JP7410792B2

JP7410792B2 - Headrest manufacturing method

Info

Publication number: JP7410792B2
Application number: JP2020080677A
Authority: JP
Inventors: 千夏宮下
Original assignee: Inoac Corp
Current assignee: Inoac Corp
Priority date: 2020-04-30
Filing date: 2020-04-30
Publication date: 2024-01-10
Anticipated expiration: 2040-04-30
Also published as: JP2021172314A

Description

この発明は、ヘッドレストの製造方法造に関し、更に詳細には、ヘッドレスト本体の表面に露出するよう線状発光部が設けられたヘッドレストの製造方法に関するものである。 The present invention relates to a method for manufacturing a headrest, and more particularly, to a method for manufacturing a headrest in which a linear light emitting portion is provided so as to be exposed on the surface of a headrest main body.

自動車等の車両や船舶、或いは航空機といった各種の乗物のシートや住宅等で利用される椅子の中には、座った人員の背部を支えるシートバックの上部に、頭部や頸部を支えて保護するヘッドレストを備えたものが知られている。このようなヘッドレストは、縫合などにより袋状に形成された軟質な表皮材の内側に弾力性を有する発泡体が充填されたヘッドレスト本体と、当該ヘッドレスト本体に部分的に埋設されて下方に延出するステーとを備えており、当該ヘッドレストのステーを、シートバッグに設けられたステー支持部に挿入することで取り付けられている。 Some chairs used in various vehicles such as automobiles, ships, and aircraft, as well as in homes, have a seat back that supports the back of the person sitting on the seat, and the upper part of the seat back supports and protects the head and neck. Some models are known that are equipped with headrests that allow Such a headrest consists of a headrest main body, which is made up of a soft skin material formed into a bag shape by suturing, etc., filled with elastic foam, and a headrest body that is partially embedded in the headrest main body and extends downward. The headrest is attached by inserting the headrest stay into a stay support provided on the seat bag.

ところで、近年は、ヘッドレストの加飾性を高めることなどを目的として、ヘッドレストを発光するよう構成したものがある。例えば、ヘッドレストの表皮材の縫合部分に蛍光塗料や蓄光顔料を混入した玉縁などを設けて、ブラックライトの照射や蓄光作用により玉縁を発光させたり、特許文献１のように、シートバック側に設けた光源から導いた光を、ヘッドレストの稜線に沿うように設けた線状発光部の端部から入射させて発光させるものが提案されている。 Incidentally, in recent years, some headrests have been configured to emit light in order to enhance the decorative properties of the headrests. For example, a bead containing fluorescent paint or phosphorescent pigment may be provided at the seam part of the headrest skin material, and the bead may be made to emit light by irradiation with a black light or a phosphorescent effect, or as disclosed in Patent Document 1, the seatback side It has been proposed that light guided from a light source provided in a headrest is made to enter from an end of a linear light emitting part provided along a ridgeline of a headrest to emit light.

特開２００１－１８６９６５号公報Japanese Patent Application Publication No. 2001-186965

しかしながら、蛍光塗料にブラックライトを照射させて発光させる場合には、ヘッドレストの外側にブラックライトを照射する設備が必要になり、またブラックライトの照射範囲しか発光させられない。また蓄光顔料を利用する場合は、その蓄光作用が続く間しか発光させられないことから、何れも発光による加飾性が限定的になる問題がある。その一方で、線状発光部の端部から光を入射させて発光させる場合には、線状発光部に対して正確に光を照射する必要があり、特にヘッドレストを着脱可能に構成した場合には、シートバック側に設けた光源から導いた光を線状発光部の端部に正確に照射することが困難となり、線状発光部の発光による加飾効果が適切に発揮されない問題がある。 However, when the fluorescent paint is irradiated with a black light to cause it to emit light, equipment for irradiating the outside of the headrest with the black light is required, and only the area irradiated by the black light can be emitted. Further, when using luminescent pigments, since the pigment can only emit light while its luminous effect lasts, there is a problem in that the decorative properties of the luminescent pigments are limited. On the other hand, when light is emitted by entering the linear light emitting part from the end, it is necessary to accurately irradiate the light to the linear light emitting part, especially when the headrest is configured to be removable. In this case, it becomes difficult to accurately irradiate the end portions of the linear light emitting portions with light guided from a light source provided on the seat back side, and there is a problem in that the decorative effect of the light emitted from the linear light emitting portions is not properly exhibited.

すなわち本発明は、シートバックに対して着脱可能に構成されたヘッドレストを発光により効果的に装飾することができるヘッドレストの製造方法を提供することを目的とする。 That is, an object of the present invention is to provide a method for manufacturing a headrest that can effectively decorate a headrest configured to be removably attached to a seat back by emitting light.

前記課題を克服し、所期の目的を達成するため、本願の請求項１に係る発明は、
表皮材の内側に弾性体が設けられたヘッドレスト本体の表面に露出するよう線状発光部が設けられると共に、前記ヘッドレスト本体から下方にステーが延出するよう形成されたヘッドレストの製造方法であって、
表皮形成材の縫合部位における当該表皮形成材の間に線状発光部を位置付けて、線状発光部の端部側に表皮形成材に縫合されない余剰部が形成されるように、当該表皮形成材と線状発光部を縫合することで前記袋状の表皮材を表裏が裏返った状態となるよう形成し、
前記表皮材に形成した引っ繰り返し用の開口を介して前記表皮形成材の表面が外側に露出するよう袋状の表皮材を引っ繰り返し、
前記表皮材の挿通孔を挿通するように前記ステーを挿通して、該ステーの前記ヘッドレスト本体に埋設される埋設部分を前記表皮材の内側に収容し、
前記表皮材の内側において、前記ヘッドレスト本体に埋設される埋設部分に形成した前記ステーの第１開口部に、前記線状発光部における余剰部を差し込んでステーの内部に線状発光部を挿通して、当該ステーの下端部に形成した第２開口部に線状発光部の端部が向くようにし、
成形型に収容した前記表皮材の内側で発泡原料を発泡させて前記弾性体を形成することで、前記ステーの内部に前記線状発光部が挿通する状態で当該線状発光部が表面に露出した前記ヘッドレスト本体を形成し、
前記ステーに形成した前記第２開口部に向く前記線状発光部の端部から入射した光により当該線状発光部を発光させ得るようにしたことを要旨とする。
このように、ステーにおいてヘッドレスト本体に埋設される埋設部分に形成した第１開口部を介してステーの内部を挿通した線状発光部の端部を、ヘッドレスト本体から下方に延出したステーの下端部に形成した第２開口部に向けるようにしてヘッドレストを製造できる。このため、ステー支持部にステーを挿入した状態で、発光手段の光が第２開口部から線状発光部の端部に入射させることができる。すなわち、シートバックに対して着脱可能に構成されたヘッドレストの線状発光部に対して、当該シートバック側に設けた発光体の光を照射することができるようになるから、ヘッドレストをシートバックに対して着脱可能にしながらも、ヘッドレストに設けた線状発光部の発光により効果的に装飾することが可能になる。 In order to overcome the above problems and achieve the intended purpose, the invention according to claim 1 of the present application:
A method for manufacturing a headrest, wherein a linear light emitting part is provided to be exposed on the surface of a headrest main body in which an elastic body is provided inside a skin material, and a stay is formed so as to extend downward from the headrest main body. ,
A linear light-emitting part is positioned between the skin-forming materials at the suture site of the skin-forming material, and the skin-forming material and the linear light emitting part are sewn together to form the bag-shaped skin material so that the front and back sides are turned inside out,
Flip the bag-shaped skin material so that the surface of the skin forming material is exposed to the outside through a flipping opening formed in the skin material,
inserting the stay so as to pass through the insertion hole of the skin material, and accommodating an embedded portion of the stay to be buried in the headrest body inside the skin material;
Inside the skin material, insert the surplus part of the linear light emitting part into the first opening of the stay formed in the embedded part embedded in the headrest main body, and insert the linear light emitting part into the inside of the stay. so that the end of the linear light emitting part faces the second opening formed at the lower end of the stay,
By foaming the foaming raw material inside the skin material housed in the mold to form the elastic body, the linear light emitting part is exposed on the surface in a state where the linear light emitting part is inserted into the inside of the stay. forming the headrest body,
The gist is that the linear light emitting section can be caused to emit light by light incident from an end of the linear light emitting section facing the second opening formed in the stay.
In this way, the end of the linear light emitting part inserted through the inside of the stay through the first opening formed in the buried part buried in the headrest body in the stay is connected to the lower end of the stay extending downward from the headrest body. The headrest can be manufactured so as to face the second opening formed in the section. Therefore, with the stay inserted into the stay support part, the light from the light emitting means can be made to enter the end of the linear light emitting part from the second opening. In other words, the linear light emitting part of the headrest, which is configured to be detachable from the seatback, can be irradiated with light from the light emitting body provided on the seatback side, so the headrest can be attached to the seatback. While the headrest is removable, it is possible to effectively decorate the headrest by emitting light from the linear light emitting section provided on the headrest.

