STRUCTURE OF FOAMING DIE FOR FORMING HEADREST
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a structure of foaming die which is used for forming a headrest for automotive seat and is so designed that an incomplete headiest unit comprising a hollow trim cover assembly and headrest stay (s) attached thereto can be placed therein, and that foaming can be effected thereto so as to produce a resultant headrest in which the trim cover assembly has been formed integrally with a resultant foam padding created by the foaming as well as with the headrest frame.In particular, the invention is directed to a .,structure of foaming die of this kind, which is so designed that a hollow trim cover assembly ' caving a generally trapezoidal head support portion and a generally inverted-L-shaped lateral configuration can be placed therein together with headiest stay ( s) for an integral foaming operation which involves injecting a liquid foaming material into the inside of the trim cover assembly and curing it into a foam padding filled therein, and a resulting headrest with headrest (s) can be removed therefrom subsequent to the foaming operation.The resulting headrest is of such configuration that, as viewed from its front side, the headrest body thereof assumes a generally trapezoidal shape, whereas, as viewed from its one lateral side, the headrest body thereof assumes a generally "inverted L" shape, with the headrest stays (s) extending downwardly therefrom. Hereinafter, such particular headrest shall be referred to as a "generally trapezoidal headrest with generally inverted-L-shaped lateral configuration".
2. Description of Prior Art As disclosed for example from the Japanese Laid-Open Patent Publication No. 11-290154, there has been known a headrest having a generally inverted-L-shaped lateral configuration as viewed from one lateral side thereof, which comprises a vertical frontal head support portion and an upper horizontal portion which extends continuously and horizontally from that vertical frontal head support portion. According to this prior art, a rigid plate member is bent formed into such horizontal top portion and vertical head support portion, and an upholstery is affixed on the outer side of that plate member, while a pair of stays are firmly connected with the horizontal top portion.Normally, in assembly of such inverted-L-shaped headrest, a foaming process has been employed, which involves a step where a preformed hollow three-dimensional trim cover assembly having an inverted-L-shaped lateral configuration is subjected to foaming together with a headrest frame including an integral pair of stays, using a foaming die. Also, as known for example from the Japanese Laid-Open Patent Publication No. 10-329151, there is a foaming die for forming a headrest, which relates to normal headrest without vertically long head support portion and teaches provision of a separate profile retaining plate which can be set and removed into and from a foaming die, the profile retaining plate being adapted to receive a bottom side of the normal headrest within the foaming die, during foaming process.Hence, in that case, the profile retaining plate is first removed before taking out a whole resulting headrest, and therefore, it is easy to remove the resulting headrest with stays from the die.
However, even those conventional foaming die devices are not applicable to the above-mentioned generally trapezoidal headrest with generally inverted-L-shaped lateral * configuration, because the upper and lower die components of the conventional foaming die 'devices are not designed to receive and endose such complicated configuration of headrest in a complete tight condition and not designed to allow easy entry and removal of that particular headrest thereinto and therefrom, neither. Thus, there has been no suitable foaming die designed for that purpose.
SUMMARY OF THE INVENTION
In view of the above-stated drawbacks, it is a purpose of the present invention to provide an improved structure of foaming die which allows a generally trapezoidal headrest with generally inverted-L-shaped lateral configuration to be easily removed therefrom subsequent to a foaming process.
In order to achieve such purpose, in accordance with the present invention, there is oasically provided; A structure of foaming die for forming a headrest with a stay means, wherein the headrest is a generally trapezoidal headrest with generally inverted-L-shaped lateral configuration, which includes a horizontal upper portion and a generally trapezoidal head support portion extending vertically from the horizontal upper portion in such a fashion as to diverge downwardly therefrom, wherein the stay means extends downwardly from the headrest, wherein the foaming die is so designed to allow an incomplete headrest unit to be placed therein, the incomplete headrest unit comprising: a hollow trim cover assembly preformed in conformity with an outer shape of such generally trapezoidal headrest with generally inverted-L-shaped lateral configuration;and the said stay means, wherein the hollow trim cover assembly therefore has: a horizontal upper region corresponding to the horizontal upper portion of the headrest; and a generally trapezoidal head support region corresponding to the generally trapezoidal head support portion of the headrest, the generally trapezoidal head support region having a lower side greater than a upper side thereof, and a pair of downwardly diverging lateral sides, and wherein the foaming die allows a liquid * foaming material to be injected into the hollow trim cover assembly, the structure of foaming die being characterized by induding:
a lower die element having a die surface on which the lower side of the hollow trim cover assembly is to be supportively contacted, the lower die element having at least one hole allowing the stay means to pass therethrough; and a pair of lateral die elements each having a die surface on which each of the pair of downwardly diverging lateral sides of the hollow trim cover assembly is to be contacted, the pair of lateral die elements being movably connected with the lower die element in symmetric fashion relative thereto so as to be displaceable toward and away from respective two lateral sides of the foaming die, thereby allowing entry of said incomplete headrest unit into the foaming die and also allowing removal of a resulting headrest from the foaming die.
