JP2008228827A - Headrest and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent wrinkles and slack, etc., from being formed on headrest upholstery by appropriately executing sealing at a cut provided on the headrest upholstery. <P>SOLUTION: A headrest core 30 to which a support stay 14 is assembled is inserted into the headrest upholstery 32 through an upholstery opening formed at an upholstery bottom part 62 by an injection port 66 and cuts 68. Upholstery pressing members 80 and 80 are mounted on the bottom part of the headrest core 30 so as to hold the upholstery bottom part 64 holding the cuts 68 there between with the headrest core 30. When mounting the upholstery pressing members 80, a first locking projection part 86 and a second locking projection part 88 provided on the respective upholstery pressing members 80 are respectively locked to a first locking receiving part 76 and a second locking receiving part 78 provided on the headrest upholstery 32 so as to be adjacent holding the cut 68 there between. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a headrest and a manufacturing method thereof, and more specifically, a headrest having a foam formed by foaming between both members between a headrest skin and a headrest core housed in the headrest skin, and manufacturing the headrest It is about the method.

  A headrest that protects the head and neck of the occupant seated in the seat when the vehicle is rear-projected from behind is standard equipment above the seat back of the seat installed in the passenger compartment of the vehicle. Yes. This type of headrest includes a headrest body that receives the head of the occupant and a headrest support that is mounted on the seat back. The headrest body is composed of a headrest core coupled to a headrest support, a headrest skin disposed outside the headrest core, and a foam disposed between the headrest skin and the headrest core. . The headrest support body is provided with a support stay that is connected to the headrest core and extends outward from the bottom of the headrest body. And a support stay is inserted in the headrest support part provided in the seat back.

For the above-described headrest molding, a headrest skin formed in a bag shape of a required shape and a headrest core attached to a headrest support are prepared. Next, it is carried out by setting the headrest core in a foam mold while being housed in the headrest skin, and foaming the foamed resin raw material injected between the headrest skin and the headrest core to mold the foam. . Such a molding method is generally referred to as a “skin-integral foam molding method”, and can simultaneously perform a foam molding process and a headrest skin mounting process on the foam, thereby reducing the manufacturing cost of the headrest. There are advantages that can be reduced. A headrest manufactured by such a method is disclosed in Patent Document 1, for example.
JP 2005-178196 A

  Incidentally, in recent years, a movable headrest has been proposed in which the headrest body can be displaced in the front-rear direction of the seatback with respect to the headrest support attached to the seatback. In addition, when a rear-end collision occurs in the vehicle, this is detected and the headrest body is instantaneously displaced in front of the seat back, and the head of the occupant who moves backward by the reaction of the rear-end collision is received. Headrests (also referred to as “active headrests”) have been proposed. In such a movable headrest, since the posture displacement mechanism that allows the posture displacement of the headrest body relative to the headrest support body is stored in the headrest core, the size of the headrest core is inevitably large.

  However, the headrest disclosed in Patent Document 1 is suitable for assembling the headrest core and the support stay in the headrest skin, but is not suitable for the headrest core in which the support stay is assembled before being inserted into the headrest skin. . For this reason, in order to insert the headrest core to which the support stay has been assembled in advance, it is necessary to form a skin opening portion having a large opening area that allows insertion of the headrest core at the skin bottom portion of the headrest skin. However, in order to increase the opening area of the skin opening, it is necessary to provide a notch that connects the insertion hole through which the support stay is inserted and the injection port. When this notch is provided, the foam is formed by integral foam molding of the skin. When foam molding is performed, it becomes a problem to perform an appropriate seal at the cut. That is, since it is difficult to properly seal at the cut, the foamed resin material leaks from the gap formed in the cut, and product defects are likely to occur. Furthermore, since there is a notch, wrinkles and slack are easily formed on the headrest skin during foam molding, so that product defects due to wrinkles and slack have not been negligible.

  Therefore, in the present invention, even if a skin opening portion having a large opening area is formed in the headrest skin, a seal at the notch provided in the headrest skin is appropriately made and no wrinkles or slacks are formed. It is an object of the present invention to provide a headrest that can be prevented from occurring.

In order to solve the above-mentioned problems and achieve the intended purpose, the invention according to claim 1 of the present application is used when injecting a foaming resin raw material and an insertion hole through which the support stay is inserted into the skin bottom. A bag-like headrest skin formed with an inlet and a notch extending from the inlet to the insertion hole;
A headrest core that is inserted into the headrest skin through the skin opening formed in the skin bottom by the inlet and the incision, and has the support stay;
A skin pressing member sandwiched between the headrest core and the skin bottom portion sandwiching the notch, and fixed to the bottom of the headrest core;
A first locked portion and a second locked portion that are provided on the headrest skin and are adjacent to each other with the notch interposed therebetween;
A first locking portion and a second engagement provided on the skin pressing member and locked to the first locked portion and the second locked portion by fixing the skin pressing member to the headrest core, respectively. Having a stop,
The foamed resin material injected into the headrest skin from the injection port with the first locking portion and the first locked portion and the second locking portion and the second locked portion locked, respectively. The gist is that the foam is formed between the headrest skin and the headrest core.

  Therefore, according to the first aspect of the present invention, it is preferable that the notch provided in the skin bottom portion is appropriately sealed, and the foam formed by foam molding between the headrest skin and the headrest core leaks from the notch to the outside of the skin. Can be prevented. Further, since the skin bottom is stretched and held during foam molding of the foam, wrinkles and slack are hardly formed on the skin bottom and the like, and the occurrence of product defects due to wrinkles and slack can be prevented.