本願の請求項２に係る発明は、
前記ステーの内部に挿通した前記線状発光部の端部を、当該ステーの第２開口部に取り付けた保持部材で保持することを要旨とする。
このように、ステーの第２開口部に取り付けた保持部材に線状発光部の端部を保持することで、当該第２開口部に対して線状発光部の端部を一定位置にすることができる。これにより、ヘッドレストの線状発光部に対して、シートバック側に設けた発光体の光を一定の位置関係で照射することができ、発光手段の光を線状発光部の端部に正確に入射させて線状発光部を効果的に発光させることが可能になる。 The invention according to claim 2 of the present application is:
The gist is that the end of the linear light emitting part inserted into the stay is held by a holding member attached to the second opening of the stay.
In this way, by holding the end of the linear light emitting part on the holding member attached to the second opening of the stay, the end of the linear light emitting part can be kept at a constant position with respect to the second opening. I can do it. This makes it possible to irradiate the linear light emitting part of the headrest with the light from the light emitting body provided on the seatback side in a fixed positional relationship, so that the light from the light emitting means can be accurately directed to the end of the linear light emitting part. It becomes possible to make the linear light emitting part emit light effectively by making the light incident thereon.

本願の請求項３に係る発明は、
前記表皮材の表裏が裏返った状態で、発泡体により筒状に形成した被覆部材を、前記表皮材における前記ステーの挿通孔に連通するよう前記表皮形成材の裏面に固定し、
前記表皮形成材の表面が外側に露出するように前記袋状の表皮材を引っ繰り返した状態で、前記被覆部材の貫通孔および前記表皮材の挿通孔を挿通するように前記ステーを挿通し、
前記表皮材の内側において、前記被覆部材で塞がれない位置に位置付けた前記第１開口部に、前記線状発光部における余剰部の端部を差し込んで前記ステーの内部に線状発光部を挿通し、
前記被覆部材で前記第１開口部が塞がれるように前記ステーを前記表皮材の外側に引き出したもとで、当該表皮材の内側で発泡原料を発泡させて前記弾性体を形成するようにしたことを要旨とする。
このように、ステーの第１開口部を被覆部材で塞ぐようにした後に、表皮材の内側で発泡原料を発泡させて弾性体を形成するようにしたことで、弾性体の形成時に発泡原料が第１開口部からステーの内部に漏出するのを防止できるから、適切な形状に弾性体を正確に成形することができる。また、発泡原料の発泡圧により、ステーの第１開口部を挿通している線状発光部に被覆部材が押し付けられることで、第１開口部に挿通した線状発光部の周りの隙間を被覆部材で効果的に塞ぐことができ、線状発光部の周りの隙間からの発泡原料の漏出も効果的に防ぐことができる。 The invention according to claim 3 of the present application is:
With the skin material turned over, a covering member formed into a cylindrical shape from a foam is fixed to the back surface of the skin forming material so as to communicate with the insertion hole of the stay in the skin material,
Inserting the stay through the through hole of the covering member and the insertion hole of the skin material while the bag-shaped skin material is turned over so that the surface of the skin forming material is exposed to the outside;
The linear light emitting part is inserted inside the stay by inserting the end of the excess portion of the linear light emitting part into the first opening located at a position not covered by the covering member on the inside of the skin material. Insert,
The elastic body is formed by foaming the foaming raw material inside the skin material while the stay is pulled out to the outside of the skin material so that the first opening is closed by the covering member. The gist is:
In this way, after the first opening of the stay is closed with the covering member, the foaming material is foamed inside the skin material to form the elastic body, so that the foaming material is foamed when forming the elastic body. Since it is possible to prevent the elastic body from leaking into the stay from the first opening, it is possible to accurately mold the elastic body into an appropriate shape. In addition, by the foaming pressure of the foaming raw material, the covering member is pressed against the linear light emitting part inserted through the first opening of the stay, thereby covering the gap around the linear light emitting part inserted into the first opening. It can be effectively blocked with a member, and leakage of the foaming material from the gap around the linear light emitting part can also be effectively prevented.

本願の請求項４に係る発明は、
前記被覆部材を形成する発泡体を、前記弾性体を形成する発泡体より軟質の発泡体で形成するようにしたことを要旨とする。
このように、被覆部材を形成する発泡体を、弾性体を形成する発泡体より軟質の発泡体で形成することで、弾性体により被覆部材を第１開口部側に押し付けるように弾性変形させることができ、被覆部材を第１開口部の開口縁部や線状発光部により密着するようにして隙間を塞ぐことができ、発泡原料の漏出をより効果的に防止できる。 The invention according to claim 4 of the present application is:
The gist is that the foam forming the covering member is made of a foam softer than the foam forming the elastic body.
In this way, by forming the foam that forms the covering member from a foam that is softer than the foam that forms the elastic body, the covering member can be elastically deformed so as to be pressed against the first opening side by the elastic body. The gap can be closed by bringing the covering member into closer contact with the opening edge of the first opening or the linear light emitting part, and leakage of the foaming raw material can be more effectively prevented.

本発明によれば、ヘッドレストをシートバックに対して着脱可能にしながらも、発光により効果的に装飾することができる。 According to the present invention, it is possible to effectively decorate the headrest with light emission while making the headrest removable from the seat back.

本実施形態に係るヘッドレストの発光構造を備えた車両用シートを、シートバックからヘッドレストを取り外した状態で示す斜視図である。FIG. 1 is a perspective view showing a vehicle seat including a headrest light emitting structure according to the present embodiment with the headrest removed from the seat back. 本実施形態に係るヘッドレストの発光構造を備えた車両用シートを、シートバックを透視した状態で示す正面図である。FIG. 1 is a front view of a vehicle seat including a headrest light emitting structure according to the present embodiment, with the seat back seen through. 図２のＡ－Ａ線断面図である。3 is a sectional view taken along line AA in FIG. 2. FIG. 本実施形態に係るヘッドレストのステー(延出支持部)と、ステー支持部の関係を示す説明図であって、(a)は、ヘッドレストのステーをステー支持部に挿入する状態を示し、(b)は、ヘッドレストのステーをステー支持部に挿入した状態を示す。FIG. 3 is an explanatory diagram showing the relationship between the stay (extending support part) of the headrest and the stay support part according to the present embodiment, in which (a) shows a state in which the stay of the headrest is inserted into the stay support part, and (b) ) shows the state in which the headrest stay is inserted into the stay support part. 図２のＡ－Ａ線位置におけるヘッドレストの構成部材の分解図であって、表皮材は表裏が裏返った状態で示してある。FIG. 3 is an exploded view of the components of the headrest taken along line AA in FIG. 2, with the skin material being shown with its front and back turned inside out. 本実施形態に係るヘッドレストの製造工程を示す説明図であって、表面が外側に向くように引っ繰り返した袋状の表皮材の挿入孔および被覆部材の貫通孔に、ステー(延出支持部)挿入する状態を示している。FIG. 3 is an explanatory diagram showing the manufacturing process of the headrest according to the present embodiment, in which stays (extending support portions) are inserted into the insertion holes of the bag-shaped skin material and the through holes of the covering member, which are turned over so that the surface faces outward. Indicates the state of insertion. 本実施形態に係るヘッドレストの製造工程を示す説明図であって、袋状の表皮材の内側において、ステーの第１開口部に線状発光部を挿入する状態を示している。FIG. 2 is an explanatory diagram showing the manufacturing process of the headrest according to the present embodiment, showing a state in which the linear light emitting part is inserted into the first opening of the stay inside the bag-shaped skin material. 本実施形態に係るヘッドレストの製造工程を示す説明図であって、第１開口部に挿入した線状発光部をステーに挿通した状態を示している。It is an explanatory view showing a manufacturing process of a headrest concerning this embodiment, and shows a state where a linear light emitting part inserted into a first opening is inserted into a stay. 本実施形態に係るヘッドレストの製造工程を示す説明図であって、ステー(延出支持部)の第２開口部から引き出した線状発光部に保持部材を取り付ける状態を示している。FIG. 2 is an explanatory diagram showing the manufacturing process of the headrest according to the present embodiment, showing a state in which the holding member is attached to the linear light emitting part pulled out from the second opening of the stay (extending support part). 本実施形態に係るヘッドレストの製造工程を示す説明図であって、ステーの第１開口部を被覆部材で塞いだ状態を示している。FIG. 3 is an explanatory diagram showing the manufacturing process of the headrest according to the present embodiment, showing a state in which the first opening of the stay is closed with a covering member. 本実施形態に係るヘッドレストの製造工程を示す説明図であって、成形型を型閉めして表皮材の内側で弾性体を発泡成形している状態を示す断面図である。FIG. 3 is an explanatory view showing the manufacturing process of the headrest according to the present embodiment, and is a cross-sectional view showing a state in which the mold is closed and an elastic body is foam-molded inside the skin material. 本実施形態に係るヘッドレストの製造工程を示す説明図であって、成形型を型開きした状態で示す断面図である。FIG. 2 is an explanatory view showing the manufacturing process of the headrest according to the present embodiment, and is a cross-sectional view showing the mold in an opened state.

