JP6889606B2 - How to make a back pad with a headrest - Google Patents

Description

The present invention relates to a method for manufacturing a back pad with a headrest that constitutes a vehicle seat.

There is a so-called high-back specification back pad with a headrest in which a headrest portion is integrally molded with the back pad portion as a back pad for a backrest, which is a seat seat mounted on a vehicle such as an automobile. In this back pad with a headrest, a bag-shaped backing material is attached to the foam molding type headrest inner surface forming mold part, then the foaming raw material is injected and the mold is closed, and then the backing material is integrated with the headrest part. It can be made by foam molding the pad body. A hole with a downward opening is formed in the headrest portion, and a bag-shaped backing material integrated with a backing on the inner wall surface thereof is interposed between the headrest portion and the vehicle body side frame (not shown) to be assembled. It prevents abnormal noise and cracks in the headrest due to the rubbing of the frame. Then, the seam allowance formed when the backing material is sewn into a bag shape narrows the flow path by foam molding of the pad body, and voids and the like are easily formed. However, inventions such as Patent Document 1 have been proposed to solve this problem. There is. In Patent Document 1, the backing material is referred to as a backing material.

Japanese Unexamined Patent Publication No. 2012-34894

However, conventional products such as Patent Document 1 are bag-shaped backing materials (FIGS. 1 to 5 of Patent Documents) that spread from the bottom of the bag to the mouth of the bag, and are foam-molded headrest inner surface forming molds. It was easy to attach the backing material Y to 92 as in FIG. 13 (a) of the present application, but it is difficult to attach the backing material Y to the headrest inner surface forming mold portion 92 as shown in FIG. 13 (b). In the recent headrest portion 3, there is a case of FIG. 1 in which the inside 3u of the hole is wider than the hole 37 on the lower surface side. In such a headrest portion 3, the thickness width of the headrest inner surface forming mold portion 92 gradually increases toward the back pad back surface forming mold portion 91 as shown in FIG. 13 (b), and the maximum thickness width Wmax is reached in the middle. Therefore, it is extremely difficult to cover the headrest inner surface forming mold portion 92 with the bag-shaped backing material Z and attach it. Even if the bag-shaped backing material Z can be forcibly covered and attached to the headrest inner surface forming mold portion 92, the hem portion Z1 of the backing material Z that exceeds the maximum protrusion portion 95 spreads, causing slack and causing trouble. Come on. The slack hem portion Z1 blocks the flow path during foam molding of the pad body, or obstructs the liquid flow of the foaming raw material, so that quality defects are likely to occur. Further, there may be a problem that the slack portion Z1 of the backing material Z is exposed on the product design surface side.

The present invention solves the above-mentioned problems, and even if the inside of the hole is wider than the hole opening of the headrest portion, the pad body can be foam-molded while maintaining quality and maintaining a high yield, and further improving workability and productivity. An object of the present invention is to provide a method for manufacturing a back pad with a headrest that also contributes to improvement.

In order to achieve the above object, the gist of the invention according to claim 1 is to attach a backing material to the inner surface forming mold portion of the headrest of the foam molding mold, inject the foaming raw material and close the mold, and then to the headrest portion. In a method for manufacturing a back pad with a headrest in which a pad body in which a backing material is integrated with an inner wall surface of the downward hole is foam-molded, the upper part is made into a bag shape by sewing a cut piece obtained by cutting the cloth material for the inner wall surface. and the lower portion, not sewn and one side of該裁fragment from one point of the lower edge toward the upper part of the bag bottom, and the other side becomes the bag opening side cylindrical portion by stitching of the one side end, the After covering the headrest inner surface forming mold portion with a backing material of a bag-like body provided with a horizontally long band portion that can be released to the headrest and extend the other side side to follow the lower outer periphery, the headrest inner surface is formed. A method for manufacturing a back pad with a headrest, which comprises winding the horizontally long band portion in the circumferential direction of the lower half region of the forming mold portion and mounting the bag. The method for manufacturing a back pad with a headrest according to a second aspect of the present invention is the method of manufacturing the back pad with a headrest according to the first aspect, wherein the bag-shaped seam allowance portion associated with the upper portion is arranged inside the bag, and the backing material is formed on the inner surface of the headrest. It is characterized by covering the part. The method for manufacturing a back pad with a headrest, which is the invention of claim 3, is the method of claim 1 or 2, wherein a tape piece containing a magnetic material is attached to a portion on the tip end side of the horizontally long band portion, while the horizontally long band portion is wound around the back pad. In the lower half region, a magnet body is embedded in the facing surface of the magnetic material-containing tape piece, the horizontally long band portion is wound around the lower half region, and the magnetic material-containing tape piece is magnetically wound around the magnet body. It is characterized by being attached by suction. The method for manufacturing a back pad with a headrest according to a fourth aspect of the present invention is the method of manufacturing the back pad with a headrest according to claims 1 to 3, wherein the lower portion of the backing material is under the lower portion in addition to the free portion between the one side and the other side. It is characterized in that a slit is provided from the edge to the bottom of the upper bag.