According to a second aspect of the present invention, the first locked portion and the second locked portion are pocket-shaped portions that open outward from the headrest skin, and the first locking portion and the second locking portion. The gist is that the stop portion is a protruding piece-like portion that can enter the corresponding locked portion.
Therefore, according to the second aspect of the invention, when the skin pressing member is attached to the headrest core, the first locking portion and the second locking portion provided on the skin pressing member are provided with the first covering provided on the headrest skin. The locking portion and the second locked portion can be easily inserted and locked.

According to a third aspect of the present invention, the opposing inner sides of the first locking portion and the second locking portion are formed with inclined surfaces in which the distance between the two gradually decreases toward the base portion. And
Therefore, according to the invention of claim 3, when the first locking portion and the second locking portion are inserted and locked into the corresponding first locked portion and the second locked portion, Since the site | part which faces incision comes relatively close, the adhesion degree of the skin bottom parts in this incision can be raised.

According to a fourth aspect of the present invention, the opposing interior of the first locked portion and the second locked portion is formed with an inclined edge portion in which the distance between the two gradually increases from the opening toward the back. It is a summary.
Therefore, according to the invention of claim 4, when the first locking portion and the second locking portion corresponding to the first locked portion and the second locked portion are inserted and locked, Since the site | part which faces incision comes relatively close, the adhesion degree of the skin bottom parts in this incision can be raised.

The invention according to claim 5 is characterized in that the support stay is inserted through the skin pressing member.
Therefore, according to the invention of claim 5, the skin pressing member is held by the headrest core, and the portion surrounding the support stay can be appropriately sealed.

The gist of the invention described in claim 6 is that a posture displacement mechanism for connecting the headrest core and the support stay is housed inside the headrest core.
Therefore, according to the sixth aspect of the present invention, it is possible to manufacture a movable headrest in which the enlargement of the headrest core cannot be avoided by storing the posture displacement mechanism by the skin-integrated foam molding method.

In the invention according to claim 7, in the skin bottom portion of the headrest skin where the insertion hole and the injection port for inserting the support stay are formed, a notch that connects these insertion hole and the injection port is formed,
The headrest core having the support stay is inserted into the headrest epidermis through the skin opening formed in the epidermis bottom by the inlet and incision in the epidermis bottom,
With the support stay aligned with the insertion hole, sandwich the skin bottoms on both sides sandwiching the notch with the headrest core, and fix the skin pressing member to the bottom of the headrest core,
When fixing the skin pressing member to the bottom portion of the headrest core, a first locking portion and a second locking portion provided on the skin pressing member are provided on the headrest skin so as to be adjacent to each other with the notch interposed therebetween. The first locked portion and the second locked portion are respectively locked,
Set the headrest skin with the headrest core inserted in a foaming mold, and inject the foamed resin raw material into the headrest skin through the inlet,
The gist is to form the foam by foaming the foamed resin material between the headrest skin and the headrest core.

  Therefore, according to the seventh aspect of the present invention, it is possible to insert the headrest core with the support stays assembled in advance into the headrest skin through the skin opening prior to foam molding. In addition, since the portion adjacent to the cut at the skin bottom is sandwiched between the headrest core and the skin presser member, the cut portion can be properly sealed, and the foamed resin material can be removed from the cut during molding of the foam. It can prevent leakage to the outside. And in the case of shaping | molding of a foam, it can prevent suitably that a wrinkle and slack are formed in the skin bottom part.

  According to the headrest of the present invention, in order to insert a relatively large headrest core to which the support stay is connected into the headrest epidermis, a cut is formed in the headrest epidermis to form a skin opening having a large opening area. Even so, since the sealing at the notch is appropriately performed and no wrinkles or slacks are formed, the occurrence of product defects can be suitably prevented.

  Further, according to the headrest manufacturing method according to another invention, the headrest manufactured by molding the foam does not have wrinkles or slack at the bottom of the headrest skin, so product defects due to wrinkles or slack Can be prevented.

  Next, the headrest and the manufacturing method thereof according to the present invention will be described below with reference to the accompanying drawings by giving a preferred embodiment. In the embodiment, as shown in FIG. 2, a movable headrest HR in which the headrest body 12 is displaced in posture when a rear-end collision of the vehicle occurs is illustrated. In the embodiment, the left side in FIG. 2 (the side in front of the seat S that receives the head of the occupant) is the front side of the headrest HR.

  As shown in FIG. 2, the headrest HR of the embodiment is configured such that the support stays 14 and 14 are inserted from above into stay support members 120 and 120 that are disposed so as to open on the upper surface of the seat back S1 that constitutes the seat S. By being inserted, it is mounted on the upper part of the seat back S1 and used for implementation. The headrest HR is a movable type in which a later-described posture displacement mechanism 20 mechanically or electrically connected to a collision detection means (not shown) is stored in the headrest body 12. Therefore, when the rear-end collision detection means detects the occurrence of a rear-end collision with respect to the vehicle, the headrest HR is moved to the normal use position (hereinafter referred to as “normal position”) indicated by a two-dot chain line in FIG. To a position (hereinafter referred to as “emergency position”) that moves when a rear-end collision accident indicated by a solid line occurs.

