JP7383301B2 - Joint structure between headrest stay and core material and headrest - Google Patents

Description

The present invention relates to a headrest attached to a seat back of a vehicle seat, and relates to a connection structure between a headrest stay and a core material therefor, and a headrest .

In order to protect the heads of seated occupants, a headrest (backward head tilt restraining device) is installed above the seat back of a seat in an automobile (vehicle), and the main body is a pillow against which the head of the seated occupant rests. There is. This headrest has a headrest stay that connects the upper ends of a pair of parallel left and right legs directly or through a bridge section of a predetermined shape, and the upper end of the headrest stay has a core made of foamed plastic. materials are combined.
According to general headrest manufacturing, the upper end of this headrest stay is inserted into the inner space of the skin by pushing the core material through the opening of the bag-shaped skin, and in this state, a foamed plastic material is applied to the skin. Headrests were obtained by injecting and molding cushion bodies.

By the way, conventionally, as a coupling structure between the upper end portion of a headrest stay and a core material, the one disclosed in Patent Document 1 entitled "Method for Manufacturing a Headrest" is known. This restricts movement of both legs of the headrest stay in the left-right direction through a pair of right and left rigid restriction projections disposed at the lower end of the core.

Japanese Patent Application Publication No. 2006-15826

In this way, in the conventional coupling structure between the headrest stay and the core material, the movement of each leg in the left-right direction is restricted through a pair of left and right regulating protrusions (rigid bodies) provided at the lower end of the core material. All I had to do was do it. Therefore, the binding force between the headrest stay and the core material in the front-rear direction is small, and as mentioned above, when inserting the upper end of the headrest stay with the core material into the epidermis by pushing the core material into the opening, There was a risk that the core material would separate from the headrest stay.

Therefore, as a result of intensive research, the inventor formed a fitting groove into which the upper end of the headrest stay is fitted on one side of the foamed plastic core material, and created a groove that overhangs the opening of this fitting groove. The inventors have discovered that all of the above-mentioned problems can be solved by providing an elastically deformable piece and using this elastically deformable piece to push the upper ends of the pair of legs of the headrest stay into the insertion groove. Completed.

That is, the present invention can increase the bonding force between the upper end of the headrest stay and the core material in the longitudinal and lateral directions, and as a result, when manufacturing the headrest, the upper end of the headrest stay to which the core material is connected can be It is an object of the present invention to provide a joint structure between a headrest stay and a core material, and a headrest that can be inserted into the epidermis without any problem and that can stabilize the quality of the manufactured headrest.

The invention according to claim 1 provides a headrest stay and a core in which a fitting groove having a roughly U-shaped cross section is provided on one surface of a core material made of foamed plastic, and the upper end of the headrest stay is inserted into the fitting groove. In the fitting structure, the fitting groove is provided with recesses recessed from the fitting groove forming wall at a plurality of positions in the middle part of the fitting groove, and elastic deformable pieces are provided on the bottom walls of these recesses. At the same time, these elastically deformable pieces have a hook-shaped head that overhangs the opening of the insertion groove, and a body that stands up from the bottom wall of the recess and supports the head. By inclining the body toward the corresponding fitting groove forming wall, the upper end of the headrest stay fitted into the fitting groove is fitted by the elastic force of the elastically deformable piece. This is a joint structure between the headrest stay and the core material, which is configured to be pushed into the back of the insertion groove .

The term "left-right direction" used herein refers to the left-right direction (width direction of the seat back, width direction of the vehicle) based on the state in which the headrest is attached to the seat back of the seat. Moreover, the "front-back direction" here refers to the front-back direction in this state (the front-back direction of the seat back, the longitudinal direction of the vehicle).
The type of vehicle equipped with a seat to which a headrest is attached is not limited. For example, cars, trains, trains, airplanes, ships, etc. can be used.
The type, shape, and size of the seat are also arbitrary as long as it has a headrest on the seat back.
The main body of this headrest is a pillow section with a headrest stay as a skeleton. The pillow part is constructed by inserting and holding the upper end of the headrest stay, to which the core material is combined, into a bag-shaped skin that serves as the exterior material.Then, in the interior space of this skin, a foam material that is softer than the core material is inserted into the bag-shaped skin that serves as the exterior material. The cushion body is internally molded by filling and foaming a synthetic resin material. Therefore, both legs of the headrest stay project in parallel from the lower end of the pillow part.