Other features and advantages will become apparent from reading the description, with reference to the annexed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a schematic sectional view of a foaming die assembly for forming a headrest in accordance with the present invention, which shows the state where an incomplete headrest unit is placed therein; Fig. 2 is a diagram for explanatorily showing how to remove a resulting headrest from the foaming die assembly; Fig. 3 is a schematic perspective view of the foaming die assembly; and Fig. 4 is a schematic perspective view of an incomplete headrest unit which is to be placed in the foaming die assembly of the present invention.
DETAILED DESCRIPTION OF PREFERRED
EMBODIMENT OF THE INVENTION
Referring to Figs. 1 to 4, there is illustrated an exemplary preferred embodiment of foaming die assembly (D) designed to form a generally trapezoidal headrest with a generally wiverted-L-shaped lateral configuration in accordance with the present invention.
At first, Fig. 4 shows an incomplete headrest unit (HU) formed in conformity with the above-described generally trapezoidal headrest with generally inverted-L-shaped lateral configuration, which has a pair of headrest stays (S) (S) attached thereto, Specifically, the incomplete headrest unit (HU) has an upper horizontal portion (H2) and a vertical trapezoidal head support portion (H1), and such headrest unit (HU) is to be subjected to a foaming process as will be described later. The vertical trapezoidal head support portion (H1 ) is an area for supporting a head of a user (not shown).
The incomplete headrest unit (HU) comprises: a hollow three-dimensional trim cover assembly (T); a headrest frame (F) disposed within that trim cove assembly (T); and a pair of headrest stays (S) (S) integral with the headrest frame (F), which extend downwardly therefrom through the trim cover assembly (T) . The trim cover assembly (T) forms a headrest body and is preformed to have such configuration that, as viewed from its front side, the headrest body region thereof, which corresponds to the trapezoidal head support portion (H1), assumes a generally trapezoidal shape, whereas, as viewed from its one lateral side, the headrest body region thereof (at H1) and the upper horizontal region thereof (at H2) in the aggregate assume a generally "inverted L" shape.
As shown, the trim cover assembly (T) basically has a generally trapezoidal frontal surface (103) corresponding to the generally trapezoidal headrest support portion ( H1 ) , a pair of sloped lateral surfaces (101) (101), and a horizontal upper surface (105) corresponding to the horizontal upper portion (H2). It is seen that the two sloped lateral surfaces (101) diverge downwardly as they proceed from the upper surface (105) to the lower end (103B). Designation (104) denotes a generally trapezoidal rear surface of the trim cover assembly (T), and designation (102) denotes a horizontal reverse surface 'opposite to the horizontal upper surface (105) in the trim cover assembly (T).
Thus, due to such trapezoidal shape, the lower end (at 103B) of trim cover assembly . (T) or the incomplete headrest unit (HU) has a width (W1) greater than a width (W2) thereof.
As best shown in Fig. 2, in accordance with the present invention, there is provided a foaming die assembly (D) which is of a novel structure for allowing the foregoing incomplete headrest unit (HU) to be set in place therein for foaming operation, and also allowing the same to be easily removed therefrom subsequent to the foaming operation.
The foaming die assembly (D) is basically comprised of : a lower die component (1); an intermediate die component (5) formed by a first intermediate die component (5A) and a second intermediate die component (5B) ; a first movable lateral die component (2) ; a second movable lateral die component (3) ; and an upper die component (4) .
The first and second intermediate die components (5A) and (5B) are integrally fixed on the lower die component (1). Defined among those first, second and lower die components (5), (6) and (1) is a space (7) for foaming, in which the headrest portions (at H1 and H2) of the above-stated incomplete headrest (HU) is to be placed for foaming purpose to be set forth later.
Designations (5S) (5S) denote a pair of lateral spaces which are respectively defined in the right and left lateral walls of the intermediate die component (5) , as shown in Fig. 3.
As illustrated, the first and second movable lateral die components (5) (6) are rotatably connected, at their respective lower ends, with the respective two lateral sides of the lower die component (1) by means of the respective two hinges (10) (10) .
More specific description will be made in regard to each of the foregoing die components, referring to Figs. 1, 2 and 3.
The upper die component (4) has a die surface (4A) formed generally in conformity with the outer shape of the upper surface (105) of trim cover assembly (T) .
The lower die component (1) has a die surface (1A) formed generally in conformity with the outer shape of the lower end (103B) of trim cover assembly (T) .