  Such a movable headrest HR includes a headrest support 10 having the above-described support stays 14 and 14 and a headrest body 12 disposed on the headrest support 10. A rotation support member 22 in the posture displacement mechanism 20 is pivotally supported by a fixed support member 16 of the headrest support 10 via a first shaft member 24. The headrest body 12 is coupled to the rotation support member 22. In addition, the headrest body 12 is coupled to a body support portion 40A (described later) provided on the headrest body 12 so as to be slidable with respect to the support stays 14 and 14 of the headrest support 10. Accordingly, the head support body 22 is rotated from the hanging posture indicated by the two-dot chain line in FIG. 2 to the horizontal posture indicated by the solid line, so that the headrest body 12 slides relative to the support stays 14 and 14 while moving upward. The posture is shifted from the normal position to the emergency position.

  In FIG. 2, reference numeral 26 denotes a torsion spring that constitutes the posture displacement mechanism 20, and reference numeral 28 denotes a lock member. The torsion spring 26 functions to apply an urging force to the rotation support member 22 and rotate it from the hanging posture to the horizontal posture. The lock member 28 holds and holds the rotation support member 22 in a suspended position (indicated by a two-dot chain line in FIG. 2), and rotates so that the front end side is displaced downward when the collision detection means detects the collision. Thus, the locking with respect to the rotation support member 22 is released. Therefore, the turning support member 22 is allowed to turn to the horizontal posture by the urging force of the torsion spring 26.

  As shown in FIG. 2, the headrest main body 12 includes a headrest core 30 having a hollow box shape, a headrest skin 32 disposed outside the headrest core 30, and between the headrest core 30 and the headrest skin 32. It is comprised from the foam 34 provided in this. The foam 34 is foam-molded between the headrest skin 32 and the headrest core 30, as will be described later, using the foam molding die 100 shown in FIGS.

  As shown in FIGS. 2 and 4, the headrest core 30 includes a front half 36 located on the front side of the headrest HR and a rear half 38 located on the rear side. The front half 36 and the rear half By assembling the body 38, it is configured as a single hollow box having rigidity. Both the front half 36 and the rear half 38 are injection-molded synthetic resin molded members. Then, a protrusion-like fitting portion 36A formed along the contact edge of the front half 36 is provided on the groove-like fitting portion 38A formed along the contact edge of the rear half 38. By fitting, a gap is not formed at the contact boundary portion between the front half 36 and the rear half 38.

  As shown in FIG. 3, insertion holes through which the support stays 14, 14 described above are inserted into the lower portion of the headrest core 30, that is, the bottom wall portions 30 </ b> A, 30 </ b> A provided at the left and right bottom portions of the front half 36 40, 40 are formed. Further, around each insertion hole 40, 40, a body support portion 40 </ b> A is formed that moves while contacting the support stay 14 when the headrest body 12 is displaced between the normal position and the emergency position. Furthermore, as shown in FIG. 3, the bottom wall portions 30A and 30A also function as an installation portion for mounting and fixing skin pressing members 80 and 80 described later. That is, locking holes 42, 42 used when attaching the skin pressing members 80, 80 are formed in the front and rear portions of the bottom wall portions 30A, 30A with the insertion holes 40 interposed therebetween, respectively. In addition, as shown in FIG. 4, the support hole 46 which inserts and supports the 2nd shaft member 44 which pivotally supports the rotation support member 22 so that rotation is possible in the vertical wall part located in the left and right of the front part half body 36. , 46 are formed. Further, on the inner wall surface of the front wall portion in the front half 36, a plurality of horizontal ribs 48 arranged at a predetermined interval in the vertical direction, and a plurality of vertical ribs 50 arranged at a predetermined interval in the horizontal direction Is formed.

  As shown in FIGS. 2 and 3, a seal member 52 formed in a ring shape is attached to each bottom wall portion 30 </ b> A of the front half 36. The seal member 52 is made of, for example, urethane foam, is rich in elasticity, and is configured to be compressively deformable by a pressing force from the outside. Therefore, when the skin pressing member 80 is attached to the headrest core 30, it is appropriately compressed and deformed between the bottom wall portion 30 </ b> A of the headrest core 30 and the headrest skin 32, and the back surface of the headrest core 30 and the headrest skin 32. It comes to seal closely.

  The headrest epidermis 32 is made of the same material as the epidermis used for the seat S and the seat back S1, and is made of, for example, genuine leather, synthetic leather or fabric, and is made of a single or a plurality of epidermis pieces cut into a required shape. A bag is formed by stitching. When the headrest HR is attached to the seat back S1, the skin bottom portion 62 that is on the lower side is separated from the lower edge of the skin front portion 60 with which the head of an occupant using the seat S contacts. A boundary portion between the skin front portion 60 and the skin bottom portion 62 functions as an injection port 66 for injecting the foamed resin material into the headrest skin 32. The skin bottom portion 62 is formed with first insertion holes 72 and 72 that are aligned with the support stays 14 of the headrest support 10 and permit the insertion of the support stays 14 at a position separated by a required distance in the left-right direction. ing. As shown in FIGS. 2 and 3, a front folded portion 60 </ b> A that is folded back inside the headrest skin 32 and extends along the inlet 66 is provided at the lower edge of the front skin portion 60. .

  As shown in FIG. 3, the skin bottom portion 62 has two cuts 68, 68 that connect the left and right ends of the injection port 66 extending in the left-right direction of the headrest skin 32 and the first insertion holes 72, 72. The right and left are spaced apart by a required distance. Accordingly, the skin portion sandwiched between the injection port 66 and the left and right cuts 68 and 68 in the skin bottom portion 62 is a substantially rectangular tongue piece portion 64 that can be turned outward. Accordingly, the skin bottom portion 62 is formed with a horizontally-long rectangular skin opening portion 70 that allows the headrest core 30 to be inserted by turning the tongue piece portion 64 outward. In addition, second insertion holes 74 and 74 that allow insertion of attachment pieces 84 and 84 of skin pressing members 80 and 80, which will be described later, are formed in portions before and after the first insertion holes 72.

