JP3062034B2 - Headrest manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the manufacture of a headrest to be mounted on an automobile seat for protecting the head of an occupant.
About the method .

[0002]

2. Description of the Related Art FIG.
As shown in FIG. 7, a bag-shaped outer skin 62, a pipe-shaped insert 65 that is partly protruded from the bottom surface 62a of the outer skin 62 and housed in the outer skin 62,
And a foam body 63 foamed therein. In many cases, a plastic blow-molded product is used for the skin 62. In this case, the insert 65 is housed in the skin with a part of the insert protruding from the skin bottom surface 62a during blow molding. The insert 65
The portion 65a protruding from the bottom surface 62a of the skin constitutes a stay for attachment to the seat back.

[0003] The headrest 60 is shown in FIG.
As shown in FIG.
2 is set in a molding die 70 together with the insert 65, and the liquid foaming raw material P is injected into the skin 62 to form a foam 63. Reference numerals 71 and 72
Indicates a split type. However, the headrest 60 having the above structure is used.
, The liquid foaming raw material P easily leaks out of the skin 62 from between the skin 62 and the insert 65 at the portion where the insert 65 of the skin bottom surface 62a protrudes. Therefore, the leaked material adheres becomes burr the skin 62 the outer surface, or damage to the visual appeal of the headrest 60 to be obtained, such as the burr removing work Ri is needed, more that extra use of liquid foaming material There was a problem.

[0004] A cylindrical portion 62b is formed so as to protrude outward from the skin 62 when the skin 62 is formed on the skin bottom surface 62a from which the insert 65 protrudes. Contact the insert 65 and the skin 6
There is also a seal between the two.

However, even in this case, the inner peripheral surface of the cylindrical portion 62b and the outer peripheral surface of the insert 65 are formed as smooth surfaces, and are merely in surface contact. Therefore, due to an increase in the inner pressure of the skin 62 during foaming of the liquid foaming raw material P,
A gap is easily formed between the inner peripheral surface of the tubular portion 62 and the outer peripheral surface of the insert 65, and the liquid foaming raw material P
5 It was not possible to sufficiently prevent intrusion between the outer peripheral surfaces. Therefore, the problem of the stain on the outer surface of the outer skin 62, the deburring operation, and the waste of the liquid foaming raw material could not be solved yet.

Further, before the molding of the foam, the insert 65 is simply inserted into the skin 62 and is slidable with respect to the skin 62. In addition, the insert 65 and the skin 62 do not have any indication of mutual positioning. Therefore, it is difficult to correctly position the insert 65 and the skin 62 during foam molding, and the length of the insert 65 embedded in the foam 63 is not constant, and the quality of the headrest is not constant.

[0007]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a method of manufacturing a headrest which has a good appearance, has a constant quality, and is economically excellent.

[0008]

SUMMARY OF THE INVENTION The present invention relates to an insert
Inside the bag-like epidermis with part of it protruding from the bottom of the epidermis to the outside
Generated by injecting and foaming a liquid foaming raw material
Integrate foam with said skin and inserts in said skin
In the method for manufacturing a headrest to be
A ring-shaped protrusion on the inner surface of the skin
An insert insertion tube portion is provided, while the outside of the insert is provided.
An annular groove is provided on the peripheral surface, and the annular protrusion is formed in the annular groove.
By fitting the
After keeping the positional relationship with the insert constant,
Place the saat in the foaming mold and apply liquid foam inside the skin.
It is characterized by injecting the raw material and foaming.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a sectional view showing an example of a headrest manufactured according to an embodiment of the present invention, and FIG. 3 and 4 are cross-sectional views showing an example of the production method of the present invention. FIG. 3 is a cross-sectional view showing a state where a skin and an insert are set in a molding die and a liquid foaming material is injected into the skin. FIG. 4 is a cross-sectional view showing a state where the liquid foaming material is filled in the epidermis in the example.

First, the head obtained by implementing the present invention is described.
The drest will be described based on the embodiment shown in FIGS. The headrest 10 according to the embodiment includes a skin 21, an insert 31, and a foam 41. The skin 21 is for protecting the foam 41 inside and improving the appearance of the headrest 10, and is made of plastic blow-molded into a desired pillow shape with the head 32 of the insert 31 housed inside. It consists of a bag made of.

The skin 21 is provided with insert-inserting tubular portions 22, 22 projecting outward at predetermined positions on the bottom surface 21a. The insert insertion tube portion 22 is for preventing the liquid foaming material for molding the foam 41 from leaking from between the skin 21 and the insert 31 when the foam 41 is molded. Is formed in close contact with the outer peripheral surface of the leg portion 33.

