JP2005153743A - Headrest and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a headrest for which a rigid polyurethane foamed body can easily be integrate-molded in a flexible polyurethane foamed body when the flexible polyurethane foamed body is molded by filling a skin, and to provide its manufacturing method. <P>SOLUTION: An internal bag 14 is attached to a stay 13 which is passed in the skin 12 in such a manner that the central bending section 13a of the stay 13 may be enveloped. The flexible polyurethane foamed body 15 is molded by filling the skin 12, and at the same time, the rigid polyurethane foamed body 16 which is harder than the flexible polyurethane foamed body 15 is molded by filling the internal bag 14. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a headrest mounted on the upper end of a seat back in a vehicle or the like and a method for manufacturing the headrest.

Conventionally, as this type of headrest, for example, those having configurations as disclosed in Patent Document 1 and Patent Document 2 have been proposed.
In the configuration described in Patent Document 1, the shock absorber is attached to the stay so as to enclose the central bent portion. In addition, a foamed elastic material that is softer than the shock absorber is contained in the bag-like skin so as to surround the shock absorber in a state where the shock-absorbing material is accommodated in the bag-like skin constituting the outer surface of the headrest. They are filled and molded into one piece. In normal times, the head of the occupant seated on the seat is elastically received by the foamed elastic material, and when the occupant of the rear seat collides with the headrest and a large impact is applied, the shock absorber collapses. By doing so, the energy of impact is effectively absorbed.

In the configuration described in Patent Document 2, a film is stretched in the bag-shaped skin that forms the outer surface of the headrest, so that a head-side (front-side) space and a rear-side space are formed in the bag-shaped skin. Is partitioned. The head side space is filled with the foamed elastic material, and the rear side space is filled with a shock absorber harder than the foamed elastic material, and these are integrally formed.
JP-A-9-85755 JP 2002-120237 A

However, these conventional headrests have the following problems.
In the configuration of Patent Document 1, it is necessary to insert and assemble the shock absorbing material into the bag-shaped skin with the shock absorbing material attached to the central bending portion of the stay in advance. Not disclosed. In this case, it is necessary to assemble the shock absorber to the stay before assembling the stay to the skin. In this state, the shock absorber is provided from the slit-shaped opening formed in a part of the bag-like skin. It is difficult to insert a stay.

  In the configuration of Patent Document 2, when the shock absorber is pressed with a strong force, the shock absorber is likely to collapse and a recess may be formed in the collapsed portion. In such a case, the recess Therefore, the appearance was damaged.

  The present invention has been made paying attention to such problems existing in the prior art. An object of the present invention is to provide a headrest that can easily form a shock absorber in the elastic material when the elastic material is filled in the skin, and a method of manufacturing the headrest that does not impair the appearance. It is in.

  In order to achieve the above object, in the invention of the headrest according to claim 1, an inner bag is inserted into a stay inserted into the epidermis and projecting both leg portions from the epidermis so as to enclose the central bent portion. It is characterized in that the inner bag is filled and molded with an impact absorbing material harder than the elastic material filled and molded in the skin.

    The invention according to claim 2 is characterized in that, in the invention according to claim 1, the elastic material is provided around the inner bag so that the inner bag filled with the shock absorbing material is embedded. And

  In the invention of the method for manufacturing the headrest according to claim 3, the inner bag containing the central bent portion of the stay is housed in the skin together with the stay, and the raw material of the elastic material is injected into the skin to be expanded by foaming. Prior to the injection of the raw material of the elastic material, the raw material of the shock absorbing material harder than the elastic material is injected into the inner bag and foamed and expanded.

The invention described in claim 4 is characterized in that, in the invention described in claim 3, the raw material of the elastic material is injected into the skin after the impact absorbing material is cured.
In the invention of the headrest manufacturing method according to claim 5, the inner bag containing the central bent portion of the stay is housed in the outer skin together with the stay, and the inner bag is inflated by blowing air into the inner bag Then, a raw material of an elastic material is injected into the outer skin and foamed and expanded, and then a raw material of an impact absorbing material harder than the elastic material is injected into the inner bag and expanded and expanded.

The invention according to claim 6 is characterized in that, in the invention according to claim 5, a raw material of the shock absorbing material is injected into the inner bag after the elastic material is cured.
Here, for example, a soft polyurethane foam or the like is used as the elastic material, and a hard polyurethane foam or polystyrene foam is used as the impact absorbing material.