  As shown in FIG. 1, the first bottom folded portion 62 </ b> A and the second bottom bent at the front end portion of the skin bottom portion 62 are bent inward of the headrest skin 32 and come into contact with the front folded portion 60 </ b> A of the skin front portion 60. A folded portion 64A is formed (the second bottom folded portion 64A is formed on the tongue piece portion 64). The extension length in the left-right direction combining the first bottom turn-up portions 62A, 62A and the second bottom turn-up portion 64A is the same as the extension length in the left-right direction of the front turn-up portion 60A, as shown in FIG. Is set. The first bottom folded portions 62A, 62A located on the left and right are stitched to the front folded portion 60A at the outer edge (opposite the notch 68). Further, the second bottom folded portion 64A is not stitched with the front folded portion 64A.

  Then, as shown in FIG. 1, the first locking receiving portion (the first bottom receiving portion 62A, 62A and the second bottom turning portion 64A of the skin bottom portion 62 are adjacent to each other with the notches 68, 68 interposed therebetween. A first locked portion) 76 and a second locked receiving portion (second locked portion) 78 are provided. The first lock receiving portion 76 and the second lock receiving portion 78 are formed as a bottomed pocket-like portion that opens outward (upward in FIG. 1) of the headrest skin 32, and the support stay 14 extends. It extends in a direction substantially parallel to the direction (mounting direction of the skin pressing member 80). A first locking portion 86 and a second locking portion 88 provided on the skin pressing member 80 are correspondingly inserted and locked to the first locking receiving portion 76 and the second locking receiving portion 78. Configured to

  In the headrest HR of the embodiment, as shown in FIGS. 1 to 3, the skin bottom portion 62 sandwiching the notch 68 and the tongue piece portion 64 of the skin bottom portion 62 are sandwiched between the headrest core 30 and the bottom portion of the headrest HR. And the skin pressing member 80 fixed to 30 A of bottom wall parts of this headrest core 30 is arrange | positioned. Each skin pressing member 80 is an integrally molded member made of synthetic resin that is injection-molded, and has a member main body 82 formed in a substantially rectangular shape, and attachment pieces 84, 84 protruding from the back surface of the member main body 82. The support stay 14 has a stay insertion hole 90 through which the support stay 14 is inserted in a loosely fitted state.

  Further, as shown in FIGS. 1 to 3, each skin pressing member 80 has a first locking projection (first engagement) that enters the first locking receiving portion 76 and the second locking receiving portion 78 described above. A stop portion) 86 and a second locking projection (second locking portion) 88 are provided so as to project from the front end edge of the member main body 82 toward the headrest skin 32. These first locking projections 86 and second locking projections 88 extend in parallel as shown in FIG. And the arrangement | positioning space | interval of both the latching protrusions 86 and 88 is the 1st latching receiving part 76 and the 2nd latching receiving part in the state by which the tongue piece part 64 is expanded appropriately, as shown in FIG. 78 is configured to coincide with the arrangement interval of 78. In other words, when the skin pressing members 80, 80 are mounted on the bottom wall portions 30A, 30A of the headrest core 30, the first locking projection 86 is inserted into the first locking receiving portion 76 and the second locking projection. By causing the portion 88 to enter the second locking receiving portion 78, the tongue piece portion 64 of the skin bottom portion 62 is held in a stretched state. Thereby, the both sides of the notches 68 and 68 in the skin bottom part 62 are comprised so that it may contact | adhere appropriately.

  As shown in FIGS. 2 and 3, each skin pressing member 80 prevents the headrest body 12 from moving to the normal position (returning back) when moving from the normal position toward the emergency position. A lock plate 92 is provided. The lock plate 92 is formed in a substantially square shape, and the support stay 14 is inserted through the central opening. Further, the lock plate 92 has a structure in which an inner edge end portion 92A of the opening is engaged with an engagement recess 96 provided in the support stay 14 by using the biasing force of the coil spring 94 (see FIG. 2). Further, by pushing the protrusion 92B facing outward from the member main body 82 with a fingertip, the lock plate 92 slides against the member main body 82 against the biasing force of the coil spring 94, and against the locking recess 96. The inner edge end 92A can be unlocked.

  As shown in FIG. 1 and FIG. 3, each of the skin pressing members 80 described above first inserts the support stay 14 through the stay insertion hole 90, and brings it close to the skin bottom 62 along the support stay 14. Then, both mounting pieces 84, 84 protruding from the back surface of the member main body 82 are aligned with the locking holes 42, 42 provided in the headrest core 30 via the second insertion holes 74, 74 provided in the headrest skin 32. At the same time, the tips of the first locking projection 86 and the second locking projection 88 are aligned with the corresponding first locking receiving portion 76 and second locking receiving portion 78. In the state where each is aligned, by pressing the skin pressing member 80 against the headrest core 30, each attachment piece 84 is locked into the corresponding locking hole 42 while being elastically deformed as appropriate, and the first locking protrusion 86 and the second locking projection 88 are inserted and locked to the first locking receiving portion 76 and the second locking receiving portion 78, and the skin pressing member 80 is fixed to the headrest core 30.

