JP2549521B2 - Headrest manufacturing method - Google Patents

Description

The present invention relates to a method of manufacturing a headrest.

(Prior Art) A headrest is mainly composed of a core body provided with a mounting stay, a cushion body such as a polyurethane foam covering the core body, and a skin covering the cushion body. In recent years, in order to make the height of the headrest and the angle of the head receiving surface variable according to the seat height of the occupant, the driving posture, etc., it has been proposed to provide those mechanisms on the core body as in JP 57-15736. There is.

On the other hand, various methods have been proposed as a method of manufacturing this headrest. However, in the case where various functions are built in the core body as in the above-mentioned Japanese Utility Model Publication No. 57-15736, as described in the publication, a predetermined method is used. A method is often used in which a pad (cushion body) having a recess for core body interior is covered with a skin and the core body is internally fixed in the cushion body. However, this method requires a separate step of manufacturing a cushion body, and further a step of applying a skin to the cushion body, and the step of assembling the cushion body is indispensable, which requires a large number of steps and a product. Tends to have insufficient adhesion between the core body and the cushion body.

Therefore, as another method, as in Japanese Patent Laid-Open No. 62-5821, a bag-shaped outer skin is set on a foaming mold, while a core body having a stick is held at a predetermined position in the outer skin, and the remaining outer skin is made of polyurethane or the like. A method has been proposed in which the skin and the core are integrated by injecting and foaming the liquid foaming raw material.
In this method, as the foaming raw material is foamed, the core body is covered with the foam produced and the outer skin is bulged and shaped into a predetermined shape. Further, since the core and the skin are adhered and fixed to each other via the foam, it is advantageous in terms of man-hours as compared with the above-mentioned method, and the fixation of the core is sufficient.

(Problems to be solved by the invention) However, since this method encloses the core body as the liquid foaming raw material is foamed as described above, if the core body that incorporates various mechanisms has an opening, It is often the case that the liquid foaming raw material in the foaming process invades and solidifies to hinder the functions of various mechanisms. However, when it is required that the core and the stay can be displaced relative to each other, such as the function of vertically adjusting the headrest, it is necessary to provide an opening for inserting the stay in the core and the mouth at the opening. It is inevitable that there will be a gap between the edge and the stay. On the contrary, if a gap is not provided, the relative displacement between the core body and the stay becomes impossible, or an extremely large force is required for the displacement. In addition, in order to hold the core body at a predetermined position in the epidermis, a sticky is projected from a hole provided in the epidermis and foam molding is performed while gripping the sticky at the predetermined position.
The foam produced at that time adheres so as to cover the stay, so that the vertical movement of the stay becomes more difficult. Furthermore, the foaming raw material often overflows from the gap between the holes formed in the skin and the stay, which may cause contamination of the outer surface of the skin.

(Means for Solving Problems) Accordingly, the present invention is to provide a novel method for manufacturing a headrest that solves the above-mentioned various problems, and the gist thereof is to provide a headrest core body having a stay. By injecting a foaming raw material into the epidermis inside
In a method of manufacturing a headrest in which a core body is covered with a foam to be generated and the core body and a skin body are integrated with each other, a tubular body made of a foam having an open cell structure is preliminarily attached to the inside of the skin. The core body is held in a predetermined position in the epidermis by lifting the stay after mounting the epidermis in the foaming mold, and the tubular foam is sandwiched between the core body and the epidermis. A method of manufacturing a headrest in which a foaming raw material is injected.

(Function) The tubular body made of foam attached to the stay is compressed and sandwiched between the core body and the inner surface of the epidermis by lifting the stay. That is, both ends of the tubular body made of foam are in close contact with each other around the stay insertion opening of the core and the stay insertion hole of the epidermis, and the opening of the core and the pore of the epidermis are separated from the remaining space in the epidermis. Will be closed. However, since the tubular body is made of a foam having an open-cell structure, residual air in the epidermis and the foaming gas released during the foaming of the liquid foaming raw material easily escape to the outside of the epidermis through the tubular body. To do. However, since the liquid foaming raw material increases its viscosity due to creaming due to the polymerization reaction, etc., some of it impregnates the outer surface of the tubular body, but due to the resistance due to the bubble structure of the tubular body and hardening of the foaming raw material, Hardens without penetrating to the inner surface of the body. As described above, the tubular foam body is impregnated and cured with the foaming raw material in a state of being sandwiched between the core body and the outer skin, so that it is integrated with the foam body produced. Therefore, a predetermined interval is maintained around the stay from the stay insertion hole provided in the outer skin to the stay insertion opening of the core, and the vertical movement of the stay is not hindered. Various functions will also be secured.