The material of the headrest stay is not limited as long as it satisfies the required strength for the headrest stay. For example, various metals such as stainless steel and aluminum alloy can be used. This headrest stay may be a pipe or a solid body.
The shape of the headrest stay (especially the shape of its tip) is arbitrary. For example, a substantially inverted U-shape, a substantially A-shape (with a hole), a torii gate shape, etc. can be adopted. Alternatively, it may have a substantially inverted U-shape when viewed from the front, or an inverted J-shape when viewed from the side.
At least the lower portions of the legs that protrude from the pillow portion may be parallel to each other.

As the material for the core material, various foamed plastics, particularly various hard foamed plastics, can be used. For example, expanded polypropylene (EPP) may be used.
The shape of the core material is arbitrary. For example, it may be rectangular or trapezoidal in plan view.
"One side of the core material" as used herein is any exposed surface of the core material. Specifically, with reference to the state in which the headrest is attached to the seat back of the seat, it may be the rear surface of the core material at that time, or the left or right surface of the core material.

The shape of the fitting groove is changed as appropriate depending on the shape of the upper end of the corresponding headrest stay. For example, if the upper end of the headrest stay is approximately in an inverted U-shape, the shape of the insertion groove (the shape when viewed directly from one surface (the insertion groove) of the core material) is also approximately in an inverted U-shape. Further, if the upper end portion of the headrest stay is approximately A-shaped (hole-opening shape), the shape of the insertion groove is also approximately A-shaped.
The cross-sectional shape of the insertion groove is approximately U-shaped into which the headrest stay can be inserted.
The expression "approximately U-shaped in cross section" means that the cross-sectional shape perpendicular to the length direction of the insertion groove is U-shaped or a shape similar thereto.

The fitting groove is provided with recesses recessed from the fitting groove forming wall at a plurality of positions in the intermediate portion in the length direction. Then, elastically deformable pieces are implanted in the bottom walls of these recesses, respectively.
These elastically deformable pieces are composed of a hook-shaped head that overhangs the opening of the insertion groove, and a body that stands up from the bottom wall of the recess and supports the head. . In this case, the body portion is inclined toward the corresponding fitting groove forming wall side.
Here, " the head of the elastically deformable piece is provided in an overhanging state with respect to the opening of the insertion groove," means that the head of the elastically deformable piece is provided over the opening of the insertion groove. It means that it is installed in the material.
Such elastically deformable pieces push the upper end portions of the pair of legs of the headrest stay deep into the insertion groove. In other words, a part of an elastically deformable piece that is pulled against elastic force (spring force) is placed over the headrest stay that is inserted into the insertion groove of the core material, and the elasticity of the elastically deformable piece is The force pushes the upper end of the headrest stay deep into this insertion groove.
The elastically deformable piece is a foamed plastic member made of the same material as the core material and integrally molded with the core material.
The shape of the elastically deformable piece includes a hook-shaped (claw-shaped) head with a portion overhanging the opening of the insertion groove, and a head that stands up from the bottom wall of the recess. It is equipped with a torso that supports the.
The formation position of the elastically deformable piece in the core material, in other words, the formation position of the recess is an intermediate portion in the length direction of the insertion groove, and is set at a plurality of positions in the length direction of the insertion groove. For example, it may be formed so as to protrude from the insertion groove forming wall (inner part forming wall, opening forming wall, etc.) of the core material.

In a second aspect of the invention, the fitting groove has a pair of parallel left and right leg fitting grooves and a bridge fitting which communicates the upper ends of these leg fitting grooves when viewed from above. and a pair of left and right leg fitting/inserting grooves and a bridge fitting/inserting groove are each provided with the elastic deformable piece at an intermediate position in the length direction thereof. This is a joint structure between the described headrest stay and core material.

