JP2004322781A - Head rest - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a head rest capable of suppressing the occurrence of an air reservoir inside a coating material, when foaming synthetic resin is injected into the coating material to perform foaming molding. <P>SOLUTION: While a head rest stay 16 is inserted into the bag-like coating material 12 having a slit-like opening 14 in its bottom, the foaming synthetic resin 17 is injected from the opening 14 into the coating material 12 to perform foaming molding. A plurality of small holes 19 are formed in a pair of butting sections 15 folded and formed in the opening 14 of the coating material 12, and air in the coating material 12 is discharged from the small holes 19 to the outside when the foaming synthetic resin 17 is foaming-molded. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a headrest attached to an automobile seat or the like.
[0002]
[Prior art]
As a conventional headrest of this type, for example, a headrest having a configuration disclosed in Patent Document 1 is known. In this conventional configuration, as shown in FIG. 4, a base end of a headrest stay 33 is inserted into a bag-shaped skin material 31 having a slit-shaped opening 32 at the bottom. Then, in this state, a liquid foam synthetic resin 34 is injected into the skin material 31 from the opening 32, and the foam material layer 35 is foamed.
[0003]
[Patent Document 1]
JP-A-9-95199
[Problems to be solved by the invention]
By the way, in this conventional headrest, as shown in FIG. 5, the skin material 31 is housed in a molding die 36 in an upside-down state, and a liquid foam synthetic resin 34 is inserted into the skin material 31 from the opening 32. Injected and foamed. In this case, since the pair of butting portions 32a is formed by folding back at the opening 32 of the skin material 31, when the foamed synthetic resin 34 is sequentially foamed from the lower portion to the upper portion in the skin material 31, the butting portions 32a are formed. Air pools 37 were generated on both sides of the inside. That is, air is trapped in a substantially triangular region between the upper wall portion of the skin material 31 and the butted portion 32a in FIG.
[0005]
When air accumulation occurs in this manner, the texture, such as elasticity and hardness, of the portion differs from that of other portions, and the commercial value is reduced. For this reason, it is necessary to reinject and correct the foamed synthetic resin 34 into the air reservoir 37 in a later step, and there is a problem that the operation is troublesome and the operation efficiency is reduced.
[0006]
In order to cope with such a problem, for example, a method of tilting the molding die 36 at the time of foaming of the foamed synthetic resin 34 to suppress the local occurrence of the air pool 37 can be considered. The skin material 31 is generally composed of a skin layer 31a made of a breathable material such as a fabric and a film layer 31b made of a synthetic resin film or the like inside the skin layer 31a. Alternatively, a method of discharging air from the entire surface of the skin material 31 is also conceivable.
[0007]
However, in the method of tilting the molding die 36, only the position where the air reservoir 37 is generated inside the skin material 31 changes, and the generation of the air reservoir 37 cannot be fundamentally prevented. Further, in the method in which the skin material 31 is composed of only the skin layer 31a, the foamed synthetic resin 34 penetrates into the skin material 31 at the time of foaming, and the surface of the skin material 21 is hardened to cause a deterioration in quality, or air is generated in the skin. Since the material 31 escapes from the entire surface of the material 31, there is a problem that the foaming pressure is insufficient and the whole tension is lost.
[0008]
The present invention has been made by paying attention to the problems existing in such a conventional technique. An object of the present invention is to provide a headrest capable of suppressing the occurrence of air pockets inside a skin material when a foam synthetic resin is injected into the skin material and foamed.
[0009]
[Means for Solving the Problems]
In order to achieve the above object, the invention according to claim 1 is characterized in that a headrest stay is inserted into a bag-shaped skin material provided with a slit-shaped opening at the bottom, and the skin material is cut from the opening. In the headrest formed by injecting a foamed synthetic resin into the inside of the headrest, a non-breathable skin material is used as the skin material, and a pair of butt portions formed by folding back at the opening of the skin material are vented. A hole is formed. Here, the term "non-breathable" means that air in the skin material hardly escapes from the gap between the fibers of the skin material when the foamed synthetic resin expands by foaming.
[0010]
Therefore, according to the first aspect of the present invention, when the foamed synthetic resin is injected into the bag-shaped skin material and foamed, the air at the upper end in the skin material passes through the plurality of small holes. It is discharged outside. Therefore, it is possible to suppress the generation of air pockets inside the skin material, and it is possible to efficiently manufacture a high-quality headrest.
[0011]
According to a second aspect of the present invention, in the first aspect, the air vent holes are a plurality of small holes arranged along the extension direction of the opening. .
