VEHICLE SEAT AND METHOD OF MANUFACTURING VEHICLE SEAT

• US 20160368405A1
• Filed: 09/10/2014
• Published: 12/22/2016
• Est. Priority Date: 01/31/2014
• Status: Active Grant

• Current Assignee: Tachi-S Company Limited
• Original Assignee: Tachi-S Company Limited
• Inventors: MIZUNO, Shinichi, ISHII, Atsushi
• Granted Patent: US 10,414,305 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60N 2/58 Seat coverings
• CPC Class Codes: B60N 2/5866 by thermal welding
• CPC Class Codes: B60N 2/5891 characterised by the manufacturing process; manufacturing seat coverings not otherwise provided for
• CPC Class Codes: B60N 2/64 Back-rests or cushions B60N2/2222 takes precedence

Abstract

A comfortable, well-designed vehicle seat (1) is provided by giving an outstanding, three-dimensional appearance to the surface layer of the vehicle seat so that a new design is achieved and that softness is improved. The vehicle seat has a seat cushion (2) serving as the sitting surface of the seat, a seatback (3) serving as the backrest of the seat, and a headrest (4) protecting the head and neck of an occupant. The surface of at least one of the seat cushion and the seatback is provided with a cover formed of a cloth including an upholstery material (6), a cushion material (8), and a heat-shrinkable material (9). The cover is stitched so that a plurality of bumps and dips are formed on the surface thereof.

Claims

1. A vehicle seat comprising:

a seat cushion serving as the sitting surface of the seat;

a seatback serving as the backrest of the seat; and

a headrest protecting the head and neck of an occupant,

wherein the surface of at least one of the seat cushion and the seatback is provided with a cover formed of a cloth including an upholstery material, a cushion material, and a heat-shrinkable material, and

wherein the cover is stitched so that a plurality of bumps and dips are formed on the surface of the cover.

2. The vehicle seat according to claim 1, wherein the plurality of bumps and dips provide a three-dimensional pattern on the surface of the cover.

3. The vehicle seat according to claim 2, wherein the three-dimensional pattern on the surface is geometric.

4. The vehicle seat according to claim 1, wherein the heat-shrinkable material is polyester.

5. The vehicle seat according to claim 1, wherein the cushion material is urethane or cotton.

6. A vehicle seat comprising:

a seat cushion serving as the sitting surface of the seat;

a seatback serving as the backrest of the seat; and

a headrest protecting the head and neck of an occupant,

wherein the surface of at least one of the seat cushion and the seatback is provided with a cover formed of a cloth including an upholstery material, a cushion material, and a rubber material, and

wherein the cover is stitched so that a plurality of bumps and dips are formed on the surface of the cover.

7. The vehicle seat according to claim 6, wherein the plurality of bumps and dips provide a three-dimensional pattern on the surface of the cover.

8. The vehicle seat according to claim 7, wherein the three-dimensional pattern on the surface is geometric.

9. The vehicle seat according to claim 6, wherein the cushion material is urethane or cotton.

10. A method of manufacturing a vehicle seat comprising:

step (a) of overlapping at least three layers of an upholstery material, a cushion material, and a heat-shrinkable material to make a stack cloth;

step (b) of pattern-stitching the stack cloth; and

step (c) of heating the stack cloth.

11. The method according to claim 10 further comprising, between step (b) and step (c), step (d) of sewing together the stack cloth and a cloth different from the stack cloth to form a trim cover of the vehicle seat.

12. The method according to claim 10 further comprising, after step (c), step (d) of sewing together the stack cloth and a cloth different from the stack cloth to form a trim cover of the vehicle seat.

13. The method according claim 10, wherein the heat-shrinkable material is polyester.

14. The method according to claim 10, wherein the cushion material is urethane or cotton.

17. The method according to claim 10, wherein at least one of a seat cushion serving as the sitting surface of the seat and a seatback serving as the backrest of the seat includes the stack cloth.

15. A method of manufacturing a vehicle seat comprising:

step (a) of overlapping at least three layers of an upholstery material, a cushion material, and a rubber material to make a stack cloth;

step (b) of pattern-stitching the stack cloth in a state where the rubber material is mechanically extended; and

step (c) of releasing the extension of the rubber material.

16. The method according to claim 15, wherein the cushion material is urethane or cotton.

18. The method according to claim 15, wherein at least one of a seat cushion serving as the sitting surface of the seat and a seatback serving as the backrest of the seat includes the stack cloth.