The left leg insertion groove is a linear groove portion on the left side of the insertion groove into which the upper end of the left leg of the headrest stay is inserted.
The right leg fitting groove is a straight groove portion on the right side of the fitting groove into which the upper end of the right leg of the headrest stay is fitted.
Moreover, the bridge portion insertion groove portion is a cross-beam-shaped groove portion of the insertion groove into which the bridge portion of the headrest stay is inserted.
The elastically deformable pieces are arranged at at least three locations, near the opening of the left leg fitting groove, near the opening of the left leg fitting groove, and near the opening of the bridge fitting groove. .
The term "near the opening of the insertion groove" as used herein includes not only the opening (including the opening end) of the insertion groove, but also the area immediately above the opening end.

The invention according to claim 3 includes the coupling structure between the headrest stay and the core material according to claim 1 or 2, which is contained in a bag-like skin and wrapped and fixed with a cushion body made of foamed synthetic resin. Accordingly, the headrest is such that both legs of the headrest stay protrude from the skin in parallel.

The skin is a bag that serves as the exterior material for the pillow part, which is the main body of the headrest.
The material of the epidermis is arbitrary. For example, various types of fabrics (woven fabrics, non-woven fabrics, knitted fabrics), various types of leathers (natural leather, synthetic leather), etc. may be used.
The position where the opening is formed in the epidermis is, for example, the lower part (bottom) of the epidermis.
The size of the opening formed in the skin is arbitrary as long as the upper end of the headrest stay to which the core material is coupled can be inserted. However, this opening size should be as small as possible, for example, when the foam molding material (foamed synthetic resin material) for the cushion body is injected (or injected) into the epidermis and then filled and foamed to produce the cushion body. This is preferred because leakage of the filler material from this opening is reduced.

The material of the cushion body (elastic body, buffer body) is not limited. For example, various foamed synthetic resins (eg, polyurethane resin) that are softer than the core material can be used.
The cushion body can be provided, for example, by injecting or injecting a foamed synthetic resin material into the inner space of the skin where the bridge portion is arranged. Alternatively, a pre-provided cushion body may be stuffed into the skin in which the bridge portion is housed. Alternatively, the cushion body may be bonded to the outer circumferential surface of the bridge portion, or may be fastened to the bridge portion using a string or the like.

The manufacturing of this headrest involves the following steps. A step of preparing a headrest stay having a pair of parallel left and right legs, and forming a fitting groove having a roughly U-shaped cross section on one side into which the upper end of the headrest stay is fitted, and forming an insertion groove in the opening of the fitting groove. In contrast, a step of preparing a core material made of foamed plastic provided with an elastically deformable piece that pushes the upper end of the headrest stay to the back of the insertion groove in an overhanging state; a step of coupling the headrest stay to the core material by inserting the upper end of each elastically deformable piece so as to push out the tips thereof; and a step of coupling the headrest stay to the core material, and then coupling the headrest stay to the core material. A step of molding a cushion body within the epidermis by filling and foaming a foamed synthetic resin material within the epidermis while holding the structure within the epidermis. The elastically deformable piece is integrally molded from the same material as the core material.

(1) Headrest stay preparation process:
The method for manufacturing the headrest stay is not limited. For example, headrest stays are manufactured by bending a single steel pipe into a predetermined shape using a bending machine. Alternatively, the headrest stay may be manufactured by dividing into a plurality of partial stays, and then these may be connected by a predetermined connection method (for example, welding, fitting, etc.).

(2) Core material preparation process:
The method of forming the core material is not limited. For example, an injection molding method, a casting method, a pressure molding method, etc. can be adopted. When this core material is molded, the elastically deformable pieces are integrally molded from the same material.

(3) Connection process of the upper end of the headrest stay and the core material:
Here, the upper end of the headrest stay is inserted into the insertion groove of the core material by pushing the tips of each elastically deformable piece apart.

(4) Cushion body forming process:
When molding the cushion body, the upper end of the headrest stay with the core material bonded to it (core material bonding structure) is inserted into the skin, and while this state is maintained, the foamed synthetic resin material is inserted into the skin. Fill and foam.

According to the coupling structure of the headrest stay and the core material according to claim 1, a fitting groove into which the upper end of the headrest stay is fitted is formed on one surface of the core material made of foamed plastic, and the fitting groove is formed in one side of the core material made of foamed plastic. An elastically deformable piece is provided in an overhanging state with respect to the opening.
Therefore, when the headrest stay is inserted into the insertion groove of the core material, a part of the elastically deformed piece that is pulled against the elastic force (spring force) is placed over the upper end of the headrest stay from above. . As a result, the upper end of the headrest stay is pushed deep into the insertion groove by the action of the elastic force of the elastically deformable piece.