次に、本発明に係るそのヘッドレストの製造方法につき、好適な実施例を挙げて、添付図面を参照しながら以下説明する。 Next, a method for manufacturing the headrest according to the present invention will be described below with reference to preferred embodiments and the accompanying drawings.

ヘッドレスト１０は、図１、図２に示すように、表面を形成する袋状の表皮材１４の内側に発泡体からなる弾性体１８が充填されたヘッドレスト本体１２と、ヘッドレスト本体１２の表面に露出するよう設けられた線状発光部２０と、ヘッドレスト本体１２から下方に延出するステー２６とを備えるよう構成されている。表皮材１４は、車両のシートバック５０に使用されるシート表皮に合わせた材質のものが好適に採用され、合成樹脂製、織布、編布または本革等により形成された適宜形状の表皮形成材１６を縫合することにより袋状に形成されている。そして、袋状に形成された表皮材１４の内部に、ウレタンフォーム等の従来公知の発泡体が人員の頭部を支持する弾性体１８として充填されている。なお、本実施形態のヘッドレスト本体１２は、人員の頭部を支える前面部１２ａと、当該前面部１２ａの上部に連なる上面部１２ｂとから側面視において逆Ｌ字状に形成してあるが、これに限られるものではなく、適宜の形態に形成することができる。 As shown in FIGS. 1 and 2, the headrest 10 includes a headrest body 12 in which an elastic body 18 made of foam is filled inside a bag-shaped skin material 14 forming the surface, and a headrest body 12 that is exposed on the surface of the headrest body 12. The headrest body 12 is configured to include a linear light emitting portion 20 provided to do so, and a stay 26 extending downward from the headrest main body 12. The skin material 14 is preferably made of a material that matches the seat skin used in the seat back 50 of the vehicle, and is formed of an appropriately shaped skin made of synthetic resin, woven fabric, knitted fabric, genuine leather, etc. The material 16 is sewn together to form a bag shape. The inside of the bag-shaped skin material 14 is filled with a conventionally known foam such as urethane foam as an elastic body 18 that supports the head of the person. The headrest main body 12 of this embodiment is formed into an inverted L-shape when viewed from the side, including a front part 12a that supports the head of a person, and an upper part 12b that continues to the upper part of the front part 12a. It is not limited to this, and can be formed into any suitable shape.

線状発光部２０は、図５に拡大して示すように、径方向に可撓変形可能な光透過性の光伝送体２２と、当該光伝送体２２の外表面を覆う被覆材２４とから構成され、表皮形成材１６の縫合部に縫合されている。具体的に、本実施形態の線状発光部２０は、ヘッドレスト本体１２において前面下部の左右方向に延在する稜線、前面左右の上下方向に延在する稜線、上面左右の前後方向に延在する稜線および背面左右の上下方向に延在する稜線を形成している縫合部に沿って連続した線状をなすよう設けられている(図１、図２参照)。すなわち、線状発光部２０は、ヘッドレスト１０を加飾する所謂玉縁を形成するよう設けられており、光伝送体２２が当該玉縁の芯材を構成している。 As shown in an enlarged view in FIG. 5, the linear light emitting section 20 includes a light transmitting body 22 that is flexibly deformable in the radial direction and a covering material 24 that covers the outer surface of the light transmitting body 22. and is sewn to the seam portion of the skin forming material 16. Specifically, the linear light emitting portion 20 of this embodiment includes a ridge line extending in the left-right direction at the lower front surface of the headrest main body 12, a ridge line extending in the up-down direction on the left and right front surfaces, and a ridge line extending in the front-rear direction on the left and right top surfaces. It is provided so as to form a continuous line along the ridgeline and the sutured portion forming the ridgeline extending in the vertical direction on the left and right sides of the back surface (see FIGS. 1 and 2). That is, the linear light emitting portion 20 is provided to form a so-called bead that decorates the headrest 10, and the light transmitting body 22 constitutes the core material of the bead.

ここで、光伝送体２２は、長手方向端部から光を入射させることで、外周部から光が出射されるものであり、側面出射型光伝送体等と称されるものである。このような光伝送体２２としては、例えば、ポリウレタン系の透明な合成樹脂材に光散乱剤を含有させたものや、光の屈折率の大きいコア層の外側にコアよりも光の屈折率の小さいクラッド層を配したもの等、従来公知のものを採用することができる。 Here, the light transmission body 22 is one in which light is input from the longitudinal end portion and light is emitted from the outer peripheral portion, and is referred to as a side emission type light transmission body or the like. Such a light transmitting body 22 may be, for example, a polyurethane-based transparent synthetic resin material containing a light scattering agent, or a core layer having a higher light refractive index and a core layer having a higher light refractive index than the core. Conventionally known materials, such as those with a small cladding layer, can be used.

また、被覆材２４は、織布、編布、合成樹脂フィルムまたは本革等により構成され、光伝送体２２を透過する光が被覆材２４の外側に出射可能な素材または形態で形成されている。具体的に、織布や編布などの繊維素材で被覆材２４を構成する場合は、被覆材２４を構成する繊維の隙間から光伝送体２２を透過する光を外側に出射させるようにすることができる。また、織布や編布などの繊維素材の他、合成樹脂シートや本革などの光を透過しない素材で被覆材２４を構成し、被覆材２４に適宜形状で孔(図示せず)を形成するようにして、当該被覆材２４の孔を介して光伝送体２２を透過する光を外側に出射させるようにすることもできる。 Further, the covering material 24 is made of woven fabric, knitted cloth, synthetic resin film, genuine leather, etc., and is formed of a material or form that allows light transmitted through the light transmitting body 22 to be emitted to the outside of the covering material 24. . Specifically, when the covering material 24 is made of a fibrous material such as a woven fabric or a knitted cloth, the light that passes through the light transmitting body 22 should be emitted to the outside through gaps between the fibers that make up the covering material 24. I can do it. In addition, in addition to fiber materials such as woven fabrics and knitted fabrics, the covering material 24 is made of a material that does not transmit light, such as a synthetic resin sheet and genuine leather, and holes (not shown) are formed in the covering material 24 in an appropriate shape. In this way, the light transmitted through the light transmitting body 22 can be emitted to the outside through the holes in the covering material 24.

ステー２６は、図１に示すように、中空の金属パイプ材を適宜箇所で折り曲げた単一部材であって、ヘッドレスト本体１２に埋設されて支持する埋設部２８と、当該ヘッドレスト本体１２の下方へ延出する延出支持部３０とを備えている。具体的に、本実施形態のステー２６は、ヘッドレスト本体１２に前面部１２ａを支持するように埋設された前面埋設部２８Ａと、前面埋設部２８Ａに連なってヘッドレスト本体１２の上面部１２ｂを支持するよう埋設された上面埋設部２８Ｂと、当該上面埋設部２８Ｂに連なるよう左右に離間して設けられると共にヘッドレスト本体１２の下方へ延出する第１延出支持部３０Ａおよび第２延出支持部３０Ｂとを備えている。なお、ステー２６の形状は、ヘッドレスト本体１２の形状に応じて適宜の形態に形成することができる。 As shown in FIG. 1, the stay 26 is a single member made by bending a hollow metal pipe material at appropriate points, and includes an embedded portion 28 that is embedded in and supports the headrest body 12, and a portion below the headrest body 12. It is provided with an extending support part 30 that extends. Specifically, the stay 26 of this embodiment includes a front buried portion 28A embedded in the headrest body 12 so as to support the front portion 12a, and a front buried portion 28A that is connected to the front buried portion 28A to support the upper surface portion 12b of the headrest body 12. The upper surface buried portion 28B is buried as shown in FIG. It is equipped with Note that the shape of the stay 26 can be formed into an appropriate shape depending on the shape of the headrest main body 12.

ここで、第１延出支持部３０Ａおよび第２延出支持部３０Ｂに関する構成は、基本的に共通することから、共通する構成部分について単に延出支持部３０と指称して説明する。なお、図１において左側に位置する延出支持部３０を第１延出支持部３０Ａであり、右側に位置する延出支持部３０を第２延出支持部３０Ｂである。すなわち、ヘッドレスト１０のステー２６は、ヘッドレスト本体１２に埋設部２８が埋設された状態で、表皮材１４に形成された挿通孔１４ａ(図３，図５参照)を挿通した各延出支持部３０がヘッドレスト本体１２の下方へ延出するようになっており、各延出支持部３０において上面埋設部２８Ｂに連なる上端側がヘッドレスト本体１２に埋設されるようになっている。 Here, since the configurations regarding the first extending support part 30A and the second extending support part 30B are basically the same, the common component will be simply referred to as the extending support part 30 for explanation. In addition, the extending support part 30 located on the left side in FIG. 1 is a first extending support part 30A, and the extending support part 30 located on the right side is a second extending support part 30B. That is, the stays 26 of the headrest 10 are inserted into the respective extending support parts 30 through the insertion holes 14a (see FIGS. 3 and 5) formed in the skin material 14, with the embedded parts 28 buried in the headrest main body 12. extends below the headrest main body 12, and the upper end side of each extended support portion 30 connected to the upper surface embedded portion 28B is embedded in the headrest main body 12.