(Function)
In the present invention, since the inner bag containing the central bent portion of the stay is freely deformed, the stay provided with the inner bag can be easily inserted into the inside through the opening of the skin. When the elastic material is filled and molded into the outer skin, the shock absorber can be easily integrally formed at the center of the elastic material by filling and molding the shock absorber inside the inner bag. And since an impact-absorbing material is embed | buried in the inside of an elastic material, it is not located in the outer surface side of a headrest.

  As described above, according to the present invention, when the elastic material is filled in the skin, the shock absorbing material can be easily integrally formed in the elastic material, and the shock absorbing material can be formed inside the elastic material. Since it is embedded and is not located on the outer surface side of the headrest, it is possible to prevent the appearance from being deteriorated due to the depression of the shock absorbing material.

(First embodiment)
Below, 1st Embodiment of this invention is described based on FIGS. 1-3.
As shown in FIGS. 1 to 3, the headrest 11 of this embodiment includes a bag-shaped skin 12, a stay 13 inserted through the skin 12, and an inner bag containing a central bent portion 13 a of the stay 13. 14, the hard polyurethane foam 16 filled in the inner bag 14, and the inner bag 14 filled with the hard polyurethane foam 16 are filled in the outer skin 12 around the inner bag 14. Soft polyurethane foam 15. A pair of leg portions 13b of the stay 13 project from the lower surface of the skin 12, and the headrest 11 is attached to the upper end of the seat back 17 of the vehicle via these leg portions 13b.

  The skin 12 forms a bag shape as a whole, for example, a circumferential skin portion 12a made of a material obtained by laminating a polyurethane film on the back surface of a fabric material or leather, and a pair of side skin portions 12b made of the same material. It is formed by sewing. In addition, a slit-like opening for inserting the inner bag 14 into the inside of the skin 12 or injecting a raw material of the flexible polyurethane foam 15 is provided below the circumferential skin portion 12a of the skin 12. 18 is formed, and a pair of stay insertion holes 19 for projecting the leg portions 13b of the stay 13 are formed in a state of being displaced with respect to the opening portion 18.

  The inner bag 14 is formed of a synthetic resin film such as polyethylene or polypropylene. In addition, on the outer peripheral edge of the inner bag 14, a pair of cylindrical insertion holes 20 for inserting the leg portions 13b of the stay 13 and a cylindrical shape for injecting the raw material of the rigid polyurethane foam 16 are used. An injection port 21 is projected. Then, as shown in FIGS. 3A and 3B, the stay 13 is inserted into the inner bag 14 through both stay insertion holes 20, and the leg portions 13 b of the stay 13 are protruded from the stay insertion holes 20. In this state, both stay insertion holes 20 are sealed by fitting metal retaining rings 22 from the outer periphery of both stay insertion holes 20 into the locking grooves 13 c of both leg portions 13 b of the stay 13.

  The soft polyurethane foam 15 is foam-molded so as to be integrated with the skin 12 by being injected into the inside through the opening 18 of the skin 12 in a state where the raw material accommodates the inner bag 14 in the skin 12. Yes. The hard polyurethane foam 16 is foam-molded so that the raw material is injected into the inner bag 14 from the injection port 21 and integrated with the inner bag 14 at the center of the flexible polyurethane foam 15.

Next, the manufacturing method of the headrest 11 comprised as mentioned above is demonstrated.
When manufacturing the headrest 11, first, as shown in FIG. 3A, the stay 13 is inserted into the inner bag 14 through the stay insertion opening 20, and the headrest 11 is inserted into the central bent portion 13a. The bag 14 is attached in an enclosed state, and the leg portion 13 b of the stay 13 is protruded from each stay insertion opening 20. The inner bag 14 is attached by passing one leg 13 b of the stay 13 from one stay insertion port 20 of the inner bag 14 to the other stay insertion port 20. Then, as shown in FIG. 3 (b), a retaining ring 22 is fitted from the outer periphery of both stay insertion ports 20 to the locking grooves 13 c of both leg portions 13 b of the stay 13, and the inner bag 14 is attached to the stay 13. While maintaining the attached state, both stay insertion ports 20 are sealed.