In the method for manufacturing a back pad with a headrest for a vehicle of the present invention, even if the inside of the hole is wider than the hole opening of the headrest portion, the bag-shaped backing material can be integrated into the inner wall surface without slack, and the pad body is foamed. In molding, the slack part eliminates defects such as obstructing the liquid flow of the foamed raw material and appearing on the product design side, and in addition, it is possible to remove the mold, so the quality is stable, the yield is improved, the productivity is improved, and the work is further done. It also has an excellent effect on improving productivity.

In one form of the method for manufacturing a back pad with a headrest of the present invention, (a) is an overall perspective view of the back pad with a headrest, and (b) is a cross-sectional view taken along the line I-I of (a). It is a developed plan view of the cut piece for a backing material. It is a perspective view of the backing material which sewed the cut piece of FIG. 2 into a bag shape. FIG. 5 is an explanatory perspective view in which the backing material of FIG. 3 is turned inside out and set in a core shape. (A) is a side view of the core-shaped headrest inner surface forming mold portion, and (b) is a side view of the headrest inner surface forming mold portion of (a) covered with a backing material. (A) is a perspective view where the backing material is put on the inner surface forming mold part of the headrest and the horizontally long band part is started to be wound, and (b) is a cross-sectional view where the winding of the horizontally long band part is completed and the backing material is installed. is there. It is a partial perspective view of a core type. It is a perspective view which shows the figure immediately after FIG. 6 (a). It is explanatory cross-sectional view which injects a foaming raw material into a lower mold. After FIG. 9, it is a cross-sectional view in which the mold is closed. After FIG. 10, it is a cross-sectional view which foam-molded the pad body. It is a perspective view of the backing material of another aspect which replaces the backing material of FIG. It is explanatory perspective view of the prior art.

Hereinafter, a method for manufacturing a back pad with a headrest according to the present invention will be described in detail.
1 to 12 are one form of the method for manufacturing a back pad with a headrest of the present invention, which is applied to a back pad with a headrest in the rear seat of a vehicle. FIG. 1 (a) is a perspective view of a back pad with a headrest, (b) is a sectional view taken along line II of (a), FIG. 2 is a developed plan view of a cutting piece for a backing material, and FIG. 3 is FIG. A perspective view of a backing material in which the cut pieces of the above are made into a bag shape, FIG. 4 is an explanatory view for setting the backing material of FIG. 3 in a core shape, and FIG. 5 (a) is a core-shaped headrest inner surface forming mold portion. In the surrounding side view, (b) is a side view in which the headrest inner surface forming mold portion of (a) is covered with a backing material, and FIG. 6 is an explanation of wrapping the headrest inner surface forming mold portion of FIG. 5 (b) with a horizontally long band portion. FIG. 7, FIG. 7 is a partial perspective view of a core type, FIG. 8 is a perspective view showing the state immediately after FIG. 6 (a), FIG. 9 is an explanatory cross-sectional view of injecting a foaming raw material into the lower mold, and FIG. A cross-sectional view, FIG. 11 is a cross-sectional view obtained by foam-molding the pad body, and FIG. 12 is a perspective view of a backing material of another aspect. Each drawing highlights the main parts of the invention to make the drawings easier to understand, and simplifies or omits parts not directly related to the present invention.