This increases the bonding force between the upper end of the headrest stay and the core material in the front, back, right and left directions, and when manufacturing the headrest, the upper end of the headrest stay, to which the core material is bonded, can be inserted into the skin without any problems. At the same time, the quality of the manufactured headrest can be stabilized (quality improved).
In addition, in the conventional coupling structure between the headrest stay and the core material, the movement of each leg in the left-right direction is only restricted through a pair of left and right regulating protrusions (rigid bodies) provided at the lower end of the core material. Met. Therefore, the binding force between the headrest stay and the core material in the front-rear direction is small, and when the upper end of the headrest stay with the core material is pushed into the bag opening, there is a risk that the core material will separate from the headrest stay. However, the present invention solves this problem.

Particularly, according to claim 2, the headrest stay has a substantially inverted U-shape in which the upper ends of both legs are connected by a bridge part, and the core material insertion groove is formed between the pair of left and right legs. An inverted U-shape consisting of a groove for inserting the part and a groove for inserting the bridge part was adopted. Further, the elastically deformable pieces were arranged in a triangular manner near each opening of the leg fitting groove and near the opening of the bridge fitting groove.
As a result, the bonding force between the upper end portion of the headrest stay and the core material through the insertion groove can be further increased.

Further, according to the headrest according to claim 3, the joint structure between the headrest stay and the core material according to claim 1 or 2 is included in the outer skin and wrapped and fixed with a cushion body made of foamed synthetic resin. Because of this structure, the bonding force between the upper end of the headrest stay and the core material in the front, rear, and left directions is increased.
Thereby, when manufacturing the headrest, the upper end portion of the headrest stay to which the core material is bonded can be inserted into the skin without any problem, and the quality of the manufactured headrest can be stabilized.

Furthermore, according to the headrest manufacturing method , a headrest stay having a pair of parallel left and right legs is prepared in advance, and a fitting groove in which an elastically deformable piece is arranged in an overhanging state with respect to the opening is formed on one side. Molding a core material made of foamed plastic. At this time, the elastically deformable piece is molded from the same material as the core material.
Thereafter, the headrest stay is coupled to the core material by fitting the upper end of the headrest stay into the fitting groove from the open end thereof so as to push the tips of each elastically deformable piece apart.

Next, with this joint structure held within the skin, a foamed synthetic resin material is filled and foamed into the skin, so that it is integrated with the joint structure between the core material and the headrest stay within the skin. mold the cushion body. In this way, the headrest is manufactured.
As a result, the binding force between the upper end of the headrest stay and the core material in the longitudinal and lateral directions is increased, and when manufacturing this headrest, the upper end of the headrest stay, to which the core material is joined, can be inserted into the skin without any hindrance. It is also possible to stabilize the quality of the manufactured headrest.

FIG. 2 is a perspective view showing a coupling structure between a headrest stay and a core material according to Embodiment 1 of the present invention. 1 is a longitudinal cross-sectional view of a headrest according to Example 1 of the present invention. FIG. 2 is a vertical cross-sectional perspective view showing a coupling structure between a headrest stay and a core material according to Example 1 of the present invention. FIG. 2 is a perspective view of a core material forming a part of the headrest according to Example 1 of the present invention. It is a perspective view from another direction of the core material which constitutes a part of headrest concerning Example 1 of this invention. 1 is a flowchart showing a manufacturing method for a headrest according to Example 1 of the present invention. FIG. 3 is a longitudinal cross-sectional view showing a cushion body forming process in the manufacturing method for the headrest according to Example 1 of the present invention.

Embodiments of the present invention will be specifically described below with reference to the drawings. Here, for convenience of explanation, the X1 direction is the front direction, the X2 direction is the rear direction, the Y1 direction is the right direction, the Y2 direction is the left direction, the Z1 direction is the upward direction, and the Z2 direction is the downward direction.