また、図３、図５、図７、図８、図１０に示すように、各延出支持部３０は、ヘッドレスト本体１２に埋設される埋設部分に第１開口部３２が形成されると共に、ヘッドレスト本体１２から下方に延出した下端部に第２開口部３４が形成されている。そして、ヘッドレスト本体１２の背面左側の稜線に沿って延在する線状発光部２０が、第１延出支持部３０Ａの第１開口部３２を介して当該第１延出支持部３０Ａの内部に導かれて、その端部が第１延出支持部３０Ａの第２開口部３４に向くと共に、背面右側の稜線に沿って延在する線状発光部２０が、第２延出支持部３０Ｂの第１開口部３２を介して当該第２延出支持部３０Ｂの内部に導かれて、その端部が第２延出支持部３０Ｂの第２開口部３４に向くよう構成されている。 Further, as shown in FIGS. 3, 5, 7, 8, and 10, each of the extending support parts 30 has a first opening 32 formed in a buried portion buried in the headrest main body 12, and A second opening 34 is formed at the lower end portion extending downward from the headrest main body 12. Then, the linear light emitting part 20 extending along the ridgeline on the left side of the back surface of the headrest main body 12 enters the inside of the first extending support part 30A through the first opening 32 of the first extending support part 30A. The linear light emitting section 20 is guided so that its end faces the second opening 34 of the first extending support section 30A and extends along the ridgeline on the right side of the back surface. It is configured to be guided into the second extending support section 30B through the first opening 32, with its end facing toward the second opening 34 of the second extending support section 30B.

また、図３、図５に示すように、各延出支持部３０には、当該各延出支持部３０を挿通した線状発光部２０の端部２０ａを保持する保持部材３６が第２開口部３４に取り付けられている。この保持部材３６は、各延出支持部３０の延在方向に貫通する貫通孔３８ａが形成された嵌合筒部３８と、当該嵌合筒部３８の端部から径方向外方へ延出する係止部４０とを備えている。すなわち、線状発光部２０の端部２０ａを嵌合筒部３８の貫通孔３８ａに嵌合すると共に、この嵌合筒部３８を各延出支持部３０の第２開口部３４に嵌合することで、線状発光部２０の端部２０ａが一定の姿勢で第２開口部３４に臨むように保持部材３６に保持される。そして、嵌合筒部３８を各延出支持部３０の第２開口部３４に嵌合した際に、第２開口部３４の開口端に係止部４０が係止することで、第２開口部３４の奥行き方向に対して線状発光部２０の端部２０ａを一定位置に位置させ得るようになっている。 Further, as shown in FIGS. 3 and 5, each extending support part 30 has a holding member 36 that holds the end 20a of the linear light emitting part 20 inserted through each extending support part 30 through the second opening. It is attached to the section 34. This holding member 36 includes a fitting cylinder part 38 in which a through hole 38a penetrating in the extending direction of each extending support part 30 is formed, and a fitting cylinder part 38 extending radially outward from an end of the fitting cylinder part 38. A locking portion 40 is provided. That is, the end portion 20a of the linear light emitting portion 20 is fitted into the through hole 38a of the fitting tube portion 38, and the fitting tube portion 38 is fitted into the second opening portion 34 of each extending support portion 30. As a result, the end portion 20a of the linear light emitting portion 20 is held by the holding member 36 so as to face the second opening 34 in a fixed posture. When the fitting cylinder portion 38 is fitted into the second opening 34 of each extending support portion 30, the locking portion 40 locks with the open end of the second opening 34, so that the second opening The end portion 20a of the linear light emitting portion 20 can be positioned at a constant position with respect to the depth direction of the portion 34.

ここで、各延出支持部３０に形成された第１開口部３２は、図１０に示すように、ヘッドレスト本体１２の表皮材１４の内側に設けられた被覆部材４２により塞ぐよう構成されている。この被覆部材４２は、表皮材１４の挿通孔１４ａに略整合する貫通孔４２ａが形成された円筒状に形成されており、当該被覆部材４２における貫通孔４２ａの一方の開口を当該挿通孔１４ａに整合するようにして表皮材１４の裏面(内面)に固定されている。すなわち、各延出支持部３０は、表皮材１４の挿通孔１４ａおよび被覆部材４２の貫通孔４２ａを挿通するようにしてヘッドレスト本体１２の下方へ延出するようになっており、表皮材１４の内側に充填された弾性体１８によりステー２６が所定位置に保持された状態において、各延出支持部３０の第１開口部３２の形成位置に対応付いた被覆部材４２が当該第１開口部３２を塞ぐようになっている。このように、各延出支持部３０に形成された第１開口部３２を被覆部材４２で塞ぐことで、当該第１開口部３２を介して表皮材１４の内側に充填された弾性体１８が各延出支持部３０に進入するのを防止している。 Here, the first opening 32 formed in each extending support portion 30 is configured to be closed by a covering member 42 provided inside the skin material 14 of the headrest main body 12, as shown in FIG. . This covering member 42 is formed in a cylindrical shape with a through hole 42a formed therein that substantially matches the through hole 14a of the skin material 14, and one opening of the through hole 42a in the covering member 42 is connected to the through hole 14a. It is fixed to the back surface (inner surface) of the skin material 14 so as to be aligned. That is, each extending support portion 30 extends downward from the headrest main body 12 so as to pass through the insertion hole 14 a of the skin material 14 and the through hole 42 a of the covering member 42 . In a state where the stay 26 is held in a predetermined position by the elastic body 18 filled inside, the covering member 42 corresponding to the formation position of the first opening 32 of each extending support portion 30 closes the first opening 32. It is designed to block the In this way, by closing the first openings 32 formed in each extending support portion 30 with the covering member 42, the elastic body 18 filled inside the skin material 14 is allowed to flow through the first openings 32. It is prevented from entering each extending support portion 30.

ここで、被覆部材４２を形成する発泡体は、弾性体１８を形成する発泡体より軟質の発泡体により構成されており、被覆部材４２が弾性体１８により押しつぶされるように弾性変形するようになっている。すなわち、第１開口部３２に挿通した線状発光部２０の外周囲に密着するように被覆部材４２が弾性変形することで、線状発光部２０を挿通したもとで第１開口部３２が被覆部材４２で塞がれるようになっている。ここで、被覆部材４２を形成する発泡体の材質は特に限定されるものではないが、この実施形態ではスラブウレタンフォームにより被覆部材４２が形成されている。 Here, the foam that forms the covering member 42 is made of a foam that is softer than the foam that forms the elastic body 18, so that the covering member 42 is elastically deformed so as to be crushed by the elastic body 18. ing. In other words, the covering member 42 is elastically deformed so as to be in close contact with the outer periphery of the linear light emitting section 20 inserted into the first opening 32, so that the first opening 32 can be closed while the linear light emitting section 20 is inserted. It is closed with a covering member 42. Here, the material of the foam forming the covering member 42 is not particularly limited, but in this embodiment, the covering member 42 is formed of slab urethane foam.

ステー支持部５２は、図４に示すように、ステー２６(延出支持部３０)を挿脱可能な挿通孔５２ａを有する筒状に形成されている。そして、シートバック５０の骨格を形成するシートフレーム５０ａの上部に、挿通孔５２ａがシートバック５０の上方に開口するようステー支持部５２が取り付けられている。このステー支持部５２には、挿通孔５２ａの下方開口を塞ぐように蓋体５４が設けられると共に、当該ステー支持部５２の内底部に位置するようＬＥＤ(発光手段)５６が蓋体５４に設けられており、当該ＬＥＤ５６の光がステー支持部５２の内側に照射されるようになっている。この実施形態では、ヘッドレスト本体１２の幅方向に離間して位置するよう設けられたステー２６の各延出支持部３０の夫々に対応するステー支持部５２の内底部にＬＥＤ５６が設けられると共に、各延出支持部３０に線状発光部２０の端部２０ａ側が挿通されており、当該線状発光部２０の両端部からＬＥＤ５６の光が入射し得るように構成されている。すなわち、ステー支持部５２にステー２６(各延出支持部３０)を挿入した状態で、ＬＥＤ５６の光が第２開口部３４から線状発光部２０の端部２０ａに入射することにより、当該線状発光部２０が発光するよう構成されており、当該線状発光部２０の発光によりヘッドレスト１０を加飾するようになっている。 As shown in FIG. 4, the stay support portion 52 is formed into a cylindrical shape having an insertion hole 52a into which the stay 26 (extended support portion 30) can be inserted and removed. A stay support portion 52 is attached to the upper part of a seat frame 50a forming the frame of the seat back 50 so that an insertion hole 52a opens above the seat back 50. This stay support part 52 is provided with a lid body 54 so as to close the lower opening of the insertion hole 52a, and an LED (light emitting means) 56 is provided on the lid body 54 so as to be located at the inner bottom of the stay support part 52. The light from the LED 56 is irradiated onto the inside of the stay support portion 52. In this embodiment, LEDs 56 are provided at the inner bottom of the stay support portions 52 corresponding to the respective extension support portions 30 of the stay 26 provided to be spaced apart in the width direction of the headrest main body 12, and each of the LEDs 56 is The end portion 20a side of the linear light emitting portion 20 is inserted through the extending support portion 30, and the light from the LED 56 is configured to be incident from both ends of the linear light emitting portion 20. That is, when the stay 26 (each extension support part 30) is inserted into the stay support part 52, the light of the LED 56 enters the end part 20a of the linear light emitting part 20 from the second opening part 34, so that the line is The linear light emitting section 20 is configured to emit light, and the headrest 10 is decorated with the light emitted from the linear light emitting section 20.

