JP3865892B2 - Headrest and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a headrest that is attached to the upper end of a seat back of a vehicle or the like, and more specifically, an insert core portion is disposed in the outer skin, and a foam material is injected between the outer skin and the core portion to foam and harden the skin. The present invention relates to an integrally molded type headrest and a method for manufacturing the headrest.
[0002]
[Prior art]
There is a headrest in which an insert core portion is arranged in a bag-like skin made by stitching skin pieces, and then a foaming raw material is injected to integrally form the skin.
Such a headrest is manufactured using, for example, a mold 8 as shown in FIG. Here, when the foaming material is injected into the skin, the lid is opened and the material is injected into the skin through the opening 0 of the skin 91. However, since the insert 92 is an obstacle, the mold 8 is shown in FIG. In many cases, the raw material is not obstructed by the insert 92 at the time of injecting the foaming raw material.
[0003]
However, if the mold 8 is tilted to either the left or right side, there is no opening in the uppermost skin 91, so the air that was originally in the skin and excess gas generated during the foam molding process cannot escape during foam molding. It was. In particular, the multilayer skin material obtained by laminating a non-breathable film on the fabric skin material has a remarkable defect. In the pillow-shaped headrest and the perforated headrest, void α is likely to occur at the uppermost position as shown in FIGS. 9 and 10, the skin 91 is removed and the foam 93 is exposed.
As a countermeasure against such defects, in the case of a two-layer skin material (for example, a fabric skin + polyurethane film), as shown in FIG. 8 (a), the present application is made to open a needle hole 95 at a predetermined pitch in the skin 91 to allow void gas to escape. A person invented and finished the application (prior art 1). Further, in the case of a three-layer skin material (for example, a fabric skin + polyurethane slab sheet + polyurethane film), the paper pattern has been divided at a place where voids are likely to occur, and the device has been devised to release void gas at the portion 96 (conventional). Technology 2). Here, dividing the pattern means dividing and sewing a skin material constituting the skin.
[0004]
[Problems to be solved by the invention]
However, only the two-layer skin material can be used as the void countermeasure for opening the needle hole in the prior art 1. In the case of a three-layer skin material, when a needle hole was opened, urethane foam as a foaming raw material was impregnated into the slab sheet from the needle hole and became hard and defective. Furthermore, when the needle hole was large, the foaming raw material leaked out of the epidermis and contaminated the epidermis.
In addition, cracking the pattern of the prior art 2 and taking measures against voids resulted in a reduction in the number of skins taken and increased costs.
[0005]
The present invention solves the above-mentioned problems. Even if the skin is not only a two-layer skin material but also a multilayer skin material such as a three-layer skin material, sufficient countermeasures against voids are taken, and the structure is simplified and the cost is reduced. It is an object of the present invention to provide a headrest and a method for manufacturing the headrest that do not require much time.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, the gist of the present invention described in claim 1 is that a two-layer skin material in which a non-breathable film is laminated on the lining of an outer fabric skin material, or three layers with a slab sheet interposed therebetween. A plurality of skin pieces made of a skin material are stitched to form a bag-like skin, and an insert core is placed in a mold, and then the foam material is injected between the skin and the core to make the skin. In the manufacturing method of the headrest which performs integral molding, the stitch line by the sewing thread is formed on the one skin piece that forms the bottom surface of the headrest so that the stitch line by the sewing thread vertically cuts the bottom surface of the headrest in the longitudinal direction without joining the skin piece that is the cutting part. Set the skin and insert in the mold so that the bottom surface of the headrest is on top, and set the seam line to the top edge of the mold cavity when the mold is tilted. Then, foaming raw material is injected to perform foam molding, and the foaming raw material enters into the holes of the film and is impregnated and cured, or the foaming raw material is impregnated and cured into the slab sheet through the holes of the film. And a method for manufacturing a headrest.
[0007]
As in the first aspect of the invention, when the stitch line is formed, air and excess gas that have created a void from the stitch hole can be released, so that generation of voids can be eliminated. If a stitch line is formed on one skin piece that forms the bottom surface of the headrest so that the stitch line by the sewing thread runs vertically in the longitudinal direction of the bottom surface of the headrest without joining the skin piece that is the cutting part, the stitch line is opened with a sewing needle, etc. Since the thread passes through the needle hole, the gap in the needle hole is extremely small. Although air and foaming gas escape from here, it is difficult for liquid foaming raw materials. Thus, it is possible to prevent a problem that the foaming material leaks out of the outer skin through the needle hole and contaminates the outer skin during foam molding while taking measures against voids. Moreover, since it is sufficient to put a stitch line in one skin piece, it does not cost much.
Further, when the foaming raw material is injected and foam molding is performed, the foaming raw material enters into the holes of the film and is impregnated and cured, or when the foaming raw material is impregnated and cured through the holes of the film , The line is fixed and contributes to preventing the headrest from losing its shape. If the seam line is provided at the corner of the skin that extends from the bottom surface of the headrest to the vertical surface, the seam line is fixed to the impregnated hardened portion, so that the skin corner is stable and helps to maintain the shape of the headrest.