The method for manufacturing a back pad with a headrest is a method for manufacturing a back pad with a headrest having a high back specification in which the headrest portion 3 is integrated with the vehicle back pad portion 2. After mounting the backing material 4 on the headrest inner surface forming mold portion 92 of the foam molding mold 6, the foaming raw material g is injected and the mold is closed, and then the backing material 4 is placed on the inner wall surface 3b of the downward hole related to the headrest portion 3. The integrated pad body 1 is foam-molded. In the foam molding of the pad body 1, a hole for a downward hole 37 for inserting a frame is provided in the headrest portion 3, and the backing material 4 is integrated with the inner wall surface 3b of the hole.

This embodiment is applied to the back pad P with a headrest on the left side in the traveling direction in the rear seat of the vehicle as shown in FIG. The back pad P with a headrest in FIG. 1 (b) has the right side of the paper surface facing the front of the vehicle and the upper side of the paper surface facing upward. The same applies to "forward" and "upward" in the present invention. Prior to foam molding of the pad body 1 of the back pad P with a headrest, a backing material 4 and a foam molding mold 6 are prepared.

The backing material 4 has an upper portion 4a formed into a bag shape by suturing a cutting fragment 5 obtained by cutting a cloth material for the inner wall surface 3b of the headrest portion 3, and the lower portion 4b has a bag bottom 420 of the upper portion 4a from one point on the lower edge thereof. This is a product in which the 43S side on one side facing toward the side and the 45S side on the other side, which becomes a tubular portion on the bag mouth side by suturing with the side, are separated without suturing (FIG. 3). In this embodiment, a cylinder is formed on the bag mouth side by suturing the one side 43S side of the cut fragment 5 from one point of the lower peripheral edge 48, which forms the bag mouth when sewn, to the bag bottom 420 of the upper 4a, and the one side 43S side. The other side 45S side to be shaped is left apart without being sewn. The other side 45S side extends as it is, forming a bag-like body having a horizontally long band portion 46 that can follow the outer circumference of the lower portion 4b. Reference numerals 47 in FIGS. 1 and 4 represent a bag mouth when one side and the other side are sewn together.

Here, a cloth material made of a non-woven fabric (or felt or the like) is cut into a single piece of cut piece 5 as shown in FIG. 2, which can be used as a bag-shaped backing material 4. The front portion 51 for the bag-shaped backing material 4 is connected vertically to the bottom portion 52 and the rear portion 53, and the side portions 54 and 55 extend on both sides of the front portion 51. A horizontally long band portion 56 extends from the lower half portion of the side portion 55 on the left side of the figure to the left side of the paper surface, and a tape piece MT containing a magnetic material is attached to the tip portion 561. In the figure, the lateral length of the horizontally elongated band portion 46 extending in the lateral direction on the paper surface is substantially equal to the sum of the lateral lengths of the rear portion 53, the side portion 54, and the front portion 51 required for winding. The magnetic material-containing tape piece MT (hereinafter, also simply referred to as “tape piece”) is a tape piece formed of a synthetic resin or rubber containing a ferromagnetic powder such as iron or nickel. Reference numerals 52j to 55j are seam allowance portions. The chain line on the base side is a seam line virtual line 5k when the bag-shaped backing material 4 is used, and at this stage, the sewing thread T has not yet been sewn. The chain line representing each boundary line between the front part 51, the bottom part 52, the rear part 53, and the side parts 54, 55 is a virtual line that becomes a bending part when making a bag shape, and there is no stitching. Reference numeral 55S is a boundary line between the horizontally long band portion 56 and the side portion, and corresponds to the other side 45S when the cut piece 5 is sewn into the backing material 4. Reference numeral 510 indicates a hole provided in the front portion 51, reference numeral 511 indicates a front protruding portion, and reference numeral 531 indicates a rear protruding portion.