ここで、ステー支持部５２の内面には、ＬＥＤ５６の光を反射する光反射面５８が設けられている。この光反射面５８は、ステー支持部５２の内面に金属メッキ処理したり、従来公知の光反射シートを貼付することで形成することができる。また、ステー支持部５２を金属で形成する場合は、ステー支持部５２の内面を光反射面５８とすることも可能である。このように、ステー支持部５２の内面に光反射面５８を設けることで、ＬＥＤ５６の光を光反射面で反射させてステー２６(延出支持部３０)に保持した線状発光部２０の端部２０ａに効果的に導くことができる。 Here, a light reflecting surface 58 that reflects the light from the LED 56 is provided on the inner surface of the stay support portion 52. This light reflecting surface 58 can be formed by metal plating the inner surface of the stay support portion 52 or by pasting a conventionally known light reflecting sheet. Moreover, when the stay support part 52 is formed of metal, it is also possible to make the inner surface of the stay support part 52 the light reflecting surface 58. In this way, by providing the light reflecting surface 58 on the inner surface of the stay support part 52, the light from the LED 56 is reflected by the light reflection surface, and the end of the linear light emitting part 20 held on the stay 26 (extending support part 30) is can be effectively guided to the portion 20a.

また、ステー支持部５２には、図４に示すように、当該ステー支持部５２にステー２６(延出支持部３０)が挿入されている挿入状態を検出可能な検出センサ６０が設けられている。この検出センサ６０としては、近接センサのような非接触式のセンサや、マイクロスイッチのような接触式のセンサなど従来公知の各種センサを採用することができる。そして、検出センサ６０およびＬＥＤ５６の夫々が制御装置７０(図２参照)に配線接続されており、ステー支持部５２の挿通孔５２ａに挿入されたステー２６(延出支持部３０)を検出する挿入状態の場合に、制御装置７０がＬＥＤ５６を発光可能に構成される。ここで、制御装置７０は、検出センサ６０が挿入状態を検出する間、ＬＥＤ５６を発光させるようにしてもよく、照度センサを別途設けて、照度センサが検出する明るさに応じてＬＥＤ５６を発光させるようにしてもよい。なお、照度センサを設ける場合に、照度センサの設置位置は、ヘッドレスト１０の配置位置周囲(例えば車内)の明るさを検出可能な位置であればよく、例えばヘッドレスト１０やシートバック５０などの背面、或いは車内ルーフなど適宜位置に設けることができる。なお、ＬＥＤ５６や制御装置７０、検出センサ６０等の電気部品に対する電源は、車両が備える電源装置(バッテリー)から供給するよう構成してもよく、当該電気部品に対する電源供給用の電源装置を別途備えるよう構成してもよい。 Further, as shown in FIG. 4, the stay support section 52 is provided with a detection sensor 60 that can detect the insertion state in which the stay 26 (extended support section 30) is inserted into the stay support section 52. . As the detection sensor 60, various conventionally known sensors such as a non-contact type sensor such as a proximity sensor or a contact type sensor such as a microswitch can be employed. The detection sensor 60 and the LED 56 are each wire-connected to a control device 70 (see FIG. 2), and are used to detect the stay 26 (extended support portion 30) inserted into the insertion hole 52a of the stay support portion 52. In the case of the state, the control device 70 is configured to be able to cause the LED 56 to emit light. Here, the control device 70 may cause the LED 56 to emit light while the detection sensor 60 detects the insertion state, or may separately provide an illuminance sensor and cause the LED 56 to emit light in accordance with the brightness detected by the illuminance sensor. You can do it like this. In the case where the illuminance sensor is provided, the illuminance sensor may be installed in any position that can detect the brightness around the position of the headrest 10 (for example, inside the car), such as the back of the headrest 10 or the seat back 50, etc. Alternatively, it can be provided at an appropriate location such as the roof of the vehicle. Note that power for electrical components such as the LED 56, the control device 70, and the detection sensor 60 may be supplied from a power supply device (battery) included in the vehicle, and a power supply device for supplying power to the electrical components may be separately provided. It may be configured as follows.

次に、前述したヘッドレスト１０の製造方法について説明する。織布、編布、合成樹脂フィルムまたは本革等により形成した被覆材２４を二つ折りにし、二つ折りした折り目の内側に光伝送体２２を配置して、光伝送体２２の外表面を被覆材２４で覆うようにして線状発光部２０を形成する。そして、表面を向き合わせるようにした表皮形成材１６の縁部(縫合部位)の間に線状発光部２０を位置付け、この状態で当該表皮形成材１６の縁部および被覆材２４を合わせて縫合することで、表裏が裏返った状態となるように袋状の表皮材１４を形成する(図５参照)。このとき、線状発光部２０は、その長手方向の中間位置を表皮形成材１６に縫合するようになっており、当該線状発光部２０の両端側に表皮形成材１６に縫合されない余剰部２０ｂが形成されるようになっている。 Next, a method for manufacturing the above-mentioned headrest 10 will be explained. The covering material 24 made of woven fabric, knitted cloth, synthetic resin film, genuine leather, etc. is folded in half, and the light transmitting body 22 is placed inside the fold of the double fold, so that the outer surface of the light transmitting body 22 is covered with the covering material. The linear light emitting section 20 is formed so as to be covered by the light emitting section 24. Then, the linear light emitting part 20 is positioned between the edges (sewn parts) of the skin forming material 16 whose surfaces are facing each other, and in this state, the edges of the skin forming material 16 and the covering material 24 are brought together and sutured. By doing so, the bag-shaped skin material 14 is formed so that the front and back sides are turned inside out (see FIG. 5). At this time, the linear light emitting section 20 is sewn to the skin forming material 16 at an intermediate position in its longitudinal direction, and surplus portions 20b that are not sewn to the skin forming material 16 are provided at both ends of the linear light emitting section 20. is starting to form.

ここで、ヘッドレスト本体１２において前面下部の左右方向に延在する稜線、前面左右の上下方向に延在する稜線、上面左右の前後方向に延在する稜線および背面左右の上下方向に延在する稜線を形成する各表皮形成材１６の端縁部に、線状発光部２０を縫合し、背面左右の下端部側から線状発光部２０の余剰部２０ｂが延出するようになっている。また、表皮形成材１６は、裏返った状態の表皮材１４を表面が外側に向くように引っ繰り返すための引っ繰り返し用の開口１４ｂを形成するように縫合される。 Here, in the headrest body 12, a ridgeline extending in the left-right direction at the lower front surface, a ridgeline extending in the vertical direction on the left and right front surfaces, a ridgeline extending in the front-rear direction on the left and right top surfaces, and a ridgeline extending in the vertical direction on the left and right back surfaces. The linear light-emitting portions 20 are sewn to the edge portions of each skin forming material 16 forming the skin, so that surplus portions 20b of the linear light-emitting portions 20 extend from the lower end portions on the left and right sides of the back surface. Further, the skin forming material 16 is sewn to form a flipping opening 14b for repeatedly flipping the skin material 14 in an inverted state so that the front surface faces outward.