In FIG. 2, reference numeral 10 denotes a headrest according to Embodiment 1 of the present invention, and this headrest 10 is attached to the upper part of the seat back of a seat of an automobile (vehicle) (not shown), and includes a pillow part 11 on which the head of a seated occupant rests. This is a head tilt restraint device with a main body.
The headrest 10 includes a vertically elongated headrest stay 12 serving as a skeleton, a core material 13 that is coupled to the upper end of the headrest stay 12, and a headrest stay 12 that constitutes the exterior material of the pillow portion 11 and to which the core material 13 is coupled. It has a bag-shaped skin 14 in which the upper end of the headrest stay 12 is housed, and a cushion body 15 filled in the skin 14 in which the upper end of the headrest stay 12 is housed. From the lower surface of this pillow part 11, lower portions of a pair of parallel left and right leg parts 16, which constitute a part of the headrest stay 12, respectively protrude.

Hereinafter, these structures will be specifically explained.
As shown in FIGS. 1 and 3, the headrest stay 12 is a member formed by bending a single long steel pipe into a substantially inverted U shape when viewed from the front and into a substantially stepped shape when viewed from the side.
In order to realize such a shape, the headrest stay 12 has intermediate portions of a pair of long and parallel left and right legs 16 bent in an inverted V-shape in the X1 direction. Both leg portions 16 are supported by a frame built into the seat back of a seat (not shown) via two stay holders so as to be slidable in the vertical direction.

The lower portions of both leg portions 16 extend in the Z1-Z2 direction and are spaced apart in parallel to the Y1-Y2 direction so that they can be slidably supported by each stay holder. Furthermore, a predetermined number of notches 16a are formed in the Z1-Z2 direction on the inner surfaces of the lower upper end portions of each leg portion 16 that face each other. A latching claw of each stay holder (not shown) is latched into this notch 16a.
Further, the tips of both leg portions 16 are integrally connected to each other by a bridge portion 17 extending in the Y1-Y2 direction. Therefore, the tip of the headrest stay 12 connects the tip of the left leg 16, the right leg 16, and the bridge 17 in a substantially inverted U shape.

As shown in FIGS. 1 to 5, the core material 13 is made of expanded polypropylene (EPP) using a bead process, and is a thick foamed plastic body that satisfies the strength required for the core material 13.
The shape of the core material 13 is a substantially rectangular shape that faces the rear surface and is elongated in the Y1-Y2 direction, and is substantially bullet-shaped when viewed from the side.
A fitting groove 18 having a roughly U-shaped cross section is formed in the X2 side (rear side) surface of the core member 13, into which the upper end of the headrest stay 12 is fitted.

The fitting groove 18 includes a pair of parallel left and right leg fitting grooves 19 extending in the Z1-Z2 direction, and a bridge extending in the Y1-Y2 direction that communicates the upper ends of these leg fitting grooves 19. It has an inverted U-shape and includes a fitting insertion groove 20.
The intermediate portion in the longitudinal direction of the inner forming wall 19a of the leg fitting groove 19 and the longitudinal intermediate portion of the inner forming wall 20a of the bridge fitting groove 20, A long rectangular recess 21 is formed in the length direction of the corresponding groove.

Moreover, three elastically deformable pieces 22 are disposed on the back side forming wall (X1 side wall) 21a of each rectangular recess 21 in an overhanging state with respect to the opening of the insertion groove 18. Each elastically deformable piece 22 has a hook-shaped head 22 a arranged near the opening of the insertion groove 18 and pushes the upper end of the headrest stay 12 deep into the insertion groove 18 . These elastically deformable pieces 22 are each made of the same material as the core material 13, and are integrally implanted in the inner wall 21a of the corresponding rectangular recess 21.
The length of each elastically deformable piece 22 from the inner surface of the corresponding rectangular recess 21 to the lower end of the hook-shaped head 22a is shorter than the diameter of the headrest stay 12. These elastically deformable pieces 22 gradually incline toward the corresponding outer forming walls 19b, 20b as they move toward the tips.

In addition, recesses 19c each having an arcuate cross section are formed in the inner forming wall 19a and the outer forming wall 19b of the leg fitting groove 19 in order to position the upper end of the fitted headrest stay 12. Furthermore, a recess 22b having a similar function is formed in the body of each elastically deformable piece 22, respectively.