  By fixing each skin pressing member 80 to the bottom wall portion 30A of the headrest core 30, the skin bottom portion 62 (tongue piece portion 64) of the headrest skin 32 is sandwiched between the skin pressing member 80 and the headrest core 30. The sealing member 52 is properly sealed. Further, the first locking projection 86 and the second locking projection 88 formed on the skin pressing member 80 are provided on the first locking receiving portion 76 and the second locking receiving portion 78 formed on the headrest skin 32. Since they are respectively inserted and locked, the tongue piece portion 64 of the skin bottom portion 62 is not formed with wrinkles or slack, and both side portions of the cuts 68 and 68 in the skin bottom portion 62 come into close contact with each other.

  The foam 34 of the headrest HR of the above-described embodiment is foam-molded using the foam molding die 100 shown in FIG. The foam mold 100 includes a first mold 100A and a second mold 100B whose lower ends are hinged to each other, a third mold 100C hinged to the upper part of the first mold 100A, and a second mold 100A. The fourth mold 100D is hinged to the upper part of the mold 100B. The foam mold 100 is closed by closing the first to fourth molds 100A, 100B, 100C, and 100D, so that the cavity 102 having the same shape as the outer contour shape of the headrest body 12 is formed inside. It has come to be defined. In addition, between the contact end surfaces of the third mold 100C and the fourth mold 100D, the first through holes 104 and 104 that allow the support stays 14 to be inserted and the inlet 66 of the headrest skin 32 are aligned. Thus, a second through hole 106 that allows insertion of an injection nozzle (not shown) is formed when both molds 100C and 100D are closed. That is, the foam molding die 100 is configured such that the foam 34 can be foam-molded with the headrest skin 32 into which the headrest core 30 assembled to the headrest support 10 is inserted in the cavity 102.

  6 and 7 are explanatory cross-sectional views showing a state in which the foam 34 of the headrest HR of the above-described embodiment is foam-molded using the foam-molding mold 100 shown in FIG. Prior to setting in the foam molding die 100, the headrest core 30 to which the headrest support 10 has been assembled in advance is housed in the headrest skin 32 through the skin opening 70. The headrest body 12 having the skin pressing members 80 and 80 mounted on the headrest core 30 is in contact with the headrest skin 32 and the inner surface of the cavity 102 of the foaming mold 100, and the support stays 14 and 14 are the first through holes 104 and 104. Then, the foam mold 100 is closed. Next, after the foam molding die 100 is closed, an injection nozzle is inserted into the injection port 66 through the second through hole 106, and a predetermined amount of foam resin material is injected into the headrest skin 32. Therefore, the injected foamed resin raw material expands so as to fill the entire space while performing a foaming reaction in the space defined between the headrest skin 32 and the headrest core 30.

  Here, in the headrest HR of the embodiment, the first locking projection 86 and the second locking projection 88 of the skin pressing members 80 and 80 described above are the first locking receiving portion 76 and the second engagement of the headrest skin 32. Since the stopper portion 78 is inserted and locked, the aforementioned skin bottom portion 62 is held in a state of being in close contact with each other at the cuts 68 and 68. Accordingly, the tongue piece portion 64 of the skin bottom portion 62 is held in the stretched state even when the foaming pressure of the foam 34 before curing that expands in the space is applied. Thereby, at the time of foam molding of the foam 34, wrinkles and slack do not occur in the tongue piece portion 64 of the skin bottom portion 62, and the occurrence of defective products due to wrinkles and slack of the headrest skin 32 is prevented. In addition, the seal member 52 disposed so as to surround the notches 68 and 68 of the skin bottom portion 62 is sandwiched between the skin pressing members 80 and 80 and the bottom wall portions 30A and 30A of the headrest core 30. Therefore, the site | part adjacent to the notches 68 and 68 is appropriately sealed with the sealing member 52, and it can prevent suitably that the foam 34 before hardening leaks out from this notch 68 and 68 outside.

  Further, since the skin bottom portion 62 is held by the skin pressing member 80, the first bottom fold portions 62A and 62A and the second bottom fold portion 64A provided in the skin bottom portion 62, and the front surface provided in the skin front portion 60 are provided. The part folding part 60A may be in a close contact state. Thereby, since the injection port 66 is held in a closed state, the foam 34 before curing is preferably prevented from leaking out of the outer skin from the injection port 66.

  If the manufacturing method of the headrest HR mentioned above is put together, it will come through the following series of work processes. First, the first insertion holes 72 and 72 through which the support stays 14 and 14 are inserted, and the skin bottom portion 62 of the headrest skin 32 in which the injection port 66 is formed, cuts connecting the first insertion holes 72 and 72 and the injection port 66. 68, 68 are formed. In another step, the headrest core 30 is assembled to the headrest support 10 (FIG. 4).

  Next, the tongue piece portion (skin portion) 64 surrounded by the injection port 66 and the cuts 68 and 68 of the skin bottom portion 62 is rolled up, and thereby the support stay is provided via the skin opening portion 70 formed in the skin bottom portion 62. The headrest core 30 having 14, 14 is inserted into the headrest skin 32 (FIG. 3). Then, with the support stays 14, 14 aligned with the first insertion holes 72, 72, the tongue piece portion 64 is returned to the original state so as to close the skin opening 70.

  Next, the skin pressing members 80, 80 are fixed to the bottom wall portions 30A, 30A of the headrest core 30 so that the skin bottom portions 62 on both sides of the cuts 68, 68 are sandwiched between the headrest core 30 (FIG. 3). ). When the skin pressing members 80, 80 are fixed to the bottom wall portions 30A, 30A of the headrest core 30, the first locking projections 86 and the second locking projections 88 provided on the skin pressing members 80, 80 are Then, the first locking receiving portion 76 and the second locking receiving portion 78 provided on the headrest skin 32 are respectively locked so as to be adjacent to each other with the notches 68 and 68 interposed therebetween (FIG. 1).