[0012]
Since such small holes can be formed by empty stitching with a sewing machine, they can be extremely easily arranged and formed.
According to a third aspect of the present invention, in the second aspect of the present invention, the small hole is formed inside a butt edge of each butt portion.
[0013]
Therefore, according to the second aspect of the present invention, even if the foamed synthetic resin in the skin material slightly leaks from the small holes, it is stopped in the opening without appearing on the outer surface of the skin material. Therefore, it is possible to prevent the appearance of the headrest from being impaired.
[0014]
According to a fourth aspect of the present invention, in the second or third aspect of the present invention, the small holes are arranged at substantially equal intervals in the length direction of each butted portion. It is.
[0015]
Therefore, according to the third aspect of the present invention, the air in the skin material can be uniformly and efficiently discharged over the entire length in the length direction of the butted portion.
[0016]
BEST MODE FOR CARRYING OUT THE INVENTION
An embodiment of the present invention will be described below with reference to FIGS.
As shown in FIG. 1, a skin material 12 of a headrest 11 of this embodiment is formed by cutting a cloth 13 into a predetermined shape, sewing the cloth 13 into a bag shape as a whole, and after sewing, turning the front and back sides. ing. A slit-shaped opening 14 is formed in the center of the bottom of the skin material 12, and the skin material 12 is inverted from the opening 14 after sewing.
The opening 14 is formed with a pair of butting portions 15 that are folded inwardly of the skin material 12 and are in contact with each other, and the opening 14 is formed between the butting portions 15.
[0017]
As shown in FIG. 3, the fabric 13 of the skin material 12 is made of a breathable material such as a fabric, and a skin layer 13a that forms the outside of the skin material 12 and a film layer 13b that is made of a synthetic resin film and located inside. Are laminated. Therefore, the skin material 12 has non-breathability.
[0018]
As shown in FIGS. 1 and 2, the skin material 12 is filled with a foam synthetic resin 17 to form a foam material layer 18. The base end of a headrest stay 16 made of a metal pipe or the like is inserted into the skin material 12 and integrated with the foam material layer 18.
[0019]
As shown in FIGS. 1 to 3, a plurality of small holes 19 are formed in each of the butting portions 15 of the opening 14 so as to penetrate the skin layer 13 a and the film layer 13 b of the cloth 13. These small holes 19 are substantially equidistant D2 along the length direction of the butting portion 15 (the width direction of the headrest 11) at a position spaced a predetermined distance D1 inside the butting edge 15a of each butting portion 15. Is formed. Then, when the foamed synthetic resin 17 is foamed inside the skin material 12, the air in the skin material 12 is discharged to the outside through the small holes 19, and the air pool is formed near the inside of the inside of the butted portion 15. Is prevented from occurring.
[0020]
That is, at the time of manufacturing the headrest 11, as shown in FIG. 2, the bag-shaped skin material 12 after being turned upside down is turned upside down so that the opening 14 faces upward, and the headrest stay 16 is inserted. The molding die 20 is housed between the upper die 20a and the lower die 20b. At the same time, a liquid synthetic foam resin 17 is injected into the skin material 12 from the opening 14 through an injection port (not shown) and foamed. In this case, as the foamed synthetic resin 17 is foamed in order from the lower part to the upper part in the skin material 12, the air inside the skin material 12 is formed with a plurality of small holes formed along each butted portion 15. From 19, it is discharged to the outside through the slit-shaped opening 14. That is, as the foamed synthetic resin 17 is foamed and expanded, the air in the skin material 12 is discharged from the opening 14. After the opening 14 is closed by the foamed synthetic resin 17, the air in the skin material 12 is discharged from each small hole 19. In this case, since the foamed synthetic resin 17 expands so as to move along the inner surface of the skin material 12, the foamed synthetic resin 17 wraps around the inner upper surface of the skin material 12 toward the small holes 19. For this reason, the residual air in the skin material 12 is discharged from the small holes 19. Therefore, unlike the headrest of the conventional configuration, there is almost no possibility that air accumulation occurs in a substantially triangular area between the upper wall of the skin material 12 and each of the butting portions 15.
[0021]
Further, when the foamed synthetic resin 17 is foamed to the upper part in the skin material 12, the foamed synthetic resin 17 may leak from the small holes 19 to some extent. However, as described above, the small holes 19 are arranged inside the butted edge 15a of each butted portion 15 at a predetermined interval D1, so that the leaked foamed synthetic resin 17 is stopped in the opening 14. As a result, the outer surface of the skin material 12 does not appear.