As can be better understood from FIG. 2, the insert insertion tube portion 22 has an inner peripheral surface 22a formed with an annular protrusion 23 projecting inward. The annular projection 23 is engaged with an annular groove 34 of an insert 31 described later to position the outer skin 21 and the insert 31 and to prevent leakage of the liquid foaming raw material. The size of the annular projection 23 varies depending on the material and thickness of the skin 21 or the thickness of the insert 31, but in this embodiment, the projection width is 0.5 mm to 1.0 mm,
The vertical height is formed to be about 0.5 mm to 1.0 mm.

On the other hand, the insert 31 is formed of a hollow or solid pipe made of a metal material or the like formed in a substantially U-shape. The insert 31 has a head 32 located at a central portion in the skin 21, and legs 33, 33 extending from both ends of the head 32, from the middle of the bottom 21 of the skin 21.
a protrudes out of the epidermis 21 from a. The head 32 of the insert 31 located inside the skin 21 enhances the shape retention of the foam 41, and the insert leg 3 protruding outside the skin 21.
The lower part 33a of 3 constitutes a stay attached to the seat.

The outer surface 33 of the leg 33 of the insert 31
“b” is in contact with the inner peripheral surface 22 a of the insert insertion tube portion 22 of the skin 21. An annular concave groove 34 is formed on the outer peripheral surface 33b of the leg 33 of the insert 31 that comes into contact with the leg 31. The annular groove 34 is fitted to the annular projection 23 of the insert insertion tube 22. The annular groove 34 has a size and a shape corresponding to the annular protrusion 23 of the skin. In this embodiment, the depth is 0.5 mm to 1.0 mm, and the vertical height is 0.5 mm to It is formed to about 1.0 mm.

The foam 41 is for absorbing and absorbing the impact to the occupant's head, and is made of polyurethane resin or the like foamed in the skin 21. The foam 41 is formed by forming a liquid foam of polyurethane resin or the like through a slit or the like (not shown) provided in the bottom surface 21a of the skin 21 in the skin 21 in which the head 32 of the insert 31 is housed. This is done by injecting the raw material and foaming.

At the time of molding the foam 41, the inner peripheral surface 22a of the insert insertion tube portion 22 and the outer peripheral surface 33b of the insert leg portion 33 abut on the bottom surface 21a of the skin 21, as described above. The contact area is increased by fitting the annular projection 23 of the inner peripheral surface 22a of the portion 22 with the annular groove 34 of the outer surface 33b of the insert 31 leg 33. Therefore, the sealing property of the contact surface is improved, and the liquid foaming material can be efficiently prevented from leaking from the contact surface between the leg portion 33 of the insert 31 and the skin bottom surface 21a.

As a result, the headrest 10 is connected to the leg 3 of the insert 31 projecting from the bottom surface 21a of the skin 21.
No material adheres to No. 3 and the appearance is good. Moreover, the headrest 10 is provided with the annular projection 23 and the annular groove 34.
The foam 41 is formed in a state where the skin 21 and the insert 31 are positioned by the fitting of
Thus, the amount of the insert 31 embedded in the headrest 1 is constant, and the quality of the headrest is constant.

Next, an embodiment of the manufacturing method of the present invention will be described. The foaming mold 50 shown in FIG. 3 and FIG.
It consists of two split dies 51 and 53 and has a molding cavity 54 inside. First, the skin 21 is arranged together with the insert 31 in the mold 50. As described above, the skin 21 is formed into a bag shape by blow molding or the like. The head 32 of the insert 31 is housed in the skin 21, and the leg 33 of the insert 31 is partially cut off from the bottom surface 21 a of the skin. 21 outside. In addition, the epidermis 21
Is formed on the bottom surface 21a thereof with an insert insertion tube portion 22 having an annular projection 23 formed on the inner peripheral surface.
And an annular groove 34 formed on the outer peripheral surface of the leg portion 33. The legs 33 of the insert 31 protruding from the bottom surface 21 a of the skin 21 are sandwiched between the divided surfaces of the molding die 50, and the tip ends are projected from the molding die 50.

When placing the skin 21 and the insert 31 in the molding die 50, the skin 21 and the insert 31
The annular projection 23 formed on the inner peripheral surface of the insert insertion tubular portion 22 of the skin 21 and the annular groove 34 formed on the outer peripheral surface of the leg 33 of the insert 31 are fitted. Position is less likely to occur. Therefore, the skin 21 and the insert 31 are placed in the correct
It can be located within 0. Also, if a displacement occurs between the epidermis 21 and the insert 31 in some time, the epidermis 2
By fitting the annular protrusion 23 of one and the annular groove 34 of the insert 31, the deviation can be easily corrected.