  Next, the headrest skin 32 into which the headrest core 30 is inserted is set in the cavity 102 of the foaming mold 100. Then, a predetermined amount of foamed resin raw material is injected into the headrest skin 32 through the injection port 66. As a result, the foam 34 is formed by foaming the foamed resin material between the headrest skin 32 and the headrest core 30 (FIGS. 6 and 6).

  Therefore, according to the headrest HR of the embodiment, the following operational effects can be obtained. First, the skin presser members 80 and 80 are attached to the bottom wall portions 30A and 30A of the headrest core 30 housed in the headrest skin 32 so as to sandwich the skin bottom portion 62 of the headrest skin 32. Accordingly, the portions of the cuts 68 and 68 provided in the skin bottom 62 are appropriately sealed, and the foam 34 that is foam-molded between the headrest skin 32 and the headrest core 30 leaks from the cuts 68 and 68 to the outside of the skin. Is preferably prevented. Further, the first locking projections 86 and the second locking projections 88 provided on the skin pressing members 80 and 80 are replaced with the first locking receiving portions 76 and the second locking projections provided on the skin bottom 62 of the headrest skin 32. The receiving part 78 is inserted and locked. Accordingly, the tongue piece portion 64 is stretched and held at the time of foam molding of the foam 34, and it is possible to prevent wrinkles and slack from occurring at the skin bottom 62, and to prevent the occurrence of product defects due to wrinkles and slack. The opening portions of the first locking receiving portion 76 and the second locking receiving portion 78 are oriented in the mounting direction of the skin pressing member 80. Therefore, when attaching the skin pressing member 80 to the headrest core 30, the first locking projection 86 and the second locking projection 88 provided on the skin pressing member 80 are connected to the first locking receiving portion 76 and the first locking receiving portion 76. The two latch receiving portions 78 can be easily inserted and locked.

  Further, by attaching the skin pressing member 80, the periphery of the cuts 68 and 68 can be properly sealed with the sealing member 52, and wrinkles and slack can be prevented from being formed in the headrest skin 32. Therefore, it is possible to increase the size of the tongue piece portion 64 in the skin bottom portion 62 by extending the length of the cut 68. That is, since the opening area of the skin opening 70 formed by rolling the tongue piece portion 64 can be increased, the size of the headrest core 30 inserted into the headrest skin 32 through the skin opening 70 is increased. It can respond suitably. Accordingly, it is possible to manufacture a movable headrest HR in which the enlargement of the headrest core 30 cannot be avoided by storing the posture displacement mechanism 20 by the skin-integrated foam molding method. Further, in the case of the movable headrest HR, the skin pressing member 80 can be a base member on which a reverse return preventing member such as a lock plate 92 is disposed.

  The skin pressing member 80 is attached to the bottom wall portions 30A and 30A of the headrest core 30 after being inserted into the support stay 14, so that the skin pressing member 80 is appropriately positioned with respect to the headrest core 30 and attached. Fixing work is done smoothly. In addition, since the stay insertion hole 90 is formed at a substantially central portion of the member main body 82 of the skin pressing member 80, the peripheral portion surrounding the support stay 14 can be sandwiched and sealed by the skin pressing member 80.

  Moreover, according to the manufacturing method of the headrest HR of an Example, there exist the following effects. First, since the cuts 68 and 68 connecting the injection port 66 and the first insertion holes 72 and 72 are provided in the skin bottom portion 62 of the headrest skin 32, the skin opening portion 70 having a large opening area is formed in the skin bottom portion 62. Can do. Therefore, prior to forming the foam 34, the headrest core 30 in which the support stays 14 and 14 (headrest support 10) are assembled in advance can be inserted into the headrest skin 32 through the skin opening 70. . Further, after the headrest core 30 is housed in the headrest skin 32, the tongue piece portion 64 is returned to its original state, and then the portions adjacent to the cuts 68 and 68 in the skin bottom portion 62 are connected to the headrest core 30 and the skin presser member. Since it is sandwiched between 80 and 80, the portions of the cuts 68 and 68 can be properly sealed, and the foamed resin material is prevented from leaking out of the cuts 68 and 68 during foam molding of the foam 34. Can do. Further, the first locking projection 86 and the second locking projection 88 provided on the skin pressing member 80 are respectively engaged with the first locking receiving portion 76 and the second locking receiving portion 78 provided on the headrest skin 32. Since it was made to stop, when forming the foam 34, it can prevent suitably that the skin bottom part 62 including the tongue piece part 64 can be wrinkled or loosened. Therefore, the headrest HR produced by molding the foam 34 does not have wrinkles or slack formed on the skin bottom 62 of the headrest skin 32, and thus can prevent product defects due to wrinkles or slack.

(Change example)
In the above-described embodiment, the skin presser member 80 is illustrated as being inserted into the support stay 14 of the headrest support 10. However, the skin presser member 80 is not inserted into the support stay 14 as shown in FIG. 8. It may be in the form. In the embodiment, the two skin pressing members 80, 80, which are separately configured on the left and right sides, are illustrated as an example. However, as shown in FIG. 9, a single skin covering almost the entire skin bottom 62 is provided. It is also possible to employ the skin pressing member 80. In addition, in the case of the single skin pressing member 80, any of a type (FIG. 9) inserted through the support stays 14, 14 and a type (not shown) not inserted through the support stays 14, 14 can be implemented.