[0022]
For this reason, when the folded width D3 of the butted portion 15 is 10 to 30 mm, it is desirable to set the distance D1 from the butted edge 15a to the formation position of the small hole 19 to be about 5 mm. Further, in consideration of the material mixing state of the foamed synthetic resin 17 and the occurrence of air pockets, the formation interval D2 of each small hole 19 is about 3 mm, and the diameter of each small hole 19 is in the range of 0.3 to 3 mm. It is desirable to set so that
[0023]
In the case of sewing the skin material 12, the small holes 19 are subjected to empty stitching (performing a sewing operation using a sewing machine without using a sewing thread) on both butted portions 15 of the opening portions 14 and using a sewing needle. It is efficient to continuously form needle passage holes of a predetermined diameter at a desired pitch.
[0024]
Therefore, according to this embodiment, the following effects can be obtained.
(1) In this headrest, when the liquid foaming synthetic resin 17 is injected into the bag-shaped skin material 12 and foamed, the air in the skin material 12 is formed at each butt portion 15 of the opening 14. It is discharged outside through the plurality of small holes 19. Therefore, it is possible to suppress the generation of air pockets inside the skin material 12, and it is not necessary to perform a troublesome work of re-injecting the foamed synthetic resin 17 into the air pockets in a later step, and a high-quality headrest Can be manufactured efficiently.
[0025]
(2) In this headrest, since the small holes 19 are formed at a predetermined interval D1 inside the butted edge 15a, the foamed synthetic resin 17 in the skin material 12 slightly leaks from the small holes 19. Even if it does, it is stopped in the opening 14 without appearing on the outer surface of the skin material 12. Therefore, it is possible to prevent the appearance of the headrest 11 from being impaired by the foamed synthetic resin 17 leaking from the small holes 19.
[0026]
(3) In this headrest, since the small holes 19 are arranged at substantially equal intervals D2 in the length direction of the butting portions 15, the air in the skin material 12 is moved in the length direction of the butting portions 15. It is possible to discharge uniformly and efficiently over the entire length. Therefore, it is possible to more reliably suppress the possibility that air accumulation is generated inside the skin material 12.
[0027]
(Example of change)
This embodiment can be embodied with the following changes.
In the above embodiment, the plurality of small holes 19 are formed so as to penetrate only the film layer 13b without penetrating all the layers 13a and 13b of the cloth 13 of each abutting portion 15. That is, sewing is performed after laminating a film in which the small holes 19 are formed in advance on a fabric.
[0028]
In the above-described embodiment, in a state where the opening 14 of the skin material 12 is not arranged above, the foamed synthetic resin 17 is injected into the skin material 12 and then the mold 20 is tilted so that the opening 14 is The posture is changed so as to be upward, and foam molding of the foamed synthetic resin 17 is performed.
[0029]
Use of a synthetic resin such as vinyl or a non-breathable material such as leather as the skin material 12.
[0030]
【The invention's effect】
As described above, as exemplified in the embodiment, in the present invention, with a simple structure, when foaming synthetic resin is injected into the skin material and foam molding is performed, it is ensured that air pockets are generated inside the skin material. And a high-quality headrest can be produced.
[Brief description of the drawings]
FIG. 1 is a partially cutaway perspective view showing a headrest according to an embodiment.
FIG. 2 is a sectional view showing the method of manufacturing the headrest of FIG. 1;
FIG. 3 is an enlarged sectional view of a main part of the headrest of FIG. 1;
FIG. 4 is a partially cutaway perspective view showing a conventional headrest.
FIG. 5 is a sectional view showing the method of manufacturing the headrest of FIG. 4;
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 11 ... headrest, 12 ... skin material, 14 ... opening part, 15 ... butting part, 15a ... butting edge, 16 ... headrest stay, 17 ... foam synthetic resin, 18 ... foam material layer, 19 ... small hole, D1 ... butting The distance from the edge to the small hole, D2 ... the small hole formation interval.

Claims (4)

In a state where a headrest stay is inserted into a bag-shaped skin material provided with a slit-shaped opening at the bottom, a foam synthetic resin is injected into the interior of the skin material from the opening to foam-mold the headrest,
A headrest, wherein a non-breathable material is used as the skin material, and an air vent hole is formed in a pair of abutting portions formed by folding back at the opening of the skin material. The headrest according to claim 1, wherein the air vent holes are a plurality of small holes arranged along an extension direction of the opening. The headrest according to claim 2, wherein the small holes are arranged at substantially equal intervals in a length direction of each butted portion. 4. The headrest according to claim 2, wherein the small hole is formed inside a butt edge of each butt portion. 5.

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