JP2021151601A - Headrest, and manufacturing method of the same - Google Patents

Abstract

To provide a headrest capable of preventing a core material configured of resin foam from coming off from a headrest stay, and to provide a manufacturing method of the same.SOLUTION: A headrest 10 includes: an insert member 30 obtained by attaching a core material 31 to an upper end part of a headrest stay 11; a pad 22 formed of resin foam and burying a part close to an upper end of the insert member 30; and a bag-like skin 21 covering an external surface of the pad 22. The core material 31 is formed of resin foam harder than resin foam forming the pad 22, and has a housing groove 33 for housing an upper end part of the headrest stay 11. A sheet 15 comprising a porous material is wound around a part in the headrest stay 11, housed in the housing groove 33.SELECTED DRAWING: Figure 2

Description

The present invention relates to a headrest in which an upper end portion of a headrest stay and a core material are embedded in a pad, and a method for manufacturing the headrest.

In the headrest of Patent Document 1, the core material is made of an injection molded product of resin, and the core material and the headrest stay are integrated by engaging the upper end portion of the headrest stay with a hook provided on the core material. ing.

Japanese Patent No. 4620581 (paragraph [0023], FIGS. 1 and 2)

By the way, in the headrest of Patent Document 1, it has been proposed to form the core material with a hard foamed resin. In this case, an accommodating groove is formed in the core material, and the upper end portion of the headrest stay is fitted and fixed in the accommodating groove. However, when the core material is made of foamed resin, a dimensional error is likely to occur in the accommodating groove, and there arises a problem that the core material comes off from the headrest stay. In particular, if the core material comes off from the headrest stay during foam molding, there may be places in the epidermis where the foamed resin does not spread, and pad deficiency may occur.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a headrest capable of preventing a core material made of a foamed resin from coming off from the headrest stay, and a method for manufacturing the headrest.

The invention of the first aspect made to achieve the above object is a pad formed of a core material attached to the upper end portion of the headrest stay and a foamed resin, in which the upper end portion of the headrest stay and the core material are embedded. A headrest including a bag-shaped skin that covers the outer surface of the pad, and the core material is formed of a foamed resin that is harder than the foamed resin that forms the pad, and the upper end of the headrest stay. It is a headrest having an accommodating groove for accommodating a portion, and a sheet made of a porous material is wound around a portion of the headrest stay accommodated in the accommodating groove.

In the invention of the second aspect, the headrest stay is formed in a substantially gate shape including a pair of legs extending in the vertical direction and a top portion connecting the upper ends of the pair of legs. The seat is the headrest according to aspect 1, which is wrapped around the top.

In the invention of the third aspect, the accommodating groove comprises a top accommodating portion accommodating the apex and a pair of leg accommodating portions accommodating the pair of legs, and the one pair of the core materials. The headrest according to the second aspect, wherein the portion sandwiched between the leg accommodating portions is sandwiched between the pair of legs and is compressed and deformed.

In the invention of aspect 4, the core material is the headrest according to any one of aspects 1 to 3, wherein the core material is made of a bead foam molded product.

The invention of aspect 5 is the headrest according to any one of aspects 1 to 4, wherein the sheet is made of a urethane foam having an open cell structure.

In the invention of the sixth aspect, the foamed resin raw material is injected into the skin in a state where the upper end portion of the headrest stay and the core material attached to the upper end portion are inserted into the bag-shaped skin, and the foamed resin raw material is used. A method for manufacturing a headrest that is foam-cured to form a pad. The core material is made of a foamed resin that is harder than the foamed resin that forms the pad, and the core material is attached to the upper end of the headrest stay. Is performed by accommodating the upper end portion of the headrest stay in the accommodating groove formed in the core material, and before accommodating the upper end portion of the headrest stay in the accommodating groove, the accommodating groove of the headrest stay This is a method for manufacturing a headrest in which a sheet made of a porous material is wrapped around a portion housed in a headrest.

In the invention of the seventh aspect, the headrest stay is formed in a substantially gate shape including a pair of legs extending in the vertical direction and a top portion connecting the upper ends of the pair of legs. The method for manufacturing a headrest according to aspect 6, wherein the sheet is wrapped around the top.

In the invention of the eighth aspect, the accommodating groove comprises a top accommodating portion accommodating the apex and a pair of leg accommodating portions accommodating the pair of legs, and the pair of leg accommodating portions. The method for manufacturing a headrest according to aspect 7, wherein the distance between the legs is made larger than the distance between the pair of legs.