  In the embodiment described above, the case where the first locking receiving portion 76 and the second locking receiving portion 78 provided on the headrest skin 32 are bottomed pocket-shaped portions has been exemplified. The portion 76 and the second locking receiving portion 78 may be a cylindrical pocket-shaped portion having an open bottom. Also, the first locking receiving portion 76 is a cylindrical pocket-shaped portion, the second locking receiving portion 78 is a bottomed pocket-shaped portion, or the first locking receiving portion 76 is a bottomed pocket-shaped portion. The second locking receiving portion 78 may be a cylindrical pocket-shaped portion. Further, although not shown in the drawings, slits extending in the lateral direction are formed in the first bottom folded portion 62A and the second bottom folded portion 64A, and these slits are respectively formed in the first locking receiving portion 76 and the second locking receiving portion. 78 may be used. In this embodiment, the first locking projection 86 and the second locking projection 88 of the skin presser member 80 enter the corresponding first locking receiving portion 76 and the second locking receiving portion 78 and enter the first It comes to be inserted into the back side of the bottom folded portion 62A and the second bottom folded portion 64A.

  As shown in FIG. 10 (a), when the inner surfaces of the first locking receiving portion 76 and the second locking receiving portion 78 extend in parallel, the first locking protrusion 86 and the first locking protrusion 86 described above. The two locking protrusions 88 may be provided with an inclined surface 110 on the inner side surface (opposing surface) where the distance between both gradually decreases toward the base. However, the interval L1 between the bases of the first locking projection 86 and the second locking projection 88 is set to be smaller than the interval W1 between the first locking receiving portion 76 and the second locking receiving portion 78. Is assumed. Under the condition of L1 <W1, when the first locking projection 86 and the second locking projection 88 are inserted and locked to the corresponding first locking receiving portion 76 and the second locking receiving portion 78, As shown in FIG. 10B, the distance between the first locking receiving portion 76 and the second locking receiving portion 78 becomes narrower as the insertion degree increases. That is, when the first locking projection 86 and the second locking projection 88 are inserted and locked to the corresponding first locking receiving portion 76 and second locking receiving portion 78, the cut 68 of the skin bottom portion 62. , 68 are relatively close to each other, and the degree of contact between the two portions 62, 64 in the cut 68 can be increased. Moreover, since the skin pressing members 80, 80 are disposed on the left and right sides of the tongue piece portion 64 in the skin bottom portion 62, the first locking projections 86 and the second locking projections 88 of the both skin pressing members 80, 80 are provided. When the inclined surface 110 is provided on the tongue piece portion 64, the tongue piece portion 64 is pulled in both the left and right directions, and an appropriate stretched state of the tongue piece portion 64 is obtained. The inclined surface 110 may be formed on both the first locking protrusion 86 and the second locking protrusion 88, or may be formed on only one of them. However, when it is formed on either the first locking projection 86 or the second locking projection 88, the second locking projection 88 may be provided in consideration of extending the tongue piece portion 64. desirable.

  As shown in FIG. 11 (a), when the opposing inner surfaces of the first locking projection 86 and the second locking projection 88 extend in parallel, the first locking receiving portion 76 and The second locking receiving portion 78 may be provided with an inclined edge portion 112 on the inner side surface in which the distance between the two gradually increases from the opening toward the back. However, the distance W2 between the first locking receiving portion 76 and the second locking receiving portion 78 on the back side is larger than the interval L2 between the first locking projection 86 and the distal end of the second locking projection 88. It is assumed to be set to. Under the condition of L2 <W2, when the first locking projection 86 and the second locking projection 88 are inserted and locked to the corresponding first locking receiving portion 76 and second locking receiving portion 78, As shown in FIG. 11B, the distance between the first locking receiving portion 76 and the second locking receiving portion 78 becomes narrower as the insertion degree increases. That is, when the first locking projection 86 and the second locking projection 88 corresponding to the first locking receiving portion 76 and the second locking receiving portion 78 are inserted and locked, the cut 68 of the skin bottom portion 62 is obtained. , 68 are relatively close to each other, and the degree of contact between the two portions 62, 64 in the cut 68 can be increased. Moreover, since the skin pressing members 80, 80 are disposed on the left and right sides of the tongue piece portion 64 of the skin bottom portion 62, the tongue piece portion 64 is pulled in both the left and right directions, and an appropriate stretched state of the tongue piece portion 64 is obtained. It is done. The inclined edge portion 112 may be formed on both the first locking receiving portion 76 and the second locking receiving portion 78, or may be formed on only one of them. However, when it is formed on either the first locking receiving portion 76 or the second locking receiving portion 78, the second locking receiving portion 78 may be provided in consideration of the expansion of the tongue piece portion 64. desirable.

  In the above-described embodiment, the skin pressing member 80 provided with the lock plate 92 is illustrated, but the skin pressing member 80 may not be provided with the lock plate 92. In addition, the headrest HR of the embodiment has been exemplified for implementation in a state in which the skin pressing member 80 is mounted on the headrest body 12, but if there is no problem even if the cut 68 is exposed to the outside, After the foam molding 34, the skin pressing member 80 may be removed.

  In the above-described embodiment, the posture displacement mechanism 20 configured to rotate and displace the rotation support member 22 inside the headrest core 30 is illustrated, but the form of the posture displacement mechanism 20 is not limited to this. Alternatively, it may be a posture displacement mechanism constituted by a link mechanism or the like.