  Subsequently, as shown in FIGS. 3C and 3D, the stay 13 and the inner bag 14 are inserted into the inside of the skin 12 through the opening 18, and both the leg portions 13 b of the stay 13 are inserted through the stay of the skin 12. While making it protrude outside from the opening | mouth 19, the injection port 21 of the inner bag 14 is protruded outside from the opening part 18 of the outer skin 12. FIG. Thereafter, as shown in FIG. 3D, the raw material of the liquid hard polyurethane foam 16 is injected into the inner bag 14 from the injection port 21, and the inner bag 14 and the hard polyurethane foam 16 are integrated. Foam molding as desired. Then, after the hard polyurethane foam 16 is cured to a predetermined hardness, the inlet 21 of the inner bag 14 is cut and removed. Further, as shown in FIG. 3 (e), the raw material of the liquid flexible polyurethane foam 15 is injected into the inside of the skin 12 from the opening 18 in a state where the skin 12 thus formed is accommodated in the foaming mold. The headrest 11 is formed by foaming and curing so as to be integrated with the skin 12.

  In this manner, the inner polyurethane bag 16 is filled and molded in the inner bag 14 with the inner bag 14 containing the central bent portion 13a of the stay 13 inserted in advance in the bag-shaped outer skin 12, and the inner skin 12 The flexible polyurethane foam 15 is filled and molded. For this reason, unlike a conventional headrest in which a shock absorber formed in advance in a predetermined size is attached to the central bent portion of the stay, and the shock absorber is inserted and assembled into the inside through a slit-like opening of the skin, the skin 12 When attaching the stay 13 to the inner bag 14, the inner bag 14 is freely deformed, so that the assembly is not difficult. Therefore, the hard polyurethane foam 16 can be easily integrally formed at the center of the soft polyurethane foam 15.

  As shown in FIG. 1, when the headrest 11 having such a configuration is used by being mounted on the upper end of the seat back 17 of the vehicle, the occupant seated on the seat by the soft polyurethane foam 15 in the outer skin 12 at normal times. The head can be elastically received. Further, when a large impact is applied to the headrest 11 due to a collision of the head of the occupant from the front portion or the rear portion, the hard polyurethane foam 16 made of a foamed resin material harder than the soft polyurethane foam 15 is formed. By being plastically deformed, the energy of impact can be effectively absorbed.

  Furthermore, in this headrest 11, since the hard polyurethane foam 16 is disposed in the center portion of the soft polyurethane foam 15 in the skin 12, the configuration in which the shock absorber is disposed on the rear surface side in the skin is as follows. In contrast, even if an impact is applied, the rigid polyurethane foam 16 that is an impact absorber is not collapsed. Therefore, unlike a conventional headrest, it is possible to prevent a recess from being formed on the surface of the epidermis with the collapse of the shock absorbing material, thereby preventing the appearance from being damaged.

(Second Embodiment)
Next, a second embodiment of the present invention will be described with a focus on differences from the first embodiment.

  In the manufacturing method of the second embodiment, as shown in FIG. 4, the method for assembling the inner bag 14 and the stay 13 to the skin 12 is different from the case of the first embodiment described above. That is, in this embodiment, the slit-shaped opening 18 and the pair of stay insertion ports 19 are formed in a substantially line on the circumferential skin 12 a of the skin 12. Then, as shown in FIG. 4A, first, the inner bag 14 is inserted into the inside through the opening 18 of the epidermis 12 so that the inlet 21 of the inner bag 14 protrudes from the opening 18 in the epidermis 12 to the outside. . Thereafter, as shown in FIG. 4B, the stay 13 is inserted into the inner bag 14 via the stay insertion port 19 of the skin 12 and the stay insertion port 20 of the inner bag 14, and both leg portions of the stay 13 are inserted. 13 b is projected from the stay insertion port 19 to the outside. Also in this case, in the same manner as in the first embodiment, one leg portion 13b of the stay 13 is connected from one stay insertion port 19 of the skin 12 and one stay insertion port 20 of the inner bag 14 to the other stay insertion port. The stay 13 is attached by passing through 19 and 20.

The subsequent filling and forming method of the soft polyurethane foam 15 and the hard polyurethane foam 16 is the same as in the first embodiment.
Therefore, also in the second embodiment, as in the case of the first embodiment, the inner bag 14 is inserted in the skin 12 in advance and the inner bag 14 is filled with the rigid polyurethane foam 16. By molding, the rigid polyurethane foam 16 can be easily integrally formed at the center of the soft polyurethane foam 15.