[Invention of Aspects 1, 4, 5, 6]
In the present invention, since the sheet is wound around the portion of the headrest stay that is accommodated in the accommodating groove, it is possible to absorb the dimensional error of the accommodating groove by the sheet and prevent the core material from coming off from the headrest stay. can.

The core material is made of, for example, a beaded foam molded product such as polyethylene, polypropylene, or polystyrene, or a rigid urethane foam, and it is particularly preferable that the core material is made of a beaded foamed molded product in terms of weight reduction (invention of aspect 4).

Examples of the porous material constituting the sheet include a breathable non-woven fabric and a urethane foam having an open cell structure. Since the sheet has breathability, when the foamed resin raw material is foamed and cured in forming the pad, the foamed resin raw material can be impregnated into the sheet and the core material can be fixed to the headrest stay. The holding power of the plastic is improved. When the sheet is made of urethane foam having an open cell structure, the elastic force of the urethane foam facilitates the accommodation of the headrest stay in the accommodation groove (invention of aspect 5).

[Inventions of Aspects 2 and 7]
According to the present invention, since the sheet is wound around the part of the headrest stay where the core material is easily removed from the accommodating groove, in other words, the part of the headrest stay where the core material is easily removed, it is possible to efficiently prevent the core material from coming off. It becomes.

[Invention of Aspects 3 and 8]
In the present invention, the portion of the core material sandwiched between the pair of leg accommodating portions is sandwiched between the pair of leg portions of the headrest stay to improve the holding force of the core material.

Perspective view of the headrest according to the embodiment of the present invention Side sectional view of the headrest Perspective view of core material (A) AA cross-sectional view, (B) BB cross-sectional view of the core material An exploded perspective view of the insert member (A) Cross-sectional view around the top accommodating portion of the insert member, (B) Cross-sectional view around the leg accommodating portion of the insert member Perspective view showing the manufacturing process of the headrest Cross-sectional view showing the manufacturing process of the headrest Cross-sectional view showing the manufacturing process of the headrest Cross-sectional view showing the manufacturing process of the headrest

As shown in FIGS. 1 and 2, in the headrest 10 of the present embodiment, the headrest main body 10H is supported by a headrest stay 11 (hereinafter, simply referred to as a stay 11) fixed to the upper part of the seat back 90. It has a structure. The headrest body 10H is formed in a quadrangular pyramid shape that is flat in the front-rear direction. With the stay 11 fixed to the seat back 90, the front surface 10HF of the headrest body 10H is arranged substantially vertically, and the rear surface 10HB of the headrest body 10H is arranged so as to incline backward.

As shown in FIG. 2, the headrest main body 10H covers the outer surface of the pad 22 with a bag-shaped skin 21. The skin 21 is formed by sewing a plurality of skin pieces 21H together, and on the bottom surface of the skin 21, a slit 21S extending in the width direction of the headrest body 10H and a pair of insertion holes 21A, 21A arranged in the width direction of the headrest body 10H. (FIG. 2 shows only one insertion hole 21A.). The pad 22 is made of, for example, a soft urethane foam and is filled in the epidermis 21.

The stay 11 is formed by processing, for example, a metal pipe, and as shown in FIG. 5, the stay 11 extends along the horizontal direction with a pair of legs 12 and 12 extending in the vertical direction. It is formed in a substantially gate shape including a top portion 13 that connects the upper ends of a pair of leg portions 12, 12 to each other. Then, the upper end portion and the top portion 13 of the pair of leg portions 12 and 12 are embedded in the pad 22, and the pair of leg portions 12 and 12 pass through the pair of insertion holes 21A and 21A of the epidermis 21 and the epidermis. It projects outward of 21 (see FIGS. 1 and 2). More specifically, the leg portion 12 has a bending point 12P at an intermediate position in the vertical direction, and a portion of the leg portion 12 below the bending point 12P constitutes an upright portion 12A that is arranged substantially vertically. Then, the portion of the leg portion 12 above the bending point 12P constitutes an inclined portion 12B that inclines toward the front side as it goes upward. Then, the standing portion 12A penetrates the insertion hole 21A.