  In the above-described embodiment, the posture displacement mechanism 20 is built in the headrest core 30 and the movable headrest (active headrest) that moves the posture from the normal position to the emergency position when a rear-end collision occurs is exemplified. Not limited to active headrests only. That is, the present invention is also suitably applied to a movable headrest that allows manual displacement of the headrest body while mounted on the seat back S1 and a non-movable headrest that cannot displace the headrest body. Is possible.

  A headrest according to the present invention is a headrest having a foam formed by foaming between both members between a headrest skin and a headrest core housed in the headrest skin, and seats of seats installed in various types of vehicles It can be suitably implemented in the back.

It is the partially broken perspective view which showed the headrest of the Example in the state which mounted | wore the headrest core accommodated in the headrest outer skin with the skin pressing member attached. It is the vertical side view which showed the headrest of the Example in the state with which the seat back was mounted | worn. It is the perspective view which showed the state which mounts a seal member and a skin pressing member while accommodating a headrest core in a headrest skin. It is the perspective view which showed the state which mounts | wears a headrest support body with a headrest core. It is a schematic perspective view of the foaming mold used when shape | molding a foam within a headrest skin. FIG. 6 is a longitudinal front view showing a state in which a foam is foam-molded between a headrest skin and a headrest core by the foaming mold shown in FIG. 5. It is the vertical side view which showed the state which foam-molds a foam between a headrest skin and a headrest core with the foaming mold shown in FIG. It is explanatory perspective view which illustrated another example of a skin pressing member. It is an explanatory perspective view which illustrated another example of form of a skin pressing member. (a) is explanatory drawing which showed another form example of the 1st latching protrusion provided in the skin pressing member, and the 2nd latching protrusion, (b) fixes a skin pressing member to a headrest core. It is explanatory drawing which showed the state by which the 1st latching protrusion and the 2nd latching protrusion were inserted and latched by the corresponding 1st latching receiving part and 2nd latching receiving part. (a) is explanatory drawing which showed the example of another form of the 1st latching receiving part and 2nd latching receiving part which were provided in the headrest skin, (b) is fixing a skin pressing member to a headrest core. FIG. 6 is an explanatory view showing a state in which the first locking projection and the second locking projection are inserted and locked into the corresponding first locking receiving portion and second locking receiving portion.

Explanation of symbols

14 support stays, 20 posture displacement mechanism, 30 headrest core,
32 headrest skin, 34 foam, 62 skin bottom, 66 inlet, 68 notch 70 skin opening, 72 first insertion hole (insertion hole), 76 first locking receiving portion (first locked portion)
78 Second locking receiving portion (second locked portion), 80 Skin pressing member 86 First locking projection (first locking portion), 88 Second locking projection (second locking portion)
100 Foam Mold, 110 Inclined Surface, 112 Inclined Edge

Claims (7)

A bag-shaped headrest skin in which an insertion hole through which the support stay is inserted, an injection port used when injecting the foamed resin material, and a cut extending from the injection port to the insertion hole are formed at the bottom of the skin When,
A headrest core that is inserted into the headrest skin through the skin opening formed in the skin bottom by the inlet and the incision, and has the support stay;
A skin pressing member sandwiched between the headrest core and the skin bottom portion sandwiching the notch, and fixed to the bottom of the headrest core;
A first locked portion and a second locked portion that are provided on the headrest skin and are adjacent to each other with the notch interposed therebetween;
A first locking portion and a second engagement provided on the skin pressing member and locked to the first locked portion and the second locked portion by fixing the skin pressing member to the headrest core, respectively. A stop and
The foamed resin material injected into the headrest skin from the injection port with the first locking portion and the first locked portion and the second locking portion and the second locked portion locked, respectively. A headrest which is foamed and a foam is formed between the headrest skin and the headrest core.   The first locked portion and the second locked portion are pocket-shaped portions that open to the outside of the headrest skin, and the first locked portion and the second locked portion are the corresponding locked portions. The headrest according to claim 1, wherein the headrest is a protruding piece-like portion that can enter the portion.   3. The headrest according to claim 2, wherein an inner surface of the first locking portion and the second locking portion facing each other is formed with an inclined surface in which an interval between the both gradually decreases toward the base portion.   3. The headrest according to claim 2, wherein the opposing inside of the first locked portion and the second locked portion is formed with an inclined edge portion in which the distance between the two gradually increases from the opening toward the back. .   The headrest according to any one of claims 1 to 4, wherein the support stay is inserted through the skin pressing member.   The headrest according to any one of claims 1 to 5, wherein a posture displacement mechanism that connects the headrest core and a support stay is stored inside the headrest core. In the skin bottom of the headrest epidermis in which the insertion hole and the injection port for inserting the support stay are formed, a cut is formed to connect the insertion hole and the injection port,
The headrest core having the support stay is inserted into the headrest epidermis through the skin opening formed in the epidermis bottom by the inlet and incision in the epidermis bottom,
With the support stay aligned with the insertion hole, sandwich the skin bottoms on both sides sandwiching the notch with the headrest core, and fix the skin pressing member to the bottom of the headrest core,
When fixing the skin pressing member to the bottom portion of the headrest core, a first locking portion and a second locking portion provided on the skin pressing member are provided on the headrest skin so as to be adjacent to each other with the notch interposed therebetween. The first locked portion and the second locked portion are respectively locked,
Set the headrest skin with the headrest core inserted in a foaming mold, and inject the foamed resin raw material into the headrest skin through the inlet,
A method for producing a headrest, comprising foaming the foamed resin material between the headrest skin and a headrest core.

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