As shown in FIG. 2, the skin 14 is made of thin synthetic leather sewn into a bag shape. In the lower part of the skin 14 (bottom cloth part), when inserting the connecting structure 23 between the core material 13 and the upper end of the headrest stay 12 into the bag, a material of a size that cannot be passed through without compressing the core material 13 is provided. A long opening 14a is formed in the Y1-Y2 direction.
The cushion body 15 is a cushion made of foamed urethane (foamed synthetic resin).

Next, a method for manufacturing the headrest 10 will be described with reference to the flow sheet shown in FIG.
A headrest stay 12 having a pair of parallel left and right leg portions 16 and a bridge portion 17 is prepared in advance (headrest stay preparation step). Specifically, the headrest stay 12 is produced by bending a single steel pipe into a substantially inverted U-shape when viewed from the front and into a substantially stepped shape when viewed from the side using a bending machine.
Further, a core material 13 having a fitting groove 18 formed on the surface on the X2 side is prepared (core material preparation step). Specifically, a bead-method foamed polypropylene material (injection molding material) is injected into an injection mold (not shown). As a result, a hook-shaped elastic deformable piece 22 is provided at the middle part of each side of the insertion groove 18, which has a generally U-shaped cross section and is approximately inverted U-shaped when viewed directly from the X2 side surface of the core material 13. A core material 13 having one each arranged thereon is injection molded.

Thereafter, the upper end portion of the headrest stay 12 is inserted into the insertion groove 18 of the core member 13 so as to push the tips of each elastically deformable piece 22 apart. As a result, a joining structure 23 between the core material 13 and the upper end of the headrest stay 12 is obtained (a step of joining the upper end of the headrest stay and the core material).
Each elastically deformable piece 22 is gradually inclined toward the corresponding outer forming wall 19b, 20b toward the tip. Therefore, when the upper end of the headrest stay 12 is inserted into the fitting groove 18 so as to push out the tips of each elastically deformable piece 22, the elasticity of each elastically deformable piece 22 in the direction of the corresponding outer forming wall 19b, 20b is Due to the action of the force (spring force), the upper end portion of the headrest stay 12 is pressed against the corresponding outer forming walls 19b, 20b. As a result, the bonding force between the upper end portion of the headrest stay 12 and the core member 13 in the left-right direction (however, in the case of the elastically deformable piece 22 on the bridge portion 17 side, in the vertical direction) is increased.

On the other hand, when the tip of the headrest stay 12 is inserted into the insertion groove 18, each hook-shaped head 22a hangs over the X1 side end of the upper end of the headrest stay 12, respectively. will be stopped.
At this time, since the length from the inner surface of each rectangular recess 21 to the lower end of the head 22a of each elastically deformable piece 22 is shorter than the diameter of the headrest stay 12, when the headrest stay 12 is inserted, each elastically deformable piece 22 A part (mainly the trunk) is pulled against elastic force (spring force) and is placed over the upper end of the headrest stay 12 from above. As a result, a force that tends to shrink in the X1 direction acts on each elastic deformation piece 22, and the upper end of the headrest stay 12 is pushed deep into the insertion groove 18, causing the upper end of the headrest stay 12 and the core material 13 The bonding force in the front and back direction is increased.
From the above, in the first embodiment, the bonding force between the upper end portion of the headrest stay 12 and the core material 13 in the front, rear, left and right directions (all directions) can be increased.

Thereafter, the coupling structure 23 between the core material 13 and the upper end of the headrest stay 12 is pushed into the skin 14 through the opening 14a formed in the lower part of the skin 14. At this time, the opening 14a of the skin 14 is of such a size that the core material 13 cannot be passed through it without being compressed. However, since the bonding force between the upper end of the headrest stay 12 and the core material 13 is increased in the front, rear, left and right directions (all directions), this bonding structure 23 is connected to the core material 13 from the upper end of the headrest stay 12 It can be inserted into the epidermis 14 without coming off.
In addition, in the conventional connection structure between the upper end of the headrest stay and the core material, movement of each leg in the left-right direction is restricted through a pair of left and right regulating protrusions (rigid bodies) provided at the lower end of the core material. It was only regulated. Therefore, the binding force between the headrest stay and the core material in the front-rear direction is small, and when the upper end of the headrest stay with the core material is pushed into the bag opening, the core material separates from the upper end of the headrest stay. However, in the first embodiment, this problem has been solved.