Then, the cut piece 5 is bent toward the front side of the paper surface along the virtual line of the bent portion shown in FIG. 2, the seam allowance portions 52j to 55j are aligned, and the upper portion 4a is sewn along the seam line E to form a bag shape. In FIG. 2, the left seam allowance portion 55j of the side portion 55 and the left seam allowance portion 53j of the rear portion 53, the upper seam allowance portion 55j of the side portion 55, the left seam allowance portion 52j of the bottom portion 52, and the right side sewing of the side portion 54. The upper seam allowance portion 54j, the right seam allowance portion 53j of the rear portion 53, the upper seam allowance portion 54j of the side portion 54, and the right seam allowance portion 52j of the bottom portion 52 are combined and sewn to form a bag-like upper portion 4a. .. The lower portion 4b is not sewn from one side 43S side and the other side 45S side of the cut piece 5 from one point of the lower peripheral edge 48 which becomes the bag mouth 47 when sewn as described above toward the bag bottom 420 of the upper 4a. Keep away from. Further, the bag-shaped backing material 4 is provided with a horizontally long band portion 46 that extends on the other side 45S side and can be rotated substantially along the outer circumference of the lower portion 4b (FIG. 3). The horizontally long band portion 56 of the cut fragment 5 is in the horizontally long band portion 46 of the backing material 4, the holes 510 provided in the cut fragment 5 are in the through holes 410 of the backing material 4, and the tape piece MT of the cut fragment 5 is in the horizontally long band portion. It becomes a tape piece MT attached to the tip portion 461 of 46.

As shown in FIG. 4, the foam molding mold 6 includes a lower mold 7, an upper mold 8, and a core mold 9, and the core mold 9 and the upper mold 8 are connected to the lower mold 7 so as to be openable and closable, respectively. As shown in FIG. 10, when the backing material 4 is attached to the headrest inner surface forming mold portion 92 of the core mold 9 and the mold is closed, the headrest is attached to the lower mold cavity surface 7S, the upper mold cavity surface 8S, and the core mold cavity surface 9S. The cavity C of the back pad P is formed.
The lower cavity surface 7S has a bowl-shaped dent to form an outer surface 3a on the vehicle front side of the headrest portion 3, a headrest front outer surface forming surface 7a, and a vehicle front side and a vehicle width direction side surface excluding the back surface 2b of the back pad portion 2. A back pad surface forming surface 7 m for forming the design surface 2a on the side is provided (FIG. 9). The upper cavity surface 8S is provided with a headrest rear outer surface forming surface 8b and a headrest rear protruding outer surface forming surface 8f (FIG. 10). On the core cavity surface 9S, a back pad back surface forming surface 9m for forming the back surface 2b of the back pad portion 2 by the back pad back surface forming mold portion 91 and an inner wall surface 3b of the headrest portion 3 are formed by the headrest inner surface forming mold portion 92. The headrest front inner surface forming surface 9a and the headrest rear inner surface forming surface 9b are provided (FIG. 7).
Reference numerals 68 and 69 indicate a hinge connecting the lower mold 7 and the upper mold 8, a hinge connecting the lower mold 7 and the core mold 9, and reference numerals 79, 89, 99 indicate a mold matching surface. In the foam molding mold 6 of FIGS. 4 and 9 to 11, the back pad P with the headrest of FIG. 1 (a) in the vehicle installed state is tilted forward, and the back pad portion back surface 2b is omitted as shown in FIG. It has a mold structure in which the pad body 1 integrated with the back pad portion 2 and the headrest portion 3 is formed in a horizontal position.

Using the foam molding mold 6 and the backing material 4, the back pad P with a headrest is manufactured, for example, as follows.
First, the backing material 4 is set in the headrest inner surface forming mold portion 92 of the core mold 9 under the mold open state of the foam molding mold 6 (FIG. 4). As for the backing material 4, the backing material 4 of FIG. 3 in which the cut piece 5 is sewn is turned inside out in advance, and the seam allowance portions 42j to 45j are arranged on the inside 40 of the bag. The headrest inner surface forming mold portion 92 of the core mold 9 which is substantially upright when the mold is opened is covered with the backing material 4 as shown in FIGS. 4 and 5 with the bag bottom 420 facing up and the bag mouth 47 side opened. .. The upper half portion from the top of the headrest inner surface forming mold portion 92 to the maximum protrusion portion 95 can be easily covered with the backing material upper portion 4a as shown in FIG. 5 (b). Since the backing material lower portion 4b is separated from the other side 45S side without being sewn, it covers the headrest inner surface forming mold portion 92 without being caught, but there is a gap between the backing material lower portion 4b and the lower half region 921. It hangs down in a certain state. The horizontally long band portion 46 also hangs down as shown in the figure.

