JPH0438580B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing a headrest.

[Prior Art and Problems Therewith] In general, a headrest is formed by covering the outer surface of a cushioning core in which a portion of a stay for attaching a seat bag is embedded and supported, with a skin material.

However, when this is molded in a single step of heat-pressing with an upper mold and a lower mold, the covering of the skin material becomes partially strained, and the skin material is difficult to adapt to the cushioning core, making it difficult to adhere tightly. Moreover, there was a drawback that the joints of the skin became protrusive, making it difficult to achieve a beautiful finish.

[Object of the Invention] The object of the present invention is to solve the above-mentioned drawbacks of the conventional art, and to provide a joint portion of the skin material that fits tightly into the cushioning core and covers the core. To provide a method for manufacturing a headrest which does not have a protruding shape, gives a smooth and beautiful finish, and is easy to carry out.

[Structure of the Invention] In order to achieve the above-mentioned object, the present invention involves forming a molded skin when manufacturing a headrest in which a cushioned core supporting a stay that can be attached to a seat bag is covered with a skin material. An upper mold and a lower mold for vacuum forming, and a heat-pressing means that is separate from the upper mold and lower mold and that presses and thermally welds the peripheral part of the molded skin are prepared, and the core body is tightly pressed from both sides. After heating and softening two skin materials made of synthetic resin that can be thermally welded so that the skin can be covered, they are each vacuum-formed using the upper and lower molds to form two sheets having an outer periphery that serves as an overlap margin. After forming a molded skin, the core body is wrapped with these two molded skins, and then the outer periphery of each molded skin is polymerized, and the polymerized area of the molded skin is adjusted to the outer shape of the core body using the heat compression bonding means. It is characterized in that it is crimped and heat welded along the same direction, and that unnecessary parts of the overlapping area of the skin material are removed after welding.

[Example] Next, an example of the present invention will be described with reference to the drawings.

In the figure, reference numeral 1 denotes a core having cushioning properties such as urethane foam, which is molded into a predetermined shape. Reference numeral 2 denotes a U-shaped stay attached to the core body 1, and the seat back attachment portion 2
A and 2A are enclosed and supported in the core body 1 with the parts A and 2A protruding outward. Note that the means for attaching the stay 2 to the core body 1 can be obtained by enclosing and supporting the U-shaped side of the stay 2 within the core body 1 during foam molding of the core body 1, or by cutting and molding a cushion material foam body. When forming a core body, the U-shaped side of the stay 2 is enclosed in the core body which is split into two parts, and then the two halves of the core body (not shown) are joined with adhesive to attach the stay 2 to the core body 1. Appropriate attachment means are employed, such as attachment means.

On the other hand, two skin materials 3 and 4 for covering the core body 1 are prepared. The skin materials 3 and 4 are made of a heat-weldable synthetic resin material, preferably a thermoplastic synthetic resin alone, or a resin-processed product obtained by impregnating a cloth material with a thermoplastic synthetic resin. It is possible to combine materials that can be heat-welded to each other, such as two sheets of resin, a thermoplastic resin sheet and a cloth body whose surface has been treated with resin, and the thermoplastic resin sheets can be of the same color or different colors. Alternatively, a resin sheet with a decorative cloth adhered in advance to the non-bonded portion may also be used. In this example, a red vinyl chloride sheet with a thickness of 1 mm and a blue vinyl chloride sheet with a thickness of 1 mm were used.

The two prepared skin materials 3 and 4 are then processed into a shape that matches the outer shape of the core body 1 by vacuum forming. That is, 7 is the head contacting side (second
In the figure, it is a vacuum molding mold having a molding recess 8 that matches the shape of the upper outer surface (1A) of the core body 1,
A suitable number of suction holes 9 to 9 communicating with a hollow chamber 10 in the mold are penetrated through the surface of the molding recess 8, and the hollow chamber 10 is connected to suction means (not shown) such as a suction pump through a connecting conduit 11. There is. Reference numeral 17 denotes a vacuum forming mold having a molding recess 18 that matches the shape of the side 1B of the core 1 on which the head does not contact (the lower outer surface of the core 1 in FIG. 2). is an appropriate number of suction holes 19~ communicating with the hollow chamber 20 in the mold.
19 is passed through, and the hollow chamber 20 is connected by a connecting conduit 21 to suction means (not shown).
Incidentally, the molding recesses 8 and 18 of the vacuum molding molds 7 and 17 are formed with recesses 12 and 22, such as semicircular shapes, from which the stay 2 portion of the core body 1 protrudes.

The skin materials 3 and 4 that have been softened by heating are placed on the molding recesses 8 and 18 of the vacuum molds 7 and 17 heated in a heated atmosphere, and the suction means is activated to vacuum the skin materials 3 and 4. Molding (70~
After molding, the atmosphere and vacuum molding molds 7 and 17 are cooled and demolded to form a molded skin 30 for covering the head contacting side 1A of the core 1 and a head non-contacting side of the core 1. A molded skin 40 for covering side 1B is obtained. The molded skins 30 and 40 have outer peripheral portions 30B and 40B that serve as overlapping margins on the outer periphery. In addition, 30A, 4
0A is a stay attachment recess formed in the molded skins 30, 40.