[0008]
Embodiment
Hereinafter, the headrest and the manufacturing method thereof according to the present invention will be described in detail.
[0009]
(1) Manufacturing method of headrest FIGS. 1-5 is one form of the manufacturing method of the headrest of this invention, FIG. 1 is a perspective view of a headrest, FIG. 2 is the IV-IV sectional view taken on the line of FIG. 3 is an enlarged perspective view of part A in FIG. 2, FIG. 4 is a partially enlarged view of FIG. 3 in the foam molding process, and FIG. 5 is a partially enlarged view of FIG. Applies to perforated headrests.
[0010]
In the method of manufacturing the headrest, the insert core portion 21 is embedded in the bag-shaped skin 1, and then the foaming raw material g is injected into the skin 1 to integrally form the skin.
Prior to production, first, the skin 1 and the insert 2 are prepared, and the stitch line 4 is formed on one skin piece 1 a constituting the skin 1.
[0011]
The skin 1 is made into a bag shape by stitching a plurality of skin pieces. The skin piece (skin) uses a multilayer skin material using a fabric skin material 11 as an outer layer. The fabric skin material 11 of the woven fabric or knitted fabric is laminated with a non-breathable film on the lining because the foam raw material g leaks out from the weave and seam when foam molding is performed. Furthermore, in order to improve the contact feeling of the head, it is tailored to a three-layer skin material or the like interposing a urethane foam sheet or the like. Also in this embodiment, a three-layer skin material in which a polyurethane film 13 is integrally overlapped with a fabric skin material 11 and a urethane foam sheet 12 (also referred to as a slab sheet) is used as a skin piece.
Here, four skin pieces 1a to 1d are stitched to form a bag shape in order to obtain a donut shape of a perforated headrest. The fabric skin material 11 for creating the design surface is taken out, and the seam allowance 19 by the stitching P is hidden in the bag-like interior.
[0012]
The insert 2 includes a pair of stays 22 that protrude outside the skin, and a core 21 that is disposed inside the skin 1 and embedded in the foam 3.
Then, a stitch line 4 is formed on one skin piece 1a that forms the headrest bottom surface S on one side of the skin 1. The stitch line 4 is formed by cutting the headrest bottom surface S longitudinally in the longitudinal direction. There are no particular restrictions on the stitch specifications, and it is assumed here that the seam is sewn (FIG. 3). The seam line 4 is generally formed by joining two skin pieces with a sewing thread 41. However, the seam line 4 according to the present invention is simply formed on the surface of one skin piece 1a by a sewing thread 41. It is only created (Fig. 2). Since it is not joining of a cutting part (skin piece), the seam allowance 19 is not formed.
[0013]
Thereafter, with the pair of stays 22 protruding outside the skin, the core portion 21 of the insert 2 is disposed in the skin, and these are set in the headrest mold 5. The outer skin 1 and the insert 2 are set on the mold 5 so that the stay 22 protrudes upward from the mold and the bottom surface S of the headrest faces upward.
At this time, as shown in FIG. 2, the mold 5 is slightly tilted upward to the right, but the seam line 4 is set so as to be arranged at the top of the mold cavity c, more preferably at the top edge line 51.
[0014]
Thereafter, a foaming raw material is injected between the skin 1 and the core 21 from the opening 14 to perform foam molding. In the foam molding process, most of the air in the skin 1 and excess foam gas are expelled from the opening 14 to the outside of the skin 1. Further, in the uppermost skin portion 15, air and excess foaming gas escape from the stitch line 4.
In the stitch line 4, since the sewing thread 41 passes through the needle hole 42 opened by a sewing needle or the like, the gap ε of the needle hole 42 is extremely small (FIG. 3). Therefore, although air and foaming gas escape from here (arrow of FIG. 4), it is difficult for the liquid foaming raw material g. Thus, while taking measures against voids, it is possible to prevent problems such as foaming raw material g leaking out of the outer skin through the needle holes 42 and contaminating the outer skin 1 during foam molding.
[0015]
By the way, when the skin 1 is formed of a three-layer skin material having the slab sheet 12 as an intermediate layer as in this embodiment, the foaming raw material g passes through the holes 421 of the film 13 as shown in FIG. The slab sheet 12 may be impregnated and cured.
However, since the seam line 4 is located on one side of the bottom surface S corresponding to the corner portion D of the headrest, the seam line 4 is fixed to the impregnated hardened portion 31, and the shape of the headrest is on the contrary. It is an advantage that does not collapse. Of course, the portion of the slab sheet 12 that has been impregnated and hardened is somewhat stiff, but is on the stitch line 4. At first glance, this stitch is misunderstood by the occupant and the hardness due to the seam allowance 19 when the cut part is sewn with the sewing thread 41. Let it be a problem.
[0016]
Then, foam molding and demolding are finished, and a desired headrest as shown in FIG. 1 is taken out.