Next, the hanging horizontally long band portion 46 is wound around the lower half region 921 of the headrest inner surface forming mold portion 92 in the circumferential direction and attached. In order to eliminate the gap and prevent wrinkles, in FIG. 6A, for example, one side 43S side of the backing material lower portion 4b arranged on the front side of the paper surface from the headrest inner surface forming mold portion 92 is appropriately to the right side of the paper surface. After the rear portion 43 and the rear protruding portion 431 of the backing material 4 are brought into close contact with the lower half region 921 of the headrest inner surface forming mold portion 92, the lower half portion is covered with the horizontally long band portion 46. The horizontally long band portion 46 is wound around the circumferential direction of the region 921, and the backing material 4 is attached to the headrest inner surface forming mold portion 92. When the horizontally long band portion 46 is mounted on the outer peripheral surface of the backing material lower portion 4b by making approximately 3/4 turns, the horizontally long band portion 46 is laminated on the rear portion 43, the side portion 44, and the front portion 41, and these are formed on the inner surface of the headrest. It can be in close contact with the mold portion 92, and there is no slack on the hem portion side of the backing material 4.

Here, in the present embodiment, as described above, the tape piece MT is attached to the tip portion 461 of the horizontally long band portion 46, while the lower half portion of the headrest inner surface forming mold portion 92 when the horizontally long band portion 46 is wound. In the area 921, the magnet body 923 is embedded in the facing surface of the tape piece MT. The horizontally long band portion 46 is wound around the lower half region 921, and the tape piece MT is magnetically attracted to the magnet body 923 and attached. Since the lower portion 4b of the backing material has better adhesion and fit to the headrest inner surface forming mold portion 92 and does not lose its shape, the subsequent foam molding of the pad body 1 is improved. Further, when the horizontally long band portion 46 is wound around the lower half region 921 of the headrest inner surface forming mold portion 92 so as to overlap the lower portion 4b of the backing material, the tape piece is passed through the through hole 410 as shown in FIG. 6 (b). When the MT comes into direct contact with the magnet body 923, the magnetic force is more strongly attracted, which is more preferable.

After that, the back pad portion 2 and the back pad main body 1 molding soft polyurethane foam raw material g (hereinafter, also simply referred to as “foam raw material”) of the back pad portion 2 and the headrest portion 3 are injected into the lower mold cavity surface 7S and the mold is closed. A predetermined amount of the foamed raw material g is injected onto the lower cavity surface 7S using an injection nozzle NL or the like (FIG. 9).
Subsequently, the core mold 9 and the upper mold 8 are operated to close the mold (FIG. 10). By closing the upper mold 8, the core mold 9, and the lower mold 7, a cavity C of the back pad P with a headrest in which the backing material 4 attached to the headrest inner surface forming mold portion 92 is insert-set is formed. By closing the mold, the tip portion 461 of the horizontally long band portion 46 is arranged on the lower side as shown in the figure, but the tape piece MT attached there is strongly magnetically attracted to the magnet body 923 embedded in the core mold 9. Therefore, the appearance of the backing material 4 attached to the core mold 9 is maintained. In this embodiment, the mold is closed after the foaming raw material g is injected, but the foaming raw material g can also be injected after the mold is closed.

After closing the mold, the process proceeds to the main step of foam molding. The pad body 1 of the back pad portion 2 with the headrest portion 3 in which the backing material 4 is integrated with the inner wall surface 3b of the downward hole related to the headrest portion 3 as shown in FIG. 11 while maintaining the mold closed state of FIG. 10 for a predetermined time. Foam molding.
In the present embodiment, as shown in FIG. 3, the total length of the other side 45S related to the backing material lower portion 4b is the band width of the horizontally long band portion 46, and the horizontally long band portion 46 covers the entire area of the backing material lower portion 4b. It is more preferable because the backing material 4 is brought into close contact with the headrest inner surface forming mold portion 92 without slack. In this way, the pad body 1 is foam-molded so that the voids due to the slack portion and the slack portion are not exposed on the design surface side of the product.