(Third embodiment)
Next, a third embodiment of the present invention will be described with a focus on differences from the first embodiment.

  In the manufacturing method of the third embodiment, as shown in FIG. 5, the injection order of the raw material of the flexible polyurethane foam 15 and the raw material of the hard polyurethane foam 16 is the same as that in the first embodiment described above. It is different. That is, in this embodiment, as shown in FIG. 5 (a), after assembling the stay 13 and the inner bag 14 in the outer skin 12, the inlet 21 of the inner bag 14 is stored in the mold. Then, air is blown into the inside to inflate the inner bag 14 to a predetermined shape and size, and the inlet 21 is temporarily closed.

  Next, in this state, the raw material of the liquid soft polyurethane foam 15 is injected into the inside from the opening 18 of the skin 12, and foam-molded integrally with the skin 12. When the soft polyurethane foam 15 is cured to a predetermined hardness, as shown in FIG. 5B, the inlet 21 of the inner bag 14 is opened, and the raw material of the liquid rigid polyurethane foam 16 is supplied from the inlet 21 to the inside. And foam-molded integrally with the inner bag 14. Further, after the flexible polyurethane foam 15 is cured to a predetermined hardness, the inlet 21 of the inner bag 14 is cut and removed.

  Accordingly, also in the third embodiment, as in the case of the first embodiment, the hard polyurethane foam 16 can be easily integrally formed in the center portion of the soft polyurethane foam 15 inside the skin 12. .

(Example of change)
In addition, this embodiment can also be changed and embodied as follows.
After the inner bag 14 and the stay 13 are assembled in the outer skin 12 by the method of the second embodiment, the raw materials of the soft polyurethane foam 15 and the hard polyurethane foam 16 are injected by the method of the third embodiment. about.

  In each of the above embodiments, with the stay 13 inserted into the inner bag 14, rubber rings are fitted from the outer periphery of both stay insertion ports 20 of the inner bag 14 to both legs 13 b of the stay 13, and both stays are inserted. Seal mouth 20.

  In each of the above embodiments, with the stay 13 inserted into the inner bag 14, the inner peripheral surfaces of both the stay insertion ports 20 of the inner bag 14 are bonded to the outer peripheral surfaces of both the leg portions 13 b of the stay 13 with an adhesive. And seal both stay insertion ports 20.

  In the first and second embodiments, after filling and forming the hard polyurethane foam 16 in the inner bag 14, the inlet 21 is pushed into the outer skin 12 in a bent state and embedded in the flexible polyurethane foam 15. about.

Sectional drawing which shows the headrest which actualized this invention. The perspective view of the headrest of FIG. (A)-(e) is explanatory drawing which shows 1st Embodiment of the manufacturing method of a headrest. (A) (b) is explanatory drawing which shows 2nd Embodiment of the manufacturing method of a headrest. (A) (b) is explanatory drawing which shows 3rd Embodiment of the manufacturing method of a headrest.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 11 ... Headrest, 12 ... Epidermis, 13 ... Stay, 13a ... Central bending part, 13b ... Leg part, 14 ... Inner bag, 15 ... Soft polyurethane foam, 16 ... Hard polyurethane foam

Claims (6)

An inner bag is attached to a stay that is inserted into the epidermis and has both leg portions protruding from the epidermis so as to enclose the central bent portion, and the inner bag is harder than the elastic material filled in the epidermis. A headrest that is filled with a shock absorber. The headrest according to claim 1, wherein the elastic material is provided around the inner bag so that the inner bag filled with the shock absorbing material is embedded. The inner bag containing the central bent part of the stay is housed inside the epidermis together with the stay, and the raw material of the elastic material is injected into the epidermis to be expanded and expanded, and prior to the injection of the raw material of the elastic material, A method of manufacturing a headrest, comprising injecting a raw material of a shock absorbing material harder than an elastic material to cause foam expansion. 4. The method of manufacturing a headrest according to claim 3, wherein a raw material of an elastic material is injected into the skin after the impact absorbing material is cured. The inner bag containing the central bent part of the stay is housed inside the epidermis together with the stay, and air is blown into the inner bag to inflate the inner bag. And then injecting a raw material of a shock absorbing material harder than the elastic material into the inner bag to expand and expand the headrest. 6. The method of manufacturing a headrest according to claim 5, wherein the material of the shock absorbing material is injected into the inner bag after the elastic material is cured.

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