そして、図５に示すように、表皮材１４に形成したステー２６(延出支持部３０)の挿通孔１４ａの形成位置に、発泡体を円筒状に形成した被覆部材４２の貫通孔４２ａの一方の開口を整合するようにして、当該被覆部材４２を接着剤等により表皮材１４の裏面(内面)に固定する。これにより、表皮材１４におけるステー２６の挿通孔１４ａに連通するよう被覆部材４２が表皮形成材１６の裏面に取り付けられる。ここで、被覆部材４２を形成する発泡体は、弾性体１８を形成する発泡体より軟質の発泡体で形成してある。そして、裏返し状態の表皮材１４の表面が外側に露出するように引っ繰り返し用の開口１４ｂを介して表皮材１４を引っ繰り返し、表面が外側に向いた袋状の表皮材１４の内側に、線状発光部２０の余剰部２０ｂが位置するようにする。この状態で、ステー２６(延出支持部３０)の端部を、一方の表皮材１４の挿通孔１４ａおよび被覆部材４２の貫通孔４２ａに差し込んで表皮材１４の内側に臨ませる。次いで、表皮材１４の内側に臨ませたステー２６(延出支持部３０)の端部を、他方の表皮材１４の挿通孔１４ａおよび被覆部材４２の貫通孔４２ａに差し込んで表皮材１４の外側に臨ませ、表皮材１４の外側に突出させた端部を引き出すようにステー２６を表皮材１４に対して移動することで、表皮材１４の内側にステー２６を順に送り込むようにする、これにより、表面が外側に向いた袋状の表皮材１４の内側にステー２６の埋設部２８を位置させると共に、被覆部材４２の貫通孔４２ａおよび表皮材１４の挿通孔１４ａを挿通した各延出支持部３０を、表皮材１４の外側に延出させる(図７参照)。 As shown in FIG. 5, one side of the through-hole 42a of the covering member 42 formed of a cylindrical foam is placed at the position where the through-hole 14a of the stay 26 (extending support portion 30) formed in the skin material 14 is formed. The covering member 42 is fixed to the back surface (inner surface) of the skin material 14 with an adhesive or the like so that the openings of the covering member 42 are aligned with each other. Thereby, the covering member 42 is attached to the back surface of the skin forming material 16 so as to communicate with the insertion hole 14a of the stay 26 in the skin material 14. Here, the foam forming the covering member 42 is made of a foam that is softer than the foam forming the elastic body 18. Then, the skin material 14 is turned over through the opening 14b for flipping so that the surface of the skin material 14 in an inside-out state is exposed to the outside, and a line is placed inside the bag-shaped skin material 14 with the surface facing outward. The redundant portion 20b of the shaped light emitting portion 20 is positioned. In this state, the end of the stay 26 (extending support portion 30) is inserted into the insertion hole 14a of one skin material 14 and the through hole 42a of the covering member 42 so as to face the inside of the skin material 14. Next, the end of the stay 26 (extending support part 30) facing the inside of the skin material 14 is inserted into the insertion hole 14a of the other skin material 14 and the through hole 42a of the covering member 42, and By moving the stays 26 relative to the skin material 14 so as to face the skin material 14 and pull out the ends protruding to the outside of the skin material 14, the stays 26 are sequentially fed into the inside of the skin material 14. , the embedded part 28 of the stay 26 is located inside the bag-shaped skin material 14 with the surface facing outward, and each extending support part is inserted through the through hole 42a of the covering member 42 and the insertion hole 14a of the skin material 14. 30 extends outside the skin material 14 (see FIG. 7).

そして、図７に示すように、表皮材１４の内側において各延出支持部３０の第１開口部３２が被覆部材４２で塞がれない位置に位置付くようにステー２６(各延出支持部３０)を位置させる。そして、表皮材１４の縫合部から延出する線状発光部２０の余剰部２０ｂの先端側の端部２０ａを、対応する第１開口部３２に差し込んで各延出支持部３０の内部に線状発光部２０を挿通して、当該各延出支持部３０の下端部に形成した第２開口部３４に線状発光部２０の端部２０ａが向くようにする(図８参照)。この状態で、第２開口部３４から引き出した線状発光部２０の端部２０ａを、保持部材３６における嵌合筒部３８の貫通孔３８ａに嵌合して固定すると共に、当該嵌合筒部３８を第２開口部３４に嵌合して、線状発光部２０の端部２０ａを第２開口部３４に臨むように保持する(図９参照)。 Then, as shown in FIG. 7, the stay 26 (each extending support part 30). Then, the tip side end 20a of the surplus part 20b of the linear light emitting part 20 extending from the seam part of the skin material 14 is inserted into the corresponding first opening 32, and a line is inserted into the inside of each extending support part 30. The linear light emitting section 20 is inserted so that the end 20a of the linear light emitting section 20 faces the second opening 34 formed at the lower end of each extending support section 30 (see FIG. 8). In this state, the end 20a of the linear light emitting part 20 pulled out from the second opening 34 is fitted into the through hole 38a of the fitting cylinder part 38 in the holding member 36 and fixed, and the fitting cylinder part 38 is fitted into the second opening 34, and the end 20a of the linear light emitting section 20 is held so as to face the second opening 34 (see FIG. 9).

更に、図１０に示すように、ステー２６(各延出支持部３０)を表皮材１４の外側に引き出して第１開口部３２を被覆部材４２で塞ぐようにした後に、この弾性体１８を形成する前の表皮材１４を所定の成形型１００に収容して、表皮材１４の内側に注入した発泡原料を発泡することにより弾性体１８を形成する。これにより、ステー２６(各延出支持部３０)の内部に線状発光部２０が挿通する状態で当該線状発光部３０が表面に露出したヘッドレスト本体１２が形成される。ここで、表皮材１４の内側への発泡原料の注入は、引っ繰り返し用の開口１４ｂを利用してもよい。なお、先述した線状発光部２０を保持部材３６で保持する工程は、弾性体１８の形成後に行うようにしてもよい。 Furthermore, as shown in FIG. 10, after the stay 26 (each extending support part 30) is pulled out to the outside of the skin material 14 and the first opening 32 is closed with the covering member 42, this elastic body 18 is formed. The skin material 14 before being molded is placed in a predetermined mold 100, and the foaming raw material injected into the inside of the skin material 14 is foamed to form the elastic body 18. Thereby, the headrest main body 12 is formed in which the linear light emitting part 20 is inserted into the stay 26 (each extending support part 30) and the linear light emitting part 30 is exposed on the surface. Here, the foaming raw material may be injected into the inside of the skin material 14 using the opening 14b for reversing. Note that the step of holding the linear light emitting section 20 with the holding member 36 described above may be performed after the elastic body 18 is formed.

ここで、ヘッドレスト本体１２の弾性体１８を成形する成形型８０は、弾性体１８を成形可能な構成であれば特に限定されるものではないが、その一例を説明する。本実施形態の成形型８０は、下型をなす第１型８２と、第１型８２の一方の縁部にヒンジ連結されて上型をなす第２型８４と、第１型８２の他方の縁部にヒンジ連結されて上型をなす第３型８６とを備え。当該第１～第３型８２,８４,８６を型締めすることで、ヘッドレスト本体１２の外径に合致するキャビティが形成されるようになっている。また第２型８４および第３型８６には、ステー２６の各延出支持部３０を支持する溝状のステー支持溝８４ｂ,８６ｂが設けられている。この成形型８０では、先ず、第１～第３型８２,８４,８６を型開き状態として、ステー２６の一部(埋設部２８)を中に挿入した袋状の表皮材１４から延出したステー２６(各延出支持部３０)を第３型８６のステー支持溝８６ｂに支持させる。そして、第１型８２および第３型８６を型閉め後、第２型を型締めし、ステー２６(各延出支持部３０)を第２型８４のステー支持溝８６ｂに支持させて、袋状の表皮材１４の内側に発泡原料を注入して、発泡原料の発泡により弾性体１８(ヘッドレスト本体１２)を成形する(図１１参照)。そして、所要の時間の経過後に、第１～第３型８２,８４,８６を型開き状態として、ステー２６を第３型８６のステー支持溝８６ｂから離脱させることで、ヘッドレスト１０が取り出される(図１２参照)。 Here, the mold 80 for molding the elastic body 18 of the headrest main body 12 is not particularly limited as long as it has a configuration that can mold the elastic body 18, but an example thereof will be described. The mold 80 of this embodiment includes a first mold 82 forming a lower mold, a second mold 84 hinged to one edge of the first mold 82 and forming an upper mold, and a second mold 84 forming an upper mold. A third mold 86 is hinged to the edge and forms an upper mold. By clamping the first to third molds 82, 84, 86, a cavity matching the outer diameter of the headrest body 12 is formed. Further, the second mold 84 and the third mold 86 are provided with groove-shaped stay support grooves 84b and 86b that support each extending support portion 30 of the stay 26. In this mold 80, firstly, the first to third molds 82, 84, 86 are opened, and a part of the stay 26 (embedded portion 28) is extended from the bag-shaped skin material 14 inserted therein. The stay 26 (each extending support portion 30) is supported by the stay support groove 86b of the third mold 86. Then, after closing the first mold 82 and the third mold 86, the second mold is clamped, the stay 26 (each extended support part 30) is supported in the stay support groove 86b of the second mold 84, and the bag is closed. A foaming raw material is injected into the inside of the shaped skin material 14, and the elastic body 18 (headrest body 12) is formed by foaming the foaming raw material (see FIG. 11). After the required time has elapsed, the first to third molds 82, 84, and 86 are opened, and the stay 26 is removed from the stay support groove 86b of the third mold 86, thereby removing the headrest 10. (See Figure 12).