After finishing the foam molding of the pad body 1, the mold is removed, and the headrest portion 3 has a hole for the lower hole 37 on the back surface side of the pad body 1, and the backing material 4 is integrated with the inner wall surface 3b of the hole. Obtain the desired back pad P with a headrest as in 1.
Incidentally, the present invention can be carried out without any trouble even if it is demolded. As shown in FIG. 1 (b), the headrest portion 3 is wider in the hole 3u than in the lower hole 37. As shown in FIG. 5 (a), the thickness width of the headrest inner surface forming mold portion 92 is gradually increased toward the back pad back surface forming mold portion 91, the maximum thickness width Wmax is set in the middle, and then the back pad back surface forming mold portion 91 is formed. The thickness width is reduced toward this point. If the lower portion 4b of the backing material 4 is sewn into a bag-shaped backing material 4 as in the past, even if it can be attached to the headrest inner surface forming mold portion 92, it becomes difficult to remove the mold.

However, in the present embodiment, after covering the headrest inner surface forming mold portion 92 with the backing material 4 in which the one side 43S side and the other side 45S side of the lower portion 4b are separated, the horizontally long band portion 46 is wound around the lower half region 921. Moreover, the tape piece MT is magnetically attracted to the magnet body 923 and attached. At the time of foam molding, the lower portion 4b of the backing material is held in close contact with the headrest inner surface forming mold portion 92 by magnetic attraction, while at the time of demolding, the portion of the horizontally long band portion 46 extends to enable demolding. Even if the headrest portion 3 has a hole 3u in which the hole 37 side where the maximum protrusion portion 95 is located is narrowed, the soft pad body 1 having abundant cushioning properties has some degree of deformation flexibility. Further, one side 43S side and the other side 45S side are separated, and the tape piece MT of the horizontally long band portion 46 can follow the deformation of the pad body 1 unlike the case of suturing while being held by the magnet body 923 by magnetic attraction. Flexible. The tape piece MT slides sideways on the magnet body 923, and the circumference of the hole 37 is opened up to the hole diameter of the maximum protrusion 95 required for demolding, so that demolding becomes possible.

In this way, even if the hole 3u has a larger headrest portion 3 than the hole 37, a desired back pad P with a headrest that can be reliably removed from the mold can be obtained. When the back pad P with a headrest is covered with a skin, it becomes a seat back for a rear seat for a vehicle.
Reference numeral 21 indicates a backrest main portion, reference numeral 22 indicates a side portion, reference numeral 29 indicates a suspension groove, reference numeral 30 indicates a hole bottom, and reference numeral 31 indicates a rear collar portion.

FIG. 12 shows a backing material 4 of another aspect that replaces FIG. The backing material 4 is provided with a slit 49 separately formed in the backing material lower part 4b from the lower edge of the lower part 4b to the bag bottom 420 of the upper part 4a, in addition to the free portion between the one side 43S side and the other side 45S side. Is. A slit 49 is provided so that the front portion 41 and the side portion 44 and the side portion 44 and the rear portion 43 on both sides of the slit can easily move independently. Further, the front portion 41 is hung long, and the back pad body 1 is foam-molded so that the backing material 4 hangs not only on the inner wall surface 3b of the headrest portion 3 but also on the back surface 2b of the back pad portion 2 for a long time. It is a back pad P with a headrest in which the parts of the above are integrated. A front projecting portion 411 is interposed between the back pad portion back surface 2b and the vehicle body side frame (not shown) to prevent rubbing noise here. Other configurations are the same as those of the backing material 4 of FIGS. 3 and 4, and the description thereof will be omitted.