(Embodiment) The present invention will be described below based on an embodiment. FIG. 1 shows a skin 30 having a core body 10 in which a tubular body 20 is mounted on a stay 15, and a foam molding die 40 which is a split mold. 2 is a partially cutaway perspective view of FIG. 2, and FIG. 2 is a cross-sectional view of a state in which the mold 40, the skin 30, and the tubular body 20 are cut in a direction perpendicular to the split surface of the foam molding mold 40 through the center of the stay 15. .

The outer skin 30 is made of plastic such as soft vinyl chloride resin and formed into a desired bag shape, and an injection port 31 for injecting a liquid foaming raw material into the bottom portion (the upper portion in the figure, which is upside down) and for mounting Hole 32 for inserting the stay 15
Is provided. Instead of plastic, the skin 30 may be a woven fabric laminated with a plastic film, a foam sheet or the like and sewn with the woven fabric as the outer surface.

The core body 10 is made of a hollow body made of plastic or the like having a stay adjusting mechanism (not shown) for the stay 15 inside, and has a stay inserting opening 11 on the bottom side thereof and passes through the opening 11. One end of the attachment stay 15 is connected to the internal mechanism. Alternatively, the stay 15 may be formed of a mesh tube having a substantially U shape, and the central portion thereof may be incorporated in the core body 10. The vertical adjustment mechanism and the like in the core body 10 are omitted because they are not the gist of the present invention, but Japanese Patent Application No. 61-15489 filed by the applicant of the present invention.
Can be used.

The tubular body 20 is made of a foam having an open cell structure, preferably a soft foam capable of being compressed and deformed, for example, a soft polyurethane foam, and a stay 15 has a center hole 21 through which the stay 15 can be inserted and slid, and a tubular wall thereof. The outer skin on both ends
The thickness is sufficient to cover the stay insertion hole 32 provided in the 30 and the stay insertion opening 11 provided in the core body 10.

The tubular body 20 is attached to the stay 15 provided on the core body 10, and the core body 10 attached with the tubular body is attached to the outer skin 30 with the stay 15.
Is installed so as to project from the insertion hole 32. When the skin 30 is made of a plastic skin during this interior decoration, it is preferable that the skin 30 is interior-molded at the time of molding. For example, when the outer skin 30 is formed by blow molding, the core 10 having the tubular body 20 mounted thereon can be held in a parison so that the outer skin 30 can be formed and the core 10 and the like can be installed at the same time. However, even if it is a plastic skin, it is not limited to this, blow molding, or other slush molding, part of the hollow skin made by rotational molding, preferably, the bottom part to be the mounting side in the headrest is torn by a predetermined length, The core body 10 having the above-mentioned tubular body 20 mounted therein may be installed from the crevice. Further, in the case of a skin made of woven cloth or the like, a bag-like skin having an opening for inserting a core body may be sewn in advance, and the opening may be sewn after the core body 10 and the like are installed.

On the other hand, the foaming mold 40 comprises a split mold (one of which is not shown), and each split surface 41 has a desired headrest cavity.
One half 42 is provided in a concave shape, and a stay holding groove 43 is provided to communicate with the cavity from the outer surface of the mold. Reference numeral 44 denotes a concave groove into which a liquid foaming raw material injection nozzle is inserted, and when the foam molding die 40 is closed, a through hole communicating with the stay holding groove 43 from the outside of the mold to the cavity 42 is formed. The injection nozzle insertion hole 44 does not necessarily have to be provided on the mold splitting surface 41, and may be provided at another position. However, it is needless to say that the injection port 31 provided in the skin 30 faces the nozzle insertion hole 44 when the skin 30 having the core body 10 therein is installed in the foam molding die 40 and the die 40 is closed. 45
Is a nail for positioning the stay 15 at a predetermined height,
It is provided side by side with the stay holding groove 43.