Next, the outer peripheral portion 30B of the molded skin 30, 40,
Weld lower mold 47 for heat welding 40B
And a weld upper mold 57 is prepared. The weld lower mold 47 has a fitting recess 48 into which the head contacting side 1A of the core 1 can be fitted, and an annular electrode 49 is provided along the outer periphery of the fitting recess 48. Then, the weld upper mold 57 is attached to the core body 1.
The non-contact side 1B of the head has a fitting recess 58 into which it can be fitted, and an annular electrode 59 is provided along the outer periphery of the fitting recess 58. The fitting recesses 48 and 58 are made of a non-conductive material such as plaster, and the electrodes 49 and 59 are provided with stays 2.
Notches 50 and 60 are provided to avoid contact with the electrodes 49 and 59, and a high voltage can be applied to each electrode 49 and 59.

In this way, the molded skin 30 is fitted into the fitting recess 48 of the weld lower mold 47, and the head abutment of the core body 1 is fitted into the recessed portion of the molded skin 30 with the stay 2 protruding through the stay attachment recess 30A. Fit the contact side 1A part. Next, the concave portion of the molded skin 40 is fitted onto the upper part of the core body 1 so that the position of the stay 2 matches the stay attachment concave portion 40A.
The fitting recess 58 of the weld upper die 57 is fitted into the molded skin 40. The lower weld mold 47 and the upper weld mold 57 each have a fitting recess 4 into which the core 1 is fitted.
8 and 58 are formed, and the molded skins 30 and 40 are formed so as to match the outer shape of the core body 1 without interfering with the stay 2. is molded skin 30,4
0 is held in close contact with the outer periphery 30 of the molded skin 30, 40 by pressing the electrodes 49, 59.
B and 40B are overlapped and crimped. Thus, when the lower weld mold 47 and the upper weld mold 57 are pressed together, the electrodes 49 of both molds,
By applying a voltage to 59, the molded skin 30,
40 polymerization sites can be thermally welded using electrodes 49 and 59. Note that welding in this example was performed at an oscillation output of 10 KW and an oscillation time of 3 to 5 seconds.

After the overlapping portions of the molded skins 30 and 40 have been thermally welded, the lower weld mold 47 and the upper weld mold 57 are released, and the molded body 61 is removed from the mold.
The molded body 61 has molded skins 30, 40 on the outer surface of the core body 1.
The molded skins 30, 40 are bonded by heat welding 41 along the core body 1, and have overlapping portions of the outer peripheries 30B, 40B of the molded skins 30, 40. A predetermined headrest 62 can then be obtained by cutting and removing the unnecessary overlapping portion along the joint portion 41. Note that the outer surface between the molded skins 30, 40 and the stay 2 portion is treated by appropriate means.
The headrest 62 of this example had one half side blue and the other half side red, and had a beautiful finish.

In this example, welding of the outer peripheries of the molded skins 30 and 40 was performed using a weld upper die and a weld lower die, but welding of the outer peripheries is not limited to this, and other heat-pressing means may be used. .

[Operations and Effects of the Invention] In the present invention, first, a heat-weldable synthetic resin skin material is vacuum-formed into a shape that covers one side and the other side of the core, and then this molded skin material is The core is wrapped with a wafer and the outer periphery of each skin material is polymerized.Then, this polymerized part is crimped along the outer shape of the core using a heat-pressing means such as a welder electrode, and then joined by heat welding. Therefore, the joining portion follows the shape of the core.

Since unnecessary polymerization sites are removed along the bonding site, no protrusions are produced at the bonding site.

In addition, in the present invention, the upper and lower molds for vacuum forming the molded skin and the heat and pressure bonding means for thermally welding the outer periphery of the molded skin are separate, so that the molding of the skin material and the outer periphery of the molded skin can be easily performed. Compared to the case of heat-pressing in one step of upper and lower molds, there is no local stress in forming the skin material, and the joint area is smooth and beautiful, and the skin without wrinkles adheres closely to the core. You can obtain a headrest that is familiar and has high commercial value. Further, the present invention does not require the preparation of special equipment and is easy to implement.

[Brief explanation of drawings]

The drawings show the steps of an embodiment of the present invention, in which Fig. 1 is a plan view of the core body with the stay attached, Fig. 2 is a sectional view taken along the line - Fig. 4 is a sectional view taken along the line shown in FIG. A plan view of the mold, FIG. 7 is an enlarged sectional view along the line in FIG. 5, FIG. 8 is an enlarged sectional view along the line in FIG. A plan view of the upper mold, FIG. 11 is a process diagram of the pre-welding process, FIG. 12 is an enlarged view showing a part of the electrode, FIG. 13 is a weld state diagram, and FIG. 14 is a plan view of the molded body after welding. FIG. 15 is a perspective view of the molded headrest. 1...core body, 2...stay, 2A...attachment part, 3,
4...Skin material, 7,17...Vacuum forming mold, 8,18...
Molded recess, 30, 40... Molded skin, 30B, 40
B...Outer peripheral part, 41...Joint part, 47...Weld lower mold, 48, 58...Fitting recess, 49, 59...Electrode,
57... Weld upper mold, 61... Molded body, 62... Head rest.

Claims (1)

[Claims] 1. When manufacturing a headrest in which a cushioning core supporting a stay that can be attached to a seat bag is covered with a skin material, an upper mold and a lower mold are used to vacuum form the molded skin, and the upper mold and lower mold are Separate heating and pressing means for pressing and thermally welding the peripheral portion of the molded skin are prepared, and two sheets of synthetic resin that can be thermally welded are prepared so that the core can be tightly covered from both sides. After the skin material is heated and softened, it is vacuum-formed using the upper and lower molds to create two molded skins each having an outer periphery that serves as an overlapping margin. Then, the outer circumference of each molded skin is polymerized, and the polymerized parts of the molded skins are crimped along the outer shape of the core and heat welded using the thermocompression bonding means, and the molded skin after welding is A method for producing a headrest characterized by cutting off unnecessary parts of the polymerization site.