As shown in FIGS. 1 and 2, the headrest 10 includes a core member 31 in the pad 22. The core material 31 is made of a foamed resin that is harder than the foamed resin that constitutes the pad 22, and is made of, for example, a polypropylene bead foamed molded product. The core member 31 is attached to the upper end of the stay 11 and constitutes the insert member 30 together with the stay 11. Then, in the headrest 10, a portion near the upper end of the insert member 30 (specifically, the upper end portion of the stay 11 and the core material 31) is embedded in the pad 22.

As shown in FIG. 3, the core material 31 is formed in the shape of a quadrangular pyramid flat in the front-rear direction, similarly to the headrest main body 10H. Then, with the stay 11 fixed to the seat back 90 (see FIG. 2), the front surface 31F of the core material 31 is arranged substantially parallel to the front surface 10HF of the headrest body 10H, and the rear surface 31B of the core material 31 is the headrest body 10H. It is arranged substantially parallel to the rear surface 10HB (see FIG. 2).

A recessed portion 32 having a substantially gate shape is formed on the rear surface 31B of the core material 31 so as to correspond to the upper end portion of the stay 11. Specifically, the top of the recessed portion 32 is formed over the entire width direction of the core material 31, and the portions of the recessed portion 32 extending downward from both ends of the top portion are formed on both side portions of the core material 31. ing. Then, a raised portion 36 protruding from the inner surface of the depressed portion 32 is formed in a portion of the core material 31 surrounded by the depressed portion 32. In the present embodiment, a central recess 31A having a shallower depression depth than the recessed portion 32 is formed in the central portion of the rear surface 31B of the core material 31 in the width direction of the core material 31. The back surface of the central recess 31A is substantially parallel to the front surface 31F of the core material 31 (see FIG. 4 (A)).

As shown in FIGS. 4 (A) and 4 (B), a housing groove 33 is provided in the entire inner surface of the recessed portion 32. The core member 31 is attached to the upper end of the stay 11 by fitting the upper end of the stay 11 into the accommodating groove 33. The inner surface of the recessed portion 32 is arranged substantially parallel to the rear surface 31B of the core material 31, and the accommodating groove 33 is also arranged substantially parallel to the rear surface 31B of the core material 31 (see FIG. 4A). ).

The accommodating groove 33 includes a pair of leg accommodating portions 34, 34 accommodating a pair of leg portions 12, 12 of the stay 11, and a top accommodating portion 35 accommodating the apex 13. Here, the portion of the core material 31 sandwiched between the pair of leg accommodating portions 34, 34 is sandwiched between the pair of leg portions 12, 12 of the stay 11 and is in a compressed state.

As shown in FIGS. 6 (A) and 6 (B), in the portion of the raised portion 36 facing the depressed portion 32, a retaining protrusion 33T that restricts the stay 11 accommodated in the accommodating groove 33 from falling off is provided. It is provided. As described above, since the core material 31 is made of foamed resin, the retaining protrusion 33T is compressed by the stay 11 when the stay 11 is accommodated in the accommodating groove 33, and the stay 11 is accommodated in the accommodating groove 33. It is designed to be restored after being housed in.

By the way, in the present embodiment, since the core material 31 is made of foamed resin, a dimensional error of the accommodating groove 33 is likely to occur. Then, when the groove width of the accommodating groove 33 becomes wider than the thickness of the stay 11, there arises a problem that the stay 11 is detached from the accommodating groove 33 and the core material 31 is detached from the stay 11. As a means for solving this problem, it is conceivable to increase the amount of protrusion of the retaining protrusion 33T, but with this means, the core material 31 cannot be removed from the foam molding mold.

In order to solve the above problem, in the headrest 10 of the present embodiment, as shown in FIGS. 5 and 6A, the sheet 15 is wound around the portion of the stay 11 accommodated in the accommodating groove 33. .. Specifically, the seat 15 is wound around the top 13 of the stay 11, which is the most easily pulled out from the accommodating groove 33.

The sheet 15 is made of a porous material, specifically, a urethane foam having an open cell structure. The sheet 15 made of urethane foam having an open cell structure is impregnated with the raw material of the foamed resin constituting the pad 22. Then, the hardness of the sheet 15 is increased by curing the impregnated foamed resin raw material, and the core material 31 is fixed to the stay 11.