Next, the outer skin 30 having the core body 10 therein is mounted so that the protruding stay 15 fits into the stay holding groove 43 of the foaming mold 40, and is closed with the other foaming mold 40. Foam type at this time
It is preferable that the closing of 40 is performed in two steps, and the sticking of the skin 30 to the cavity 42 is performed during the closing of the first step.
15 closes so that it is movable. Then, the stay 15 is lifted up, and the notch 16 or the like provided for engaging and fixing the stay to the seat back or the like is used to attach the stay 15 to the claw 45.
Then, the second stage mold closing is performed, and the stay 15 is tightly attached with the foaming mold 40. At this time, the tubular foam body 20 attached to the core body 10 and the stay 15 in the epidermis 30 is initially not regulated at all, but is lifted up together by the suspension of the stay 15, so that the core body 10 is at a predetermined position in the epidermis. While being held, the tubular body 20 is sandwiched between the core body 10 and the inner surface of the skin 30, and further compressed so as to be sandwiched. Therefore, the stay insertion opening 11 of the core body 10 and the stay insertion hole 32 of the skin 30 are closed at both end surfaces of the tubular body 20, and the center hole 21 of the tubular body 20 is separated from the intra-epidermal space 33. Becomes The fixing of the position of the stay 15 is not limited to the above, but the claw 45 may be fixed to the stay holding groove.
The stay 15 may be locked at a predetermined position by being provided inside the 43.

After that, an injection nozzle (not shown) for the liquid foaming raw material is inserted into the nozzle insertion hole 44, and the skin 30 facing the insertion hole 44.
A liquid foaming raw material such as flexible polyurethane foam is injected into the outer skin 30 through the injection port 31 of. The injected raw material is thickened by the reaction and generates carbon dioxide gas and the like to be foamed to fill the inside of the epidermis. Therefore, the air in the skin 30 is expelled to the outside of the skin 30 due to the increase in the volume of the generated foam, but at this time, even if the skin 30 is a non-breathable plastic skin, Since the tubular body 20 attached to the cell has a communicating bubble structure, air will escape from the outside of the skin to the outside of the mold through the tubular body 20 and the stay insertion hole 32. On the other hand, when the outer skin 30 is made of woven fabric or the like, the air also escapes from the weave or the like. However, since the foaming raw material is thickened as described above, the flow is hindered by the cell wall of the tubular foam 20, and the outer surface of the tubular body 20 is slightly impregnated to be hardened. It does not reach 21. Further, the hardening fixes the shape of the tubular body 20 in a compressed state.

The above is an embodiment in which the core body 10 is provided with an internal mechanism in order to explain various operations of the present invention. However, even if the core body 10 does not have an internal mechanism, the same thing can be done and functions. It is easy to understand that

(Effects) As described above, in the present invention, in obtaining a headrest in which a core having a stay is integrally covered with a foam and a skin, the possibility that the liquid foaming raw material overflows from the stay insertion hole of the skin can be almost eliminated. Is. Therefore, the outer surface of the epidermis is not contaminated, the finishing process is not necessary, and the product retention can be greatly improved. In particular, even a skin such as a woven fabric which could not prevent permeation of the overflowing foaming raw material in the past can be integrally molded. Further, even if the up-and-down mechanism of the stay is provided in the core, it is possible to prevent the foaming raw material from intruding into the core through the opening for inserting the stay and to secure a void around the stay in the foam. Therefore, the vertical movement mechanism of the stay and the like are not hindered, and the smooth operation of the stay can be ensured.
Even if the core has various functions like this,
The core can be set at a desired position in the foam, and the degree of freedom in designing the headrest can be increased.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view of a skin having a core body and one of the split foaming molds showing the embodiment of the present invention, and FIG. 2 shows the center of the stay when the skin is used as the foaming mold. A longitudinal sectional view through.

Claims (1)

(57) [Claims] 1. A method of manufacturing a headrest in which a core body and a skin are integrated by a foam produced by injecting a liquid foaming raw material into a skin containing a core having a stay, wherein A tubular body made of foam is attached to a stay in the epidermis, the epidermis is placed in a foaming mold, and then the stay is lifted to hold the core body at a predetermined position in the epidermis and the tubular foam body is cored. A method of manufacturing a headrest, which is characterized in that it is sandwiched between a body and an epidermis, and then a foaming raw material is injected.