With regard to the intermediate die component (5), the second intermediate die 'component (5B) has, formed in its inward die surface, a recessed die surface area (5C) adapted to receive the upper horizontal region (at H2) of the incomplete headrest unit (HU) . ,Thought not shown clearly, the intermediate die component (5) is or may be formed in its inward die surface with a slightly recessed die surface which is formed generally in conformity with the forward and backward surfaces (at 103 and 104) of the incomplete headrest unit (HU) In accordance with the present invention, the first and second movable lateral die components (2) (3) are rotatable vertically between an operative position and an inoperative position in relation to their respective hinges (10) (10) .In this respect, as shown in Fig. 1, the operative position is defined as a position where both the first and second movable lateral die components (2) (3) are set in the two lateral spaces (5S) (5S) defined respectively in the two lateral sides of the intermediate die component (5) , thereby to place both first and second movable lateral die components (2) (3) in a state ready for foaming operation. By contrast, as can be seen from Figs. 2 and 3, the inoperative position is defined as a position where the first and second movable lateral die components (2) (3) are displaced away from the respective two spaces (5S) (5S), thereby to allow removal of a resulting headrest from the die assembly (5) as will be elaborated later.
Further, as viewed from Figs. 1 for instance, the first movable lateral die component (2) is formed with a downwardly diverging recessed die surface (2A) in the inward side thereof so as to substantially conform in shape to the corresponding sloped right lateral side (at 101) of the generally trapezoidal headrest body portion (H1). Likewise, the second movable lateral die component (3) is formed with a downwardly diverging recessed die surface (3A) in the inward side thereof so as to substantially conform in shape to the corresponding sloped left lateral side (at 101) of the generally trapezoidal headrest body portion (H1).
Designations (11) and (11) denote a pair of stay insertion holes formed in the lower die component (1), thorough which the two headrest stays (S) (S) may be inserted, respectively. Designation (12) denotes a nozzle insertion hole though which an injection nozzle (not shown) is to be inserted for allowing a liquid foaming material to be injected 'therethrough into the inside of trim cover assembly (T) .
In operation, at first, both first and second movable lateral die components (2) (3) are displaced relative to their respective hinges (10) in a direction away from the respective two lateral sides of the intermediate die component (5) to the inoperative position stated previously, which can be understood from Fig. 3.
Then, the incomplete headrest unit (HU) is inserted and placed in the space (7) defined among the first, second and lower die components (5) (6) (1), such that, as shown in Fig. 1, the two headrest stays (S) pass through the respective two stay insertion holes (11). Thereafter, both first and second movable lateral die components (2) (3) are displaced back to the corresponding two lateral sides of intermediate die component (5) relative to their respective hinges (10), so as to enter and engage in the two lateral spaces (5S) , respectively, whereby, as seen in Fig. 1, the two downwardly diverging die surfaces (2A) (3A) respectively of the first and second movable lateral die components (2) (3) fittingly contact and support the respective two sloped lateral surfaces (101) of the trim cover assembly (T).Accordingly, the generally trapezoidal head support portion (H1) of trim cover assembly (T), excepting the top region (105) of its upper horizontal portion (H1), is fittingly and embracingly endosed by the die components (1), (2) , (3) and (5) .
Finally, the upper die component (4) is engaged with the top portions of the thus-formed die components (1, 5 and 3) to completely enclose a whole of the trim cover assembly (T) . Then, while not shown, an injection nozzle is inserted through the nozzle insertion holes (12) and (Th) respectively of the lower die component (1) and trim cover assembly (T) , and a liquid foaming material is injected through the nozzle into the inside of the trim cover assembly (T). Foaming operation is then effected to cure the foaming material and thereby a foam padding (P) is filled in the trim cover assembly (T) .
At the completion of such foaming operation, as indicated by the upward arrow in Fig. 1, the upper die component (4) is disengaged from the die assembly (D) , and then, as can be seen from the two arcuate arrows in Fig. 1 as well as from Figs. 2 and 3, both first and second lateral die components (2) (3) are rotatively displaced and disengaged from the respective two spaces (5S) of the intermediate die component (5) . Thus, the resulting ; headrest (H) is easily removed from the die assembly (D) as shown in Fig. 2.In this respect, it is to be appreciated that, with the outward rotation of the first and second lateral , die components (2) (3) , the two lower end portions respectively of those particular die components (2) (3) , adjacent to the hinges (10), are displaced upwardly to press and raise the two lower corner regions of the foamed trapezoidal headrest body portion ( H1 ) , whereby the top portion of the resulting headrest (H) automatically projects upward from the die assembly (D) and therefore, a worker can grasp the top portion of headrest (H) and easily take out a whole of the headrest (H) from the die assembly (D).
Accordingly, the foaming die assembly (D) in accordance with the present invention, effectively allows for easy entry and removal of a generally trapezoidal headrest thereinto and therefrom.
It should be understood that the present invention is not limited to the illustrated embodiment, but any modification, replacement, and addition may be applied thereto without departing from the scopes of the appended claims.