In the method of manufacturing the back pad with a headrest configured in this way, the upper portion 4a is formed into a bag shape, and the lower portion 4b is formed by stitching the lower portion 4b to the side 43S side from one point on the lower edge toward the bag bottom 420 of the upper portion 4a. Since the backing material 4 which is released without suturing the other side 45S side which becomes the bag mouth 47 side tubular part is adopted, the headrest as shown in FIG. 1 (b) in which the inside 3u is wider than the downward hole 37. Also in the portion 3, the backing material 4 can be neatly integrated with the inner wall surface 3b of the headrest portion hole 3u by foam molding of the pad body 1. In FIG. 5, the thickness width is increased toward the back pad back surface forming mold portion 91, the maximum thickness width Wmax is set in the middle, and then the thickness width is decreased toward the back pad back surface forming mold portion 91. Since the lower portion 4b of the backing material whose one side 43S side and the other side 45S side are separated from the forming mold portion 92 is expanded, the bag-shaped upper portion 4a reaches the maximum thickness width Wmax of the pad body inner surface forming mold portion 92. Can be covered and easily covered.

Further, conventionally, even if the cover exceeds the maximum thickness width Wmax as shown in FIG. 13 (b), the hem portion Z1 of the backing material Z arranged on the headrest inner surface forming mold portion 92 expands and the followability is poor, and the pad During the foam molding of the main body 1, slack of the backing material 4 was generated, which blocked the flow path of the foamed raw material g and obstructed the liquid flow, which easily caused poor quality. No problems occur. The lower portion 4b of the backing material 4 that exceeds the maximum thickness width Wmax and covers the headrest inner surface forming mold portion 92 is separated from the one side 43S side and the other side 45S side, and the lower portion 4b is formed on the headrest inner surface by winding the horizontally long band portion 46. The structure is such that it is brought close to the mold portion 92 to eliminate slack. A horizontally long band portion 46 is laminated on the lower portion 4b, and is wound around the lower half region 921 of the headrest inner surface forming mold portion 92 in the circumferential direction to be mounted, so that the lower portion of the backing material 4 including the hem portion is attached. 4b is in close contact with the headrest inner surface forming mold portion 92 as shown in FIG.
After covering the headrest inner surface forming mold portion 92, the horizontally long band portion 46 covers the lower portion 4b of the backing material and is wound in the circumferential direction of the lower half region 921 related to the headrest inner surface forming mold portion 92. Even the front portion 41 and the rear portion 43 of the backing material lower portion 4b in which the 43S side and the other side 45S side are separated and hang down can be easily joined to the surface of the headrest inner surface forming mold portion 92 without slack and attached. ..
Further, when the seam allowance portions 42j to 45j accompanying the sewing of the bag-shaped backing material upper portion 4a are arranged on the bag inner side 40 and the backing material 4 is put on the headrest inner surface forming mold portion 92 as shown in FIG. Since the seam allowance portions 42j to 45j serve as resistance and do not disturb or narrow the flow path in the foam molding of the pad body 1, it is possible to eliminate void defects.

Further, a tape piece MT containing a magnetic material is attached to the tip portion 461 of the horizontally long band portion 46, and a tape piece containing a magnetic material is formed in the lower half region 921 of the core type 9 when the horizontally long band portion 46 is wound. When the magnet body 923 is embedded in the facing surface of the MT, the horizontally long band portion 46 is wound around the lower half region 921, and the tape piece MT containing the magnetic material is magnetically attracted to the magnet body 923 and attached, the horizontally long band portion 46 is attached. The winding of the magnet is easily and surely held. The tip portion 461 of the horizontally long band portion 46, which is located below when the mold is closed and easily hangs down due to gravity, is provided with a backing material lower portion 4b in which one side 43S side and the other side 45S side of the lower portion 4b are released by a simple configuration using magnetic force adsorption. Including, the backing material 4 can be safely attached and held on the headrest inner surface forming mold portion 92 without loosening, and the pad body 1 can be foam-molded safely.

Furthermore, even in the headrest portion 3 as shown in FIG. 1 in which the hole opening 37 is narrower than the hole 3u, the tape piece MT follows the soft pad body 1 which is rich in cushioning and has deformation flexibility, and the tape piece MT is a magnet. It moves smoothly on the surface of the body 923 to facilitate demolding. The headrest portion 3 can be removed from the headrest inner surface forming mold portion 92 by increasing the hole opening 37 to the hole diameter formed by the maximum protrusion portion 95.

