JPS60232942A - Manufacturing of headrest - Google Patents

Abstract

PURPOSE:To facilitate a smooth and beautiful finishing without protrusions at joints of skin materials which cover a core by wrapping a core with two sheets of formed skin and heat welding the joints of the formed skin along the external shape of the core while applying pressure and by removing an unnecessary portion of the joints. CONSTITUTION:Skin materials 3 and 4 are formed into a shape in conformity with the external shape of a core 1. The core 1 fits respectively into a weld bottom force 47 and a weld top force 57, and formed skins 30 and 40 do not obstruct a stay 2 and are formed in conformity with the external shape of the core 1 so that the formed skins 30 and 40 are kept tightly to the core 1 by the weld bottom force 47 and the weld top force 57, and by being pressed by electrodes 49 and 59 and outer peripheries 30B and 40B of formed skins 30 and 40 are superposed and heat welded with application of pressure. The formed product is taken out after release from the forces, and extra portions of joints of the outer peripheries of 30B and 40B are cut along the joint 41 and removed. By the above method, a headrest with smooth joint, beautiful appearance, no wrinkles and with the surface skin set closely to the core, and of a high market value is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a headrest.

In general, headrests are attached to the outer surface of a cushioned core that embeds and supports a portion of the stay for seat back mounting.
It is formed by covering a skin material, but the skin material does not blend well with the cushioning core and does not adhere closely, and the joints of the skin become protrusive, resulting in a poor finish.

An object of the present invention is to eliminate the above-mentioned conventional drawbacks, and the purpose of the present invention is to prevent the skin material from adhering to the cushioning core and the joint portion of the skin material covering the core from forming a protrusion. First, it is an object of the present invention to provide a method for manufacturing a headrest that has a smooth and beautiful finish and is easy to carry out.

Next, one embodiment of the present invention will be described with reference to the drawings.

In the figure, reference numeral 1 denotes a core having cushioning properties such as urethane foam, which is molded into a predetermined shape. Reference numeral 2 denotes a U-shaped stay attached to the core body 1, and the seat back is attached to a portion 2A.

2A is enclosed and supported in the core body 1 with the part 2A protruding outward.

Note that the means for attaching the stay 2 to the core body 1 may be a means of encasing and supporting the U-shaped side of the stay 2 within the core body 1 during foam molding of the core body 1, or a means of cutting and molding a cushion material foam body. When forming a core body, the U-shaped side of the stay 2 is enclosed in the core body which is split into two parts, and then the two halves of the core body (not shown) are joined with adhesive to attach the stay 2 to the core body 1. Appropriate mounting means are employed, such as mounting means.

Meanwhile, two skin materials 3 and 4 for covering the core body 1 are prepared. The skin material 3.4 is made of a heat-weldable synthetic resin material, preferably a single thermoplastic synthetic resin, or a resin processed product in which a can body or the like is impregnated with a thermoplastic synthetic resin. It is possible to combine materials that can be heat-welded to each other, such as two sheets of resin, a thermoplastic resin sheet and a can body whose surface is treated with resin, and the thermoplastic resin sheets can be of the same color or different colors. Fortunately, a resin sheet with a decorative cloth adhered to the non-bonded portion in advance may also be used. In this example, the thickness is 1#1l.
A red vinyl chloride sheet with a thickness of 11 mm and a blue vinyl chloride sheet with a thickness of 1 mm were used.

The two prepared skin materials 3.4 are then molded into a shape that matches the outer shape of the core body 1. In other words, 7 is core body 1
The head contact side (in Fig. 2, the upper outer surface of the core 1)
This is a vacuum molding mold having a molding recess 8 that matches the shape of the IA, and an appropriate number of suction holes 9 to 9 are provided through the surface of the molding recess 8 to communicate with a hollow chamber 10 in the mold, and the hollow chamber 10 is connected. conduit 1
1 is connected to suction means (not shown) such as a suction pump. Reference numeral 17 denotes a vacuum forming mold having a molding recess 18 that matches the shape of the head non-contacting side 1B of the core 1 (the lower outer surface of the core 1 in FIG. 2). A suitable number of suction holes 19 to 19 communicating with the hollow chamber 20 in the mold are provided through the hollow chamber 20, and the hollow chamber 20 is connected to a connecting conduit 21.
is connected to a suction means (not shown). Note that the core body 1 is placed in the molding recesses 8 and 18 of the vacuum molding molds 7 and 17.
A recess 1 such as a semicircle for protruding the stay 2 part of the
2.22 is formed.

