JPH08141232A - Method of manufacturing swing head rest and head rest formed integrally with surface material by foaming - Google Patents

Abstract

PURPOSE: To form a cushion pad integrally with a surface material by foaming by finishing smoothly the peripheral portions of holes on a surface material from which head rest pillars protrude to prevent the resin foam from leaking outside the surface material so that the head rest can swing smoothly without generating noise. CONSTITUTION: A stand-up portion 11a that allows the head rest body to swing in forward and backward directions of a seat is provided on the bottom of a head rest frame 11 from which head rest pillars 10a protrude, whereas a long hole 12a is sealed by forcibly sandwiching the peripheral portion of the holes on the surface material 12 with the front edge of the stand-up portion 11a and the inner face of a forming mold 20; a cushion pad 13 is formed by foaming integrally with the surface material 12; and the peripheral portions of the holes on the surface material 12 are put onto the front edge of the stand-up portion 11a to fix them thereon.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a headrest main body for assembling a headrest main body so that the headrest main body can swing and swing in the front-rear direction of a seat and a headrest mechanism incorporated in a cushion frame, and the headrest frame is housed inside a skin material. Therefore, the present invention relates to a method of manufacturing a foam material swing-molded head swing headrest in which the cushion pad is foam-molded integrally with the skin material.

[0002]

2. Description of the Related Art Generally, in a swing headrest in which a cushion pad is foam-molded integrally with a skin material, a headrest shown in FIG.
The horizontal axis of the headrest pillar 1a as shown by
A friction type swing mechanism in which a bearing is rotatably mounted on b is used. In order to manufacture a headrest equipped with the swinging mechanism, the core metal 1b is housed inside a three-dimensionally formed skin material 2, and the headrest pillar 1a is provided on the bottom surface of the skin material 2 with the same diameter. The swinging mechanism is attached to the skin material 2 by being positioned so as to project to the outside from the opening. The skin material 2 is provided with a slab material 3 attached to the inner surface side in order to prevent the foamed resin from seeping out from the openings of the skin material 2. In addition, the skin material 2 has the headrest pillar 1a projected outside the mold and is inserted inside the molding die, and the foaming resin is injected into the skin material 2 through the resin injection hole so that the cushion pad 4 is formed inside the molding die. Is foam-molded integrally with the skin material 2.

After the cushion pad 4 is foam-molded, an elongated hole 5 is cut out by a heat cutter or the like on the bottom surface of the skin material 2 around the axis where the headrest pillar 1a projects, as shown in FIG. Thus, the headrest body can be swung in the front-rear direction.

In the swing headrest, it is inevitable that the headrest pillar rubs against the cushion pad as the headrest body swings and swings, which causes