Although the case where the skin 1 is formed of a three-layer skin material has been described here, the case where the skin 1 is formed of a two-layer skin material is performed according to the same manufacturing method as described above. In this case as well, air and foaming gas can escape from the needle hole 42 without difficulty, but leakage of the foaming raw material g from the needle hole 42 becomes difficult. As shown in FIG. 6, there is a case where the foaming raw material g enters the hole 421 of the film 13 and impregnates and hardens 31. This also fixes the stitch line 4 and contributes to preventing the headrest from being deformed. It becomes.
[0017]
(2) Headrest A headrest obtained by the above-described headrest manufacturing method includes a bag-shaped skin 1 in which a plurality of skin pieces are stitched, a core portion 21 disposed in the skin 1 and a pair of An insert 2 that projects a stay 22 outside the skin, and a foam 3 that is embedded in the skin 1 with the core 21 embedded therein are provided.
The skin 1 is formed of a multi-layer skin material using a fabric skin material 11, and the seam line is formed along the bottom corner along the bottom corner of one skin piece 1a that forms a bottom surface near one side of the head rest bottom surface S. Is formed so as to be longitudinally cut. It is more preferable that the seam line is provided at the skin corner D from the bottom surface of the headrest to the vertical surface. This is because the stitch line 4 is fixed to the impregnated and hardened portion 31 as described above, so that the skin corner portion D is stabilized and helps to keep the headrest in shape. The stitch line 4 has no sense of incongruity because the skin 1 is a sewing skin formed by stitching a plurality of skin pieces.
[0018]
(3) Effects According to the headrest configured as described above and the manufacturing method thereof, the stitch line 4 is formed on one skin piece 1a disposed on the top (preferably the top ridge 51) of the mold cavity c. Thus, sufficient void countermeasures can be taken not only in the two-layer skin material but also in the skin 1 composed of a multilayer skin material such as a three-layer skin material. Since it is sufficient to simply form the stitch line 4 on the skin piece 1a, it is simple and does not require much cost. Since there is no need to break the paper pattern, the number of skins is not reduced.
Furthermore, in the skin 1 composed of the three-layer skin material, the foam raw material g may impregnate and cure the slab sheet 12 through the needle holes 42 during foam molding. The stitch line 4 formed at the corner portion D is fixed, and the shape of the headrest is not broken and a good result is obtained.
[0019]
The present invention is not limited to those shown in the above embodiment, and various modifications can be made within the scope of the present invention depending on the purpose and application. The shape, size, material and the like of the skin 1, the insert 2, the foam 3, the stitch line 4 and the like can be appropriately selected according to the application. For example, the stitch line 4 is not limited to one row as in the embodiment, and a plurality of rows can be provided. Of course, the present invention is not limited to a perforated headrest, and can be applied to a pillow-type headrest.
[0020]
【The invention's effect】
As described above, the headrest of the present invention and the method for producing the headrest have excellent effects because the void countermeasures are sufficiently taken even though the skin using a multilayer skin material has a simple structure without cost. Demonstrate.
[Brief description of the drawings]
FIG. 1 is a perspective view of a headrest according to the present invention.
FIG. 2 is a cross-sectional view taken along line IV-IV in FIG.
FIG. 3 is an enlarged perspective view of a part A in FIG. 2;
FIG. 4 is a partially enlarged view of FIG. 3 in a foam molding process.
FIG. 5 is a partially enlarged view of FIG. 3 after foam molding.
FIG. 6 is a partially enlarged view corresponding to FIG. 5 using another embodiment of the skin.
FIG. 7 is a central sectional view of a mold in which a skin and an insert are set in the prior art.
FIG. 8 is an explanatory diagram of a conventional technique.
FIG. 9 is an explanatory diagram of a conventional technique.
FIG. 10 is an explanatory diagram of a conventional technique.
[Explanation of symbols]
1 skin 11 fabric skin 12 slab sheet (urethane foam sheet)
13 Film 1a-1d Skin piece 2 Insert 21 Core part 22 Stay 3 Foam 4 Stitch line
41 sewing thread 421 hole (film hole)
5 Mold 51 Top ridge line D Corner part S Bottom c Mold cavity g Foaming raw material

Claims (1)

Inserted into a bag-like skin by stitching multiple skin pieces made of a two-layer skin material with a non-breathable film laminated to the outer fabric fabric lining, or a three-layer skin material with a slab sheet interposed In the method of manufacturing the headrest, in which the core part is arranged and these are set in the mold, and then the foam raw material is injected between the skin and the core part to integrally form the skin. First, set the skin and insert in the mold so that the bottom surface of the headrest faces up, and the seam line by the sewing thread is formed so that the bottom surface of the headrest is longitudinally cut without joining the skin pieces as cutting parts. Then, when the mold is further tilted, the seam line is set so as to be arranged on the top ridge line of the mold cavity, and then foaming raw material is injected to perform foam molding. Manufacturing method of the headrest, wherein the or impregnated cured enters the pores of the film, impregnated cured in the slab sheet foam material is passed through a hole in the film.

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