本実施形態のヘッドレスト１０は、ヘッドレスト本体１２に埋設されるステー２６(各延出支持部３０)の埋設部分に第１開口部３２が形成されており、当該第１開口部３２を介してステー２６(各延出支持部３０)の内部を挿通させた線状発光部２０の端部２０ａが、ヘッドレスト本体１２から下方に延出したステー２６(各延出支持部３０)の下端部で開口する第２開口部３４に向くように構成されている。この一方で、シートバック５０に設けたステー支持部５２には、当該ステー支持部５２の内側に光を照射するＬＥＤ５６が内底部に設けられている。このように、ステー２６(各延出支持部３０)の第１開口部３２を介してステー２６の内部を挿通した線状発光部２０の端部を、ステー２６(各延出支持部３０)の第２開口部３４に向けることで、ステー支持部５２にステー２６を挿入した状態において、ＬＥＤ５６の光が第２開口部３４から線状発光部２０の端部に入射させることができる。すなわち、シートバック５０に対して着脱可能に構成されたヘッドレスト１０の線状発光部２０に対して、当該シートバック５０側に設けたＬＥＤ５６の光を照射することが可能になるから、ヘッドレスト１０をシートバック５０に対して着脱可能にしながらも、ヘッドレスト１０に設けた線状発光部２０の発光により効果的に装飾することができる。 In the headrest 10 of the present embodiment, a first opening 32 is formed in the buried portion of the stay 26 (each extension support part 30) buried in the headrest main body 12, and the stay 26 is inserted through the first opening 32. The end portion 20a of the linear light emitting portion 20 inserted through the inside of the stay 26 (each extended support portion 30) is opened at the lower end portion of the stay 26 (each extended support portion 30) extending downward from the headrest main body 12. It is configured to face the second opening 34 where the opening 34 is opened. On the other hand, the stay support portion 52 provided on the seat back 50 is provided with an LED 56 on the inner bottom portion thereof that irradiates light onto the inside of the stay support portion 52 . In this way, the end of the linear light emitting part 20 inserted into the stay 26 through the first opening 32 of the stay 26 (each extension support part 30) is connected to the stay 26 (each extension support part 30). By directing the light from the LED 56 toward the second opening 34 , the light from the LED 56 can be made to enter the end of the linear light emitting portion 20 from the second opening 34 in a state where the stay 26 is inserted into the stay support portion 52 . That is, it becomes possible to irradiate the linear light emitting portion 20 of the headrest 10, which is configured to be detachably attached to the seatback 50, with light from the LED 56 provided on the seatback 50 side. While being removable from the seat back 50, it can be effectively decorated by emitting light from the linear light emitting section 20 provided on the headrest 10.

しかも、ヘッドレスト本体１２の幅方向に離間して位置するように第１延出支持部３０Ａおよび第２延出支持部３０Ｂが設けられたステー２６の幅方向の夫々に第１開口部３２および第２開口部３４を形成して、各延出支持部３０に対応するステー支持部５２の内底部にＬＥＤ５６を設けるよう構成し、線状発光部２０の両端部からＬＥＤ５６の光が入射するようになっている。すなわち、線状発光部２０の両端部からＬＥＤ５６の光が入射するよう構成することで、ＬＥＤ５６の光を線状発光部２０の全体に導くことができる。このため、線状発光部２０を長尺に形成しつつ線状発光部２０を全体的に発光させることができ、線状発光部２０の発光による装飾効果を高めることができる。 Moreover, the first opening 32 and the first opening 32 and the second opening 32 are formed in the stay 26 in which the first extending support part 30A and the second extending support part 30B are provided so as to be spaced apart in the width direction of the headrest main body 12, respectively. 2 openings 34 are formed, and an LED 56 is provided at the inner bottom of the stay support part 52 corresponding to each extension support part 30, so that the light from the LED 56 enters from both ends of the linear light emitting part 20. It has become. That is, by configuring the linear light emitting section 20 so that the light from the LED 56 enters from both ends thereof, the light from the LED 56 can be guided throughout the linear light emitting section 20 . Therefore, the linear light emitting section 20 can be made elongated and emit light as a whole, and the decorative effect of the light emitted from the linear light emitting section 20 can be enhanced.

更に、各延出支持部３０に挿通した線状発光部２０の余剰部２０ｂの端部２０ａは、各延出支持部３０の第２開口部３４に取り付けた保持部材３６(嵌合筒部３８)の貫通孔３８ａに挿通して保持してあるから、当該第２開口部３４に対して線状発光部２０の端部２０ａを一定位置にすることができる。従って、ヘッドレスト１０の線状発光部２０に対して、シートバック５０側に設けたＬＥＤ５６を一定の位置関係で対向位置させて、当該ＬＥＤ５６の光を一定の位置関係で照射することができる。これにより、ＬＥＤ５６の光を線状発光部２０の端部２０ａに正確に入射させて線状発光部２０を効果的に発光させることが可能になる。更に、第２開口部３４の開口端に保持部材３６の係止部４０が係止することで、第２開口部３４の奥行き方向に対して線状発光部２０の端部２０ａを一定位置に位置させることができるから、ＬＥＤ５６の光を線状発光部２０の端部２０ａにより正確に入射させて線状発光部２０を効果的に発光させることが可能になる。 Furthermore, the end portion 20a of the surplus portion 20b of the linear light emitting portion 20 inserted into each extending support portion 30 is attached to the holding member 36 (fitting cylinder portion 38) attached to the second opening portion 34 of each extending support portion 30. ), the end 20a of the linear light emitting section 20 can be kept at a fixed position with respect to the second opening 34. Therefore, the LED 56 provided on the seat back 50 side can be positioned opposite to the linear light emitting portion 20 of the headrest 10 in a fixed positional relationship, and the light from the LED 56 can be irradiated in a fixed positional relationship. Thereby, it becomes possible to make the light of the LED 56 accurately enter the end portion 20a of the linear light emitting section 20 and to cause the linear light emitting section 20 to emit light effectively. Furthermore, by locking the locking portion 40 of the holding member 36 at the open end of the second opening 34, the end 20a of the linear light emitting portion 20 is kept at a constant position with respect to the depth direction of the second opening 34. Since the LED 56 can be positioned more accurately, the light from the LED 56 can be made to more accurately enter the end 20a of the linear light emitting section 20, and the linear light emitting section 20 can effectively emit light.

また、線状発光部２０を挿通したステー２６(各延出支持部３０)の第１開口部３２を、ヘッドレスト本体１２の表皮材１４の内側に設けた被覆部材４２で塞ぐように構成してある。このため、ヘッドレスト本体１２を構成する弾性体１８が第１開口部３２に侵入するのを防止できる。これにより、第１開口部３２の開口縁部との接触により弾性体１８が削られるのを防ぐことができ、ステー２６の内側に入った弾性体１８の削り屑による異音等の発生を効果的に防ぐことができる。また、弾性体１８を所定の形状に保つことができるから、ヘッドレスト本体１２の性能を維持することができる。 Further, the first opening 32 of the stay 26 (each extending support portion 30) through which the linear light emitting portion 20 is inserted is configured to be closed with a covering member 42 provided inside the skin material 14 of the headrest main body 12. be. Therefore, the elastic body 18 that constitutes the headrest main body 12 can be prevented from entering the first opening 32. This can prevent the elastic body 18 from being scraped due to contact with the opening edge of the first opening 32, and can effectively reduce the occurrence of abnormal noises etc. due to scraps of the elastic body 18 that have entered the inside of the stay 26. can be prevented. Furthermore, since the elastic body 18 can be kept in a predetermined shape, the performance of the headrest main body 12 can be maintained.

また、ステー支持部５２にステー２６(延出支持部３０)が挿入されている挿入状態を検出可能な検出センサ６０を設けるようにし、ステー支持部５２の挿通孔５２ａに挿入されたステー２６(延出支持部３０)を検出する挿入状態の場合に、制御装置７０がＬＥＤ５６を発光可能に構成してある。従って、ヘッドレスト１０を取り外した状態でＬＥＤ５６が無駄に発光しないようにすることができる。 Further, a detection sensor 60 capable of detecting the insertion state in which the stay 26 (extending support portion 30) is inserted into the stay support portion 52 is provided, and the stay 26 (extension support portion 30) inserted into the insertion hole 52a of the stay support portion 52 is provided. In the case of an inserted state in which the extended support portion 30) is detected, the control device 70 is configured to enable the LED 56 to emit light. Therefore, it is possible to prevent the LED 56 from emitting unnecessary light when the headrest 10 is removed.

ここで、前記ヘッドレスト１０は、表皮材１４の内側において、ヘッドレスト本体１２に埋設される埋設部分に形成したステー２６(各延出支持部３０)の第１開口部３２を、被覆部材４２で塞がれない位置に位置付けた状態で、線状発光部２０における余剰部２０ｂの端部２０ａを第１開口部３２に差し込み、ステー２６(各延出支持部３０)を表皮材１４の外側に引き出して第１開口部３２を被覆部材４２で塞ぐようにした後に、当該表皮材１４の内側で発泡原料を発泡させて弾性体１８を形成することで形成される。このように、ステー２６の第１開口部３２を被覆部材４２で塞ぐようにした後に、表皮材１４の内側で発泡原料を発泡させて弾性体１８を形成することで、弾性体１８の形成時に発泡原料が第１開口部３２からステー２６の内部に漏出するのを防止できるから、適切な形状に弾性体１８を正確に成形することができる。また、発泡原料の発泡圧により、ステー２６の第１開口部３２を挿通している線状発光部２０に被覆部材４２が押し付けられることで、第１開口部３２に挿通した線状発光部２０の周りの隙間を被覆部材４２で効果的に塞ぐことができ、線状発光部２０の周りの隙間からの発泡原料の漏出も効果的に防ぐことができる。 Here, in the headrest 10, the first opening 32 of the stay 26 (each extended support part 30) formed in the buried part buried in the headrest main body 12 inside the skin material 14 is closed with the covering member 42. Insert the end portion 20a of the excess portion 20b of the linear light emitting portion 20 into the first opening 32 in a position where it will not come off, and pull out the stay 26 (each extended support portion 30) to the outside of the skin material 14. After closing the first opening 32 with the covering member 42, the elastic body 18 is formed by foaming the foaming raw material inside the skin material 14. In this way, after the first opening 32 of the stay 26 is closed with the covering member 42, the foaming raw material is foamed inside the skin material 14 to form the elastic body 18. Since the foaming material can be prevented from leaking into the stay 26 from the first opening 32, the elastic body 18 can be accurately molded into an appropriate shape. In addition, the covering member 42 is pressed against the linear light emitting part 20 inserted through the first opening 32 of the stay 26 due to the foaming pressure of the foaming raw material, so that the linear light emitting part 20 inserted into the first opening 32 The gap around the linear light emitting part 20 can be effectively closed with the covering member 42, and leakage of the foaming raw material from the gap around the linear light emitting part 20 can also be effectively prevented.