The headrest 10 is manufactured as follows. To manufacture the headrest 10, first wrap the seat 15 around the top of the stay 11. Next, the upper end of the stay 11 is fitted into the accommodating groove 33 of the core material 31. As a result, the insert member 30 is completed. Here, the width L1 of the portion of the core material 31 sandwiched between the pair of leg accommodating portions 34, 34 (see FIG. 4B) is the distance L2 between the pair of leg portions 12, 12 of the stay 11. It is slightly larger than (see FIG. 5). Therefore, when the stay 11 is fitted into the accommodating groove 33, the portion of the core material 31 sandwiched between the pair of leg accommodating portions 34, 34 is sandwiched between the pair of leg portions 12, 12 of the stay 11. Compressed in the width direction. Then, the width L1 of the portion sandwiched between the pair of leg accommodating portions 34, 34 becomes the same as the interval L2 of the pair of leg portions 12, 12.

Next, the pair of legs 12 and 12 of the stay 11 to which the core material 31 is attached is passed through the slit 21S of the skin 21 from the tip, and the tips of the legs 12 and 12 are passed through the insertion hole 21A from the inside of the skin 21 as they are. And put it outside (see Fig. 7). Then, the portion of the legs 12 and 12 arranged inside the skin 21 is shifted toward the upper end of the stay 11, and the upper end of the stay 11 is inserted into the skin 21 through the slit 21S.

Next, as shown in FIG. 8, the skin 21 and the stay 11 are set in the foam molding mold 41. At this time, the skin 21 and the stay 11 are arranged upside down, the bottom surface of the skin 21 faces upward, and the pair of legs 12 and 12 of the stay 11 project upward. Then, the injection tube 42 is inserted into the slit 21S of the epidermis 21.

Next, the liquid foamed resin raw material is discharged from the injection pipe 42 into the skin 21 (see FIG. 9). Here, when the foamed resin raw material discharged from the injection pipe 42 hits the core material 31, the core material 31 may come off from the stay 11 due to the discharge pressure. However, in the present embodiment, the central recess 31A of the core material 31 is formed. By arranging it on the extension line of the injection pipe 42, it is possible to prevent the foamed resin raw material discharged from the injection pipe 42 from hitting the core material 31.

When the injection of the foamed resin raw material is completed, the injection pipe 42 is removed from the slit 21S. Then, the foam molding mold 41 is closed, and the foamed resin raw material is foamed and cured. Then, the pad 22 is formed in the epidermis 21 (see FIG. 10). Here, in the foaming and curing process, for example, when the core material 31 is detached from the stay 11 due to the foaming pressure, the distance between the core material 31 and the skin 21 becomes narrow, and the foamed resin raw material does not spread in the gap, and the pad 22 There is a shortage of meat. However, in the present embodiment, the seat 15 makes it difficult for the stay 11 to come out of the accommodating groove 33. Further, when the sheet 15 is impregnated with the foamed resin, the sheet 15 is cured and the core material 31 is fixed to the stay 11. As described above, the core material 31 is prevented from coming off from the stay 11, and the pad 22 is prevented from being deficient.

When the pad 22 is formed, the molded product is removed from the foam molding mold 41. As a result, the headrest 10 shown in FIGS. 1 and 2 is completed.

As described above, in the headrest 10 and the manufacturing method thereof of the present embodiment, since the sheet 15 of the porous material is wound around the portion of the stay 11 accommodated in the accommodating groove 33, the elastic of the sheet 15 causes the accommodating groove 33 to be wound. The dimensional error can be absorbed, and the core material 31 can be prevented from coming off from the stay 11. Further, when the sheet 15 is made of a breathable porous material, when the foamed resin raw material is foamed in forming the pad 22, the foamed resin raw material is impregnated into the sheet 15 and the core material 31 stays. It can be fixed to 11.

Further, according to the present embodiment, the sheet 15 is wound around the top 13 of the stay 11, which is a portion of the stay 11 where the core material 31 is easily detached from the accommodating groove 33, in other words, the core material 31 of the stay 11. It is possible to efficiently prevent the 31 from coming off.

Further, in the present embodiment, since the portion of the core material 31 sandwiched between the pair of leg accommodating portions 34, 34 is sandwiched between the pair of leg portions 12, 12 of the stay 11, the holding force of the core material 31 is increased. Is improved.

[Other Embodiments]
The present invention is not limited to the above-described embodiment. It can be changed and implemented.

(1) In the above embodiment, the sheet 15 may be composed of a closed cell structure foam instead of the open cell structure urethane foam. Even in this case, the dimensional error of the accommodating groove 33 can be absorbed by the elasticity of the foam having the closed cell structure.