Thereafter, as shown in FIG. 7, while holding the joint structure 23 between the core material 13 and the upper end of the headrest stay 12 in the skin 14 set in the molding die 24, the skin 14 is opened from the opening 14a. The injection nozzle 25 is inserted into the skin 14, and the urethane foam material a is injected into the skin 14 to fill and foam. Thereby, the cushion body 15 integrated with the core material 13 and the upper end portion of the headrest stay 12 is molded within the skin 14, and the pillow portion 11 is produced (cushion body molding step).
As described above, it is possible to manufacture the headrest 10 with stable quality and high safety.
The headrest 10 manufactured in this way has two leg parts 16 protruding from the lower part of the pillow part 11 attached to a frame built in the seat back of an automobile seat (not shown) via two stay holders, and attached to Z1. - It is used by inserting them so that they can slide freely in the Z2 direction.

In the headrest 10 of the first embodiment, the headrest stay 12 has a substantially inverted U-shape in which the upper ends of both leg parts 16 are connected by the bridge part 17. An inverted U-shape consisting of a leg fitting groove 19 and a bridge fitting groove 20 is adopted, and three elastically deformable pieces 22 are inserted near each opening of both leg fitting grooves 19 and the bridge. They are arranged in a triangular manner near the opening of the fitting insertion groove 20. Therefore, the bonding force between the upper end portion of the headrest stay 12 and the core material 13 via the insertion groove 18 can be further increased.

In particular, here, one elastically deformable piece 22 is installed at the intermediate portion in the length direction of each of the leg part fitting groove part 19 and the bridge part fitting part groove part 20 in the fitting groove 18 having a substantially inverted U shape. As a result, the bonding force of the coupling structure 23 between the headrest stay 12 and the core material 13 (especially , the resistance of the coupling structure 23 to breakage against impact force generated at the time of a rear-end collision of a vehicle can be improved.
Note that when the upper end of the headrest stay 12 is inserted into the insertion groove 18, the tip of each elastically deformable piece 22 is placed at the position of the opening end of the insertion groove 18, or at a position near the opening end of the insertion groove 18 on the X1 side. It's okay. The reason for this is that in the cushion body forming process shown in FIG. This is because it does not become an obstacle that obstructs the flow of the urethane material a, and as a result, no voids due to this occur in the obtained cushion body 15.

INDUSTRIAL APPLICATION This invention is useful as a technique regarding the headrest stay attached to the seat back of the seat of a vehicle, and the headrest using this.

10 Headrest 12 Headrest stay 13 Core material 14 Outer skin 15 Cushion body 16 Leg portion 17 Bridge portion 18 Fitting groove 19 Leg fitting groove 20 Bridge portion fitting groove 22 Elastic deformation piece 23 Joint structure a Urethane foam material ( (foamed synthetic resin material)

Claims (3)

In the joint structure of the headrest stay and the core material, a fitting groove having a roughly U-shaped cross section is provided on one surface of the core material made of foamed plastic, and the upper end of the headrest stay is inserted into the fitting groove.
The insertion groove is provided with recesses recessed from the insertion groove forming wall at a plurality of positions in the intermediate portion in the length direction, and elastically deformable pieces are respectively implanted in the bottom walls of these recesses, These elastically deformable pieces are composed of a hook-shaped head provided in an overhanging state with respect to the opening of the insertion groove, and a body that stands up from the bottom wall of the recess and supports the head, and By tilting the body toward the corresponding fitting groove forming wall, the upper end portion of the headrest stay fitted into the fitting groove is pushed into the inner side of the fitting groove by the elastic force of the elastically deformable piece. A joint structure between the headrest stay and the core material. The fitting groove is composed of a pair of parallel left and right leg fitting grooves and a bridge fitting groove which communicates the upper ends of these leg fitting grooves when viewed from above. The headrest stay and the core material according to claim 1, wherein the pair of left and right leg fitting grooves and the bridge fitting groove are each provided with the elastic deformable piece at an intermediate position in the length direction thereof. bond structure. By enclosing the coupling structure between the headrest stay and the core material according to claim 1 or claim 2 in a bag-shaped skin and wrapping and fixing it with a cushion body made of foamed synthetic resin, the headrest stay can be removed from the skin. A headrest with both legs protruding parallel to each other.

Images