In addition, if the lower portion 4b of the backing material 4 is provided with a slit 49 from the lower edge of the lower portion 4b to the bag bottom 420 of the upper portion 4a in addition to the free portion between the one side 43S side and the other side 45S side, a slit 49 is provided. The front portion 41 and the side portion 44 on both sides and the side portion 44 and the rear portion 43 can easily move independently (FIG. 12). After covering the headrest inner surface forming mold portion 92 with the backing material 4, the presence of the slit 49 increases the degree of freedom in the movement of the backing material lower portion 4b, and the lower portion 4b creates slack or wrinkles on the headrest inner surface forming mold portion 92. The horizontally long band portion 46 can be easily wound around the lower half region 921 of the headrest inner surface forming mold portion 92 so as to be easily brought into close contact with the headrest.
As described above, according to the method for manufacturing the back pad with the headrest, not only the pad body 1 can be foam-molded while maintaining the quality and the high yield even in the headrest portion 3 in which the hole 37 is narrower than the hole 3u. , It enables demolding and has excellent workability, and exhibits excellent effects such as quality stability, productivity improvement, and workability improvement.

In the present invention, the present invention is not limited to the one shown in the above embodiment, and various modifications can be made within the scope of the present invention according to the purpose and application. The shape, size, number, material, etc. of the pad body 1, back pad portion 2, headrest portion 3, backing material 4, cutting fragment 5, foam molding mold 6, etc. can be appropriately selected according to the intended use. For example, in the embodiment, one piece is used for the cutting piece 5 for the backing material 4, but the backing material 4 can be composed of a plurality of cutting pieces 5. The backing material 4 in FIG. 12 is also provided with a through hole 410 and a tape piece MT, and similarly to FIG. 6, a magnet body 923 can be provided in the headrest inner surface forming mold portion 92 facing the tape piece MT.

1 Pad body 3 Headrest part 3b Inner wall surface 4 Backing material 4a Upper part 4b Lower part 42j to 45j Seam allowance part 43S One side 45S Other side 46 Horizontal band part 49 Slit 5 Cutting fragment 6 Foam molding type 92 Headrest inner surface forming type part 921 Lower half Area 923 Magnet body P Back pad with headrest g Foaming material MT Magnetic material containing tape piece (tape piece)

Claims (4)

After attaching the backing material to the foam molding type headrest inner surface forming mold part, the foaming material is injected and the mold is closed, and then the pad body in which the backing material is integrated into the inner wall surface of the downward hole related to the headrest part is attached. In the method of manufacturing a back pad with a headrest to be foam-molded,
The upper a bag shape by stitching a cut piece of fabric material was cut for the inner wall, bottom, and one side of該裁fragment from one point of the lower edge toward the upper part of the bag bottom, and the one edge side A bag-like body provided with a horizontally long band portion that can be separated from the other side that becomes a tubular part on the bag mouth side by suturing, and the other side can be extended and run along the lower outer circumference. A back with a headrest, which comprises covering the headrest inner surface forming mold portion with the backing material, and then wrapping the horizontally long band portion in the circumferential direction of the lower half region of the headrest inner surface forming mold portion. How to make the pad. The method for manufacturing a back pad with a headrest according to claim 1, wherein a bag-shaped seam allowance portion associated with suturing of the upper portion is arranged inside the bag, and the backing material is put on the headrest inner surface forming mold portion. While the magnetic material-containing tape piece is attached to the tip end side portion of the horizontally long band portion, the magnet body is embedded in the facing surface of the magnetic material-containing tape piece in the lower half region when the horizontally long band portion is wound. The method for manufacturing a back pad with a headrest according to claim 1 or 2, wherein the horizontally long band portion is wound around the lower half region, and the tape piece containing the magnetic material is magnetically attracted to and attached to the magnet body. Any one of claims 1 to 3 in which a slit from the lower edge of the lower portion to the bottom of the bag of the upper portion is provided in the lower portion of the backing material in addition to the free portion between the one side side and the other side side. The method for manufacturing a back pad with a headrest according to item 1.

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