(2) In the above embodiment, the sheet 15 may be made of a non-woven fabric. Even in this case, the foamed resin constituting the pad 22 invades the sheet 15 and the core material 31 can be fixed to the stay 11.

(3) In the above embodiment, the seat 15 may be wound around a portion of the leg portion 12 of the stay 11 that is accommodated in the leg portion accommodating portion 34.

(4) In the above embodiment, the core material 31 may be made of a bead foam molded product of polyethylene or polystyrene, or may be made of a hard urethane foam molded product.

(5) In the above embodiment, the accommodating groove 33 is formed on the rear surface 31B of the core material 31, but may be formed on the front surface 31F.

(6) In the above embodiment, the recessed portion 32 is formed in the entire width direction of the core material 31, but may be formed in a part in the width direction.

(7) In the above embodiment, the accommodating groove 33 is formed on the inner surface of the recessed portion 32 provided in the core material 31, but the core material 31 is not provided with the recessed portion 32 and is formed on the rear surface of the core material 31. It may be formed in 31B.

(8) Before the stay 11 is fitted into the accommodating groove 33, the width L1 of the portion of the core material 31 sandwiched between the pair of leg accommodating portions 34, 34 is the width L1 of the pair of leg portions of the stay 11. It may be the same as the interval L2 between 12 and 12, or may be narrower than the interval L2. In this case, the portion sandwiched between the pair of leg accommodating portions 34, 34 is not compressed and deformed by the pair of leg portions 12, 12.

(9) In the above embodiment, the stay 11 is inserted into the skin 21 after the insert member 30 is completed. However, only the stay 11 is inserted into the skin 21 through the insertion hole 21A in advance, and then the stay 11 is inserted. The upper end of the stay 11 is pulled out of the skin 21 through the slit 21S, the sheet 15 is wound around the top 13 of the stay 11, the upper end of the stay 11 is fitted into the accommodating groove 33 of the core material 31, and the upper end of the stay 11 is fitted with the slit 21S. It may be returned to the inside of the epidermis 21. Further, the stay 11 is set in the skin 21 (that is, the upper end portion of the stay 11 around which the seat 15 is wound is arranged in the skin 21, and the legs 12 and 12 of the stay 11 penetrate the insertion hole 21A. The core material 31 may be inserted into the skin 21 and the upper end portion of the stay 11 may be fitted into the accommodating groove 33 of the core material 31 in the skin 21 to attach the core material 31 to the stay 11.

10 Headrest 11 Headrest stay 15 Seat 21 Skin 22 Pad 31 Core material 33 Storage groove

Claims (11)

A core material that can be attached to a part of the headrest stay,
A foamed resin pad that incorporates a part of the headrest stay and the core material and is molded so that the outer surface is covered with a skin.
An elastic member sandwiched between the headrest stay and the core material,
Headrest with. The headrest according to claim 1, wherein the elastic member is porous. The headrest stay has a substantially gate shape in which one ends of a pair of legs are connected at the top, and the core material is provided with a raised portion fitted inside the pair of legs.
The headrest according to claim 1 or 2, wherein the elastic member is sandwiched between the raised portion and the headrest stay. The headrest according to claim 3, wherein the raised portion is press-fitted inside the pair of legs. The core material is provided with an accommodating groove for accommodating a part of the headrest stay.
The headrest according to any one of claims 1 to 4, wherein the elastic member has a sheet shape and is wound around a portion to be accommodated in the accommodating groove. The headrest according to any one of claims 1 to 5, wherein the core material is a bead foam molded product. The headrest according to any one of claims 1 to 6, wherein the elastic member is a urethane foam having an open cell structure. Manufacture of a headrest that forms a pad by attaching a core material to a part of the headrest stay and injecting a foamed resin raw material into the skin with a part of the headrest stay and the core material housed in a bag-shaped skin. It ’s a method,
A method for manufacturing a headrest in which an elastic member is sandwiched between the headrest stay and the core material. The method for manufacturing a headrest according to claim 8, wherein the elastic member is porous. A headrest stay with a core material that is used for the headrest by assembling a core material to a part of the headrest stay.
A headrest stay with a core material in which an elastic member or a porous material is sandwiched between the headrest stay and the core material. A headrest stay used for a headrest with a core material attached to a part of the headrest stay.
A headrest stay in which an elastic member or a porous material is wound around a portion of the headrest stay to be assembled with the core material.

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