portion 37 in a state where the occupant is not sitting. However, it is not limited to this. For example, as shown in FIG. 16A, the occupant detection sensor 40 itself moves from the inner side to the outer side in the left-right direction so that the detection unit 42 moves away from the convex portion 37 in a state where no occupant is sitting. The shape may be curved toward the upper side. Further, as shown in FIG. 16B, the occupant detection sensor 40 has both left and right end portions on the outer side in the left and right direction with respect to the central portion so that the detection unit 42 is separated from the convex portion 37 in a state where no occupant is sitting. You may form in the shape bent so that it may extend toward diagonally upward. According to such a configuration, when the occupant is not sitting, a space can be secured between the detection unit 42 and the convex portion 37. Therefore, it is detected that the occupant is present only by applying a small load to a cushion member (not shown). Thus, the detection accuracy can be further improved.

  In the embodiment, the leaf spring member 50 has a gap between the first pressing portion 51A that forms a gap between the cushion member 60 and the first facing portion 35A, and the cushion member 60 and the second facing portion 35B. Although it is one spring member which has the 2nd press part 51B to form and the connection part 52 which connects the 1st press part 51A and the 2nd press part 51B integrally, it is not limited to this. For example, the structure which equips separately the spring member which forms a clearance gap between a cushion member and a 1st opposing part, and the spring member which forms a clearance gap between a cushion member and a 2nd opposing part may be sufficient. In addition, according to the configuration in which the first pressing portion 51A and the second pressing portion 51B are integrally connected as in the above-described embodiment, the assemblability of the leaf spring member 50 is improved as compared with the configuration in which the spring member is provided separately. Can be improved.

  In the embodiment, the leaf spring member 50 has the second through hole 55 (through hole) as the air flow path facing the exhaust port 45 of the occupant detection sensor 40. However, the present invention is not limited to this. The leaf spring member may have a groove-shaped air flow path. Moreover, in the said embodiment, although the leaf | plate spring member 50 had the through-hole 56 as opening facing the detection part 42, it is not limited to this, For example, a leaf | plate spring member has notch-shaped opening. You may have.

  In the embodiment, the clip 93 is exemplified as the fixing member that fixes the occupant detection sensor 40 and the leaf spring member 50 to the connecting member 30F. However, the fixing member is not limited to this, and the fixing member is, for example, a screw or a pin. May be.

  In the embodiment, the connecting member 30F is supported by the pan frame 12 with a part thereof (the front end portion of the main body 31 and the sandwiching portion 32A) contacting the pan frame 12, but is not limited thereto. Absent. For example, the whole connecting member may be supported by the pan frame in contact with the pan frame.

  In the embodiment, the connecting member 30F that connects the seat springs 20B and 20C is exemplified as the sensor supporting member that supports the occupant detection sensor 40. However, the sensor supporting member is a member that connects the seat springs. Other members may be used. Similarly, in the above-described embodiment, the connecting member 30F is exemplified as the opposing member disposed on the side opposite to the passenger side of the cushion member 60. However, the opposing member is not limited thereto, and the opposing member is a member that connects the seat springs. Other members may be used. Further, the sensor support member and the opposing member may be separate members instead of the same member.

  In the above-described embodiment, as shown in FIG. 12, each mold-side positioning portion 84A is arranged at a position that overlaps the center 64C of the corresponding positioning portion 64A. However, the present invention is not limited to this. For example, referring to FIG. 12, each mold-side positioning portion 84A has a corresponding positioning portion as viewed from a direction orthogonal to the sensor operating portion 63 in a state before the positioning portion 64A is aligned with the mold-side positioning portion 84A. 64A may be arranged on the side opposite to the sensor operating unit 63 side. In other words, the entirety of each mold-side positioning portion 84A may be disposed at a position farther from the center 62C of the region 62A than the entire corresponding positioning portion 64A. Also by this, by aligning the positioning part 64A with the mold side positioning part 84A, the sheet material 62 can be set on the molding die 80 with the sensor operating part 63 stretched, and therefore the sensor operating part 63 of the cushion member 60 can be wrinkled. Can be suppressed.