また被覆部材４２を形成する発泡体は、弾性体１８を形成する発泡体より軟質の発泡体で形成するようにしたことで、弾性体１８により被覆部材４２を第１開口部３２側に押し付けるように弾性変形させることができる。これにより、被覆部材４２を第１開口部３２の開口縁部や線状発光部２０に対し、より密着させるようにして隙間を塞ぐことができるから、発泡原料の漏出をより効果的に防止できる。 Further, the foam forming the covering member 42 is made of a softer foam than the foam forming the elastic body 18, so that the covering member 42 is pressed against the first opening 32 by the elastic body 18. It can be elastically deformed. As a result, the covering member 42 can be brought into closer contact with the opening edge of the first opening 32 and the linear light emitting part 20 and the gap can be closed, so leakage of the foaming raw material can be more effectively prevented. .

(変更例)
本発明に係るヘッドレストの製造方法は、前述した構成に限定されるものではなく、例えば以下のように変更することができる。
(１) 実施形態のヘッドレスト１０は、ステー２６においてヘッドレスト本体１２の幅方向に離間して位置する第１延出支持部３０Ａおよび第２延出支持部３０Ｂの夫々に線状発光部２０を挿通するよう構成したが、何れか一方の延出支持部３０Ａ,３０Ｂにのみ第１開口部３２および第２開口部３４を形成して線状発光部２０を挿通するよう構成してもよい。
(２) 実施形態のヘッドレスト１０は、ヘッドレスト本体１２の表面に露出する１本の線状発光部２０を設けて、当該線状発光部２０の各端部２０ａを対応する第１延出支持部３０Ａおよび第２延出支持部３０Ｂに挿通するよう構成したが、複数(例えば２本)の線状発光部２０を設けるようにして、延出支持部３０Ａ,３０Ｂ毎に異なる線状発光部２０の端部２０ａを挿通するようにしてもよい。
(３) また、１つの延出支持部３０Ａ,３０Ｂに複数の線状発光部２０の端部２０ａを挿通して、１つステー支持部５２の内底部に設けたＬＥＤ５６の光が複数の線状発光部２０の端部２０ａに入射するよう構成してもよい。
(４) 実施形態では、延出支持部３０に挿通した線状発光部２０の端部２０ａを保持部材３６で保持するよう構成したが、当該保持部材３６を省略することも可能である。例えば線状発光部２０の端部２０ａを延出支持部３０の内周面に接着等することで保持部材３６を省略できる。
(５) 実施形態では、被覆部材４２を円筒状に形成したが、延出支持部３０の外形形状に応じて角筒状など任意の形態に形成することができる。
(６) 実施形態では、被覆部材４２を形成する発泡体を、ヘッドレスト本体１２の弾性体１８を形成する発泡体より軟質の発泡体で形成するようにしたが、被覆部材４２と弾性体１８とを同じ発泡体で形成するようにしてもよく、ヘッドレスト本体１２の弾性体１８を、被覆部材４２を形成する発泡体を形成する発泡体より軟質の発泡体で形成するようにしてもよい。この場合でも、第１開口部３２を被覆部材４２で塞ぐことで、第１開口部３２を介して延出支持部３０内へ発泡原料が漏出するのを防止できる。 (Example of change)
The method for manufacturing a headrest according to the present invention is not limited to the configuration described above, and can be modified as follows, for example.
(1) In the headrest 10 of the embodiment, the linear light emitting part 20 is inserted into each of the first extending support part 30A and the second extending support part 30B, which are located apart in the width direction of the headrest main body 12 in the stay 26. However, the first opening 32 and the second opening 34 may be formed in only one of the extending support parts 30A, 30B, and the linear light emitting part 20 may be inserted therethrough.
(2) The headrest 10 of the embodiment includes one linear light emitting section 20 exposed on the surface of the headrest main body 12, and each end 20a of the linear light emitting section 20 is connected to a corresponding first extending support section. 30A and the second extending support part 30B, but by providing a plurality of (for example, two) linear light emitting parts 20, different linear light emitting parts 20 are provided for each of the extending support parts 30A and 30B. It is also possible to insert the end portion 20a of the.
(3) In addition, by inserting the ends 20a of the plurality of linear light emitting parts 20 into one extending support part 30A, 30B, the light from the LED 56 provided at the inner bottom of one stay support part 52 can be transmitted to a plurality of lines. The light may be configured to be incident on the end portion 20a of the shaped light emitting portion 20.
(4) In the embodiment, the end portion 20a of the linear light emitting portion 20 inserted into the extending support portion 30 is held by the holding member 36, but the holding member 36 may be omitted. For example, the holding member 36 can be omitted by bonding the end portion 20a of the linear light emitting portion 20 to the inner peripheral surface of the extending support portion 30.
(5) In the embodiment, the covering member 42 is formed into a cylindrical shape, but it can be formed into any shape such as a rectangular tube shape depending on the external shape of the extending support portion 30.
(6) In the embodiment, the foam forming the covering member 42 is made of a foam that is softer than the foam forming the elastic body 18 of the headrest main body 12. The elastic body 18 of the headrest body 12 may be made of a foam that is softer than the foam that forms the covering member 42. Even in this case, by blocking the first opening 32 with the covering member 42, it is possible to prevent the foaming raw material from leaking into the extending support portion 30 through the first opening 32.

１２ヘッドレスト本体，１４表皮材，１８弾性体，２０線状発光部
２０ａ端部，２６ステー，３２第１開口部，３４第２開口部
３６保持部材，３８ａ貫通孔，４２被覆部材，５２ステー支持部
５６ＬＥＤ(発光手段)

12 headrest main body, 14 skin material, 18 elastic body, 20 linear light emitting part 20a end, 26 stay, 32 first opening, 34 second opening 36 holding member, 38a through hole, 42 covering member, 52 stay support Section 56 LED (light emitting means)

Claims

A method for manufacturing a headrest, wherein a linear light emitting part is provided to be exposed on the surface of a headrest main body in which an elastic body is provided inside a skin material, and a stay is formed so as to extend downward from the headrest main body. ,
A linear light-emitting part is positioned between the skin-forming materials at the suture site of the skin-forming material, and the skin-forming material By sewing together the linear light emitting part, a bag -shaped skin material is formed with the front and back sides turned inside out.
Flip the bag -shaped skin material so that the surface of the skin forming material is exposed to the outside through a flipping opening formed in the skin material;
inserting the stay so as to pass through the insertion hole of the skin material, and accommodating an embedded portion of the stay to be buried in the headrest body inside the skin material;
Inside the skin material, insert the surplus part of the linear light emitting part into the first opening of the stay formed in the embedded part embedded in the headrest main body, and insert the linear light emitting part into the inside of the stay. so that the end of the linear light emitting part faces the second opening formed at the lower end of the stay,
By foaming the foaming raw material inside the skin material housed in the mold to form the elastic body, the linear light emitting part is exposed on the surface in a state where the linear light emitting part is inserted into the inside of the stay. forming the headrest main body,
A method for manufacturing a headrest, characterized in that the linear light emitting section is made to emit light by light incident from an end of the linear light emitting section facing the second opening formed in the stay.

2. The method of manufacturing a headrest according to claim 1 , wherein an end of the linear light emitting part inserted into the stay is held by a holding member attached to a second opening of the stay.

With the skin material turned over, a covering member formed into a cylindrical shape from a foam is fixed to the back surface of the skin forming material so as to communicate with the insertion hole of the stay in the skin material,
Inserting the stay through the through hole of the covering member and the insertion hole of the skin material while the bag-shaped skin material is turned over so that the surface of the skin forming material is exposed to the outside;
The linear light emitting part is inserted inside the stay by inserting the end of the excess portion of the linear light emitting part into the first opening located at a position not covered by the covering member on the inside of the skin material. Insert,
The elastic body is formed by foaming a foaming raw material inside the skin material while the stay is pulled out to the outside of the skin material so that the first opening is covered with the covering member. Item 2. A method for manufacturing a headrest according to item 1 or 2.

4. The method of manufacturing a headrest according to claim 3, wherein the foam forming the covering member is made of a softer foam than the foam forming the elastic body.