Next, a liquid foaming material P such as a polyurethane material is injected into the skin 21. This injection is for epidermis 2
This is performed using a slit or the like (not shown) formed on one bottom surface. The liquid foaming raw material P injected into the skin 21
Starts the foaming reaction and forms the foam 21 while forming the foam.
To be charged within. At this time, the leg 33 of the insert 31
Is projected on the bottom surface 21a of the skin 21 protruding outside.
Insert insertion tube 22 and insert 31 leg 3
3. The outer peripheral surface abuts, and the abutment surface is increased by the fitting of the annular projection 23 and the annular groove 34 as described above, and the sealing performance is high. Therefore, the liquid foaming raw material P
It is efficiently prevented from entering between the inner peripheral surface of the insert insertion tube portion 22 of the outer skin 21 and the outer peripheral surface of the leg portion 33 of the insert 31 and leaking to the outer surface side of the outer skin 21.

Further, the rigidity of the insert insertion tubular portion 22 of the skin 21 is increased by the annular projection 23. Therefore, even if the liquid foaming raw material P tries to enter between the inner peripheral surface of the insert insertion tube portion 22 and the outer peripheral surface of the leg portion 33 of the insert 31, the insert insertion tube portion 22 is hardly deformed due to the increased rigidity. As a result, the inner peripheral surface of the insert insertion cylinder 22 and the leg 33
A gap is hardly generated between the outer peripheral surfaces, and the intrusion of the liquid foaming raw material is more effectively prevented.

After the foam 21 is filled with the liquid foaming raw material P to form the foam 41, the foaming mold 50 is opened and the molded product is taken out to obtain the desired headrest 1 shown in FIG.
0 is obtained. The obtained headrest 10 has a skin 21
The leg portion 33 of the insert 31 protruding from the bottom surface 21a and the surrounding skin bottom surface 21a have no adhesion of spilled material (burrs), have a good appearance, and are manufactured without performing the work of removing the burrs. Can be. The headrest 10 has a constant positional relationship between the skin 21 and the insert 31 by fitting the annular projection 23 provided on the insert insertion tube portion 22 on the bottom surface 21 a of the skin 21 with the annular groove 34 of the insert 31. Therefore, the quality is also constant.

[0023]

As shown and described above, the present invention
According to the headrest manufacturing method , the inner peripheral surface of the insert-inserting tubular portion of the skin comes into contact with the outer peripheral surface of the insert, and the annular protrusion of the insert-inserting tubular portion of the skin and the annular concave groove of the insert fit. As a result, a good seal is provided between the bottom surface of the skin and the insert. Therefore, the foam molding raw material does not leak to the outer surface of the skin from the contact portion between the bottom surface of the skin and the insert, and does not become dirty due to the adhesion of the leaked raw material, thereby improving the appearance of the headrest. In addition, since there is no need to remove the leaked and attached raw materials (burrs), a headrest having a good appearance can be obtained very easily. Further, there is no waste of the liquid raw material, and there is also an effect of being economical.

Further, a method of manufacturing a headrest according to the present invention.
According to the above, the fitting of the annular projection of the skin and the annular groove of the insert makes it difficult for positional displacement to occur between the skin and the insert during foam molding, and the foam can be molded under a fixed positional relationship. This has the effect of stabilizing the quality of the headrest. Further, even when the annular protrusion of the skin is displaced from the annular groove of the insert during foam molding and a gap occurs between the skin and the insert, the annular protrusion of the skin and the annular groove of the insert are fitted. The misalignment can be easily corrected, and a headrest of constant quality can be easily obtained.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an example of a headrest manufactured according to the present invention.

FIG. 2 is an enlarged sectional view showing a main part thereof.

FIG. 3 is a cross-sectional view showing an example of the production method of the present invention, in which a skin and an insert are set in a molding die, and a liquid foaming material is injected into the skin.

FIG. 4 is a cross-sectional view showing a state in which the foam is filled with a liquid foaming raw material foam in the embodiment.

FIG. 5 is a sectional view showing an example of a conventional headrest.

FIG. 6 is a sectional view showing an example of the manufacturing method.

[Explanation of symbols]

 10: Headrest 21: Skin 21a: Bottom surface of skin 22: Insert insertion tube 22a: Inner peripheral surface of insert insertion tube 23: Annular projection 31: Insert 32: Insert head 33: Insert leg 34 ： Circular groove 41 ： Foam

Claims (1)

(57) [Claims] 1. A foam formed by injecting and foaming a liquid foaming raw material into a bag-shaped skin in which a part of an insert protrudes from the bottom surface of the skin to the outside is integrated with the skin and the insert in the skin. In the method of manufacturing a headrest to be formed, on the bottom surface of the skin from which the insert protrudes, an insert insertion cylinder having an annular projection on the inner peripheral surface is provided,
On the other hand, an annular groove is provided on the outer peripheral surface of the insert,
Wherein the Rukoto fitted to the annular projection on the annular groove
Constant positional relationship between insert insertion tube and insert
And place the skin and insert in the foam mold
A method for manufacturing a headrest , comprising injecting a liquid foaming material into the skin and foaming the material.