  In the above-described embodiment, as shown in FIG. 12, the positioning portion 64 and the mold-side positioning portion 84A are circular, but the present invention is not limited to this. For example, the positioning part and the mold side positioning part may have an oval shape, an elliptical shape, or a polygonal shape. In addition, when the positioning part or the mold side positioning part has an oval shape, an elliptical shape, or a polygonal shape, the center of the positioning part or the mold side positioning part is viewed from a direction orthogonal to the sheet material (sensor operating part). The center of gravity of the positioning part and the mold side positioning part shall be meant.

  In the embodiment described above, the sheet material 62 of the cushion member 60 has the four positioning portions 64A in the vicinity of the periphery of the sensor operating portion 63, but the present invention is not limited to this. For example, the number of positioning units provided in the vicinity of the periphery of the sensor operating unit may be two, three, or five or more. Moreover, the structure which consists of a permanent magnet may be sufficient as a positioning part. Further, the positioning portion may be formed in a hole shape and engage with the convex mold side positioning portion. Moreover, in the said embodiment, although the sheet material 62 consisting of a nonwoven fabric (cloth) was illustrated, it is not limited to this, For example, a resin-made sheet | seat etc. may be sufficient.

  In the above embodiment, the configuration in which the seat spring 20, the connecting member 30F, the occupant detection sensor 40, and the leaf spring member 50 are provided in the seat cushion S1 is exemplified, but the present invention is not limited to this. For example, a seat spring, a connecting member (sensor support member / opposing member), an occupant detection sensor, and a leaf spring member (spring member) may be provided on the seat back. In this case, the front side corresponds to the “occupant side” and the rear side corresponds to “the side opposite to the occupant side”.

  In the above-described embodiment, the vehicle seat S used in an automobile is exemplified as the vehicle seat. However, the vehicle seat is not limited thereto, and the vehicle seat is a vehicle other than an automobile, for example, a railway vehicle, a ship, an aircraft, and the like. The sheet used may be used.

40 Occupant Detection Sensor 60 Cushion Member 61 Pad Material 62 Sheet Material 63 Sensor Actuator 64A Positioning Unit 64C Center 80 Mold 80 First Mold 82 Second Mold 84A Model Side Positioning Unit 84C Center S Vehicle Seat

Claims (6)

It is used for a vehicle seat configured to detect the presence or absence of an occupant by activating an occupant detection sensor when the occupant sits, and the pad material and the surface of the pad material opposite to the occupant side are used. A seat that is arranged to be in contact with the occupant detection sensor, and when the occupant sits down, the occupant detection sensor is operated to operate the occupant detection sensor. A cushion member having a portion and a plurality of positioning portions that are provided around the sensor operating portion and position the sheet material with respect to a mold,
The sheet material is set in the mold in a state where the positioning portion is aligned with the mold-side positioning portion of the mold and the sensor operation section is stretched, and the material of the pad material is poured into the mold and solidified. Manufacturing method of cushion member.   When viewed from the direction orthogonal to the sensor operating part in a state before the positioning part is aligned with the mold side positioning part, each mold side positioning part is opposite to the sensor operating part side with respect to the corresponding positioning part. The method for manufacturing a cushion member according to claim 1, wherein the cushion member is disposed on the surface.   When viewed from the direction orthogonal to the sensor operating unit in a state before the positioning unit is aligned with the mold side positioning unit, the center of each mold side positioning unit is on the sensor operating unit side with respect to the center of the corresponding positioning unit. The method for manufacturing a cushion member according to claim 1, wherein the cushion member is disposed on the opposite side of the cushion member.   Each mold side positioning part is disposed at a position overlapping the center of the corresponding positioning part when viewed from the direction orthogonal to the sensor operating part in a state before the positioning part is aligned with the mold side positioning part. The manufacturing method of the cushion member according to claim 3 characterized by things.   The method for manufacturing a cushion member according to any one of claims 1 to 4, wherein the positioning portion is smaller than the mold-side positioning portion when viewed from a direction orthogonal to the sensor operation portion. .   The said mold side positioning part is a magnet, The said positioning part contains a ferromagnetic body, The manufacturing method of the cushion member of any one of Claims 1-5 characterized by the above-mentioned.

Images