Therefore, the vacuum molding mold 7 heated in the heating atmosphere
, 17, the skin materials 3.4 are placed on the molding recesses 8, 17, and the suction means is activated to vacuum form the skin materials 3, 4 (forming at 70 to 80°C in this example).After molding, the atmosphere and The vacuum forming molds 7 and 17 are cooled and demolded to obtain a molded skin 30 for covering the head contact side 1A of the core 1 and a molded skin 40 for covering the head non-contacting side 1B of the core 1. In addition, 30A,
40A is a recessed portion for attaching the stay molded in the molded skin 30.40.

Next, a weld lower mold 47 and a weld F mold 57 are prepared for heat-welding the molded skin 30, 40.

The lower weld mold 47 has a fitting recess 48 into which the head contacting side 1A of the core body 1 can be fitted, and an annular electrode 49 is provided along the outer periphery of the fitting recess 48.

The upper weld mold 57 has a fitting recess 58 into which the head non-contacting side 1B of the core body 1 can be fitted, and an annular electrode 59 is provided along the outer periphery of the fitting recess 58. It is. The fitting recesses 48.58 are made of a non-conductive material such as plaster, and the electrodes 49.59 are provided with cutouts 50.60 to avoid contact with the stay 2. A high voltage can be applied to the electrodes 49° and 59.

Thus, the molded skin 30 is fitted into the fitting recess 48 of the lower weld mold 47, and the stay 2 is attached to the recessed portion of the molded skin 30 so that the stay 2 protrudes through the recess 30A. Fit the contact side 1A portion. Next, the stay 2 position is located on the upper part of the core body 1, and the stay is installed in the recess 40.
The concave portion of the molded skin 40 is fitted so as to match A, and the fitting recess 58 of the weld upper die 57 is fitted into the molded skin 40. The lower weld mold 47 and the upper weld mold 57 are each formed with fitting recesses 48° and 58 into which the core 1 is fitted, and the molded skins 30 and 40 are formed so as to match the outer shape of the core 1 without interfering with the stay 2. Therefore, the molded skins 30 and 40 are held in close contact with the core body 1 by the lower weld mold 47 and the upper weld mold 57, and the electrodes 49.
59, the outer peripheral part 30 of the molded skin 30.40
8.40B are overlapped and crimped. By applying a voltage to the electrodes 49.59 of both molds while the lower weld mold 47 and the upper weld mold 57 are pressed together, the overlapping portion of the molded skin 30.40 is moved to the electrode 49.
．． It can be thermally welded at step 59. Note that welding in this example was performed at an oscillation output of 10 and an oscillation time of 3 to 5 seconds.

After the overlapping parts of the molded skin 30 and 40 have been thermally welded, the lower weld mold 47 and the upper weld mold 57 are released from the mold, and the molded body 61 is taken out.

The molded body 61 has a molded skin 30.40 attached to the outer surface of the core 1, and the molded skin 30.40 is heat-welded and bonded 4 along the core 1.
1. Outer periphery 308, 40 of molded skin 30.40
It has a polymerized portion of B. By cutting and removing the unnecessary overlapping portion along the joint portion 41, a predetermined headrest '62□,ゎ is formed. 1. Engineering. . , 40 and the two parts are subjected to external surface treatment by appropriate means. The headrest 62 of this example had one half side blue and the other half side red, and had a beautiful finish.

In this example, the skin material 3.4 is molded using a vacuum molding die 7.
17 to form the molded skin 30.40, but the molding method for the molded skin 30.40 is not limited to vacuum forming, and other molding methods using an upper mold and a lower mold may be employed. Furthermore, the welding of the outer periphery of the molded skin 30, 40 is not limited to the weld type, but may be performed by other heat-pressing means. .

As explained above, the present invention provides an upper mold and a lower mold for forming a molded skin when manufacturing a headrest in which a cushioning core body supporting a stay is covered with a skin material that can be attached to a seat back. and a heat welding means which is separate from the upper and lower molds and which presses and thermally welds the periphery of the molded skin, and heat welds the core body so as to tightly cover it from both sides. Two sheets of synthetic resin skin materials that can be used are formed using the upper and lower molds to create two molded skins, and then the core body is wrapped with these two molded skins, and then each The outer circumference of the molded skin is polymerized, the polymerized part of the molded skin is crimped along the outer shape of the core body using the heat compression bonding means, and is thermally welded, and the unnecessary part of the polymerized part of the skin material after welding is removed. As a result, the above-mentioned object of the present invention can be achieved. That is, in the present invention, heat-weldable synthetic resin skin material is molded into a shape that covers one side and the other side of the core, and the molded skin material wraps the core and covers each side. The outer periphery of the skin material is polymerized, and this polymerized part is crimped along the outer shape of the core using a heat-pressing means such as a welder electrode, and the joint is thermally welded, so the joint part follows the shape of the core. It becomes something.

Since unnecessary polymerized parts are removed along the joining part, it is possible to obtain a headrest with high commercial value in which the joining part is smooth, beautiful and wrinkle-free, and the skin fits closely to the core body.

In addition, in the present invention, the upper and lower molds for forming the molded skin and the heat and pressure bonding means for heat welding the periphery of the molded skin are separate, so there is no need to prepare special equipment and it is easy to carry out the process. It's easy.

[Brief explanation of drawings]

The figure shows the steps of an embodiment of the present invention.
The figure is a plan view of the core body with the stay attached, and Figure 2 is the same as Figure 1■
3 is a sectional view taken along the line ■-■ in FIG. 1, FIG. 4 is a sectional view taken along the IV-mV line in FIG. plan view of
Fig. 6 is a plan view of the vacuum forming mold for obtaining the other molded skin, Fig. 7 is an enlarged sectional view taken along the line Vl-Vf in Fig. 5, and Fig. 8 is an enlarged sectional view taken along the line ■-■ in Fig. 6. Figure, No. 9
The figure is a plan view of the weld lower mold, Fig. 10 is a plan view of the weld upper mold, Fig. 11 is a process diagram of the weld pre-process, Fig. 12 is an enlarged view showing a part of the electrode, and Fig. 13 is a weld state diagram. , FIG. 14 is a plan view of the molded body after welding, and FIG. 15 is a perspective view of the molded headrest. 1... Core body 2... Stay 2A... Mounting part 3.4... Skin material 7.17...
・Vacuum forming mold 8.18...Molding recess 30.40...
- Molded skin 30B, 40B...Outer peripheral part 41...Joint part 47...Weld lower mold 48.58...Fitting recess 49, 59...Electrode 57...Weld upper mold 6
1°... Molded body 62... Headrest applicant Kyowa Sangyo Co., Ltd. Agent Patent attorney Oka 1) Hidehiko Figure 1 m4-I ■'' Figure 2 1Δ Figure 3 Figure 4 Figure 6 Figure 7 ! ! 1 Figure 6 917 Figure 8 M

Claims (1)

[Claims] When manufacturing a headrest that can be attached to a seat back and has a cushioning core that supports stays and is covered with a skin material, the upper and lower molds that form the molded skin and the upper and lower molds are Separate heating and pressing means for pressing and thermally welding the peripheral portion of the molded skin are prepared, and two sheets of synthetic resin that can be thermally welded are prepared so that the core can be tightly covered from both sides. Skin materials are formed using the upper mold and the lower mold to create two molded skins, and then the two molded skins wrap the core body, and then the outer periphery of each molded skin is polymerized, A method for manufacturing a headrest, characterized in that the polymerized portion of the molded skin is crimped along the outer shape of the core body using the heat compression bonding means and heat welded, and unnecessary portions of the polymerized portion of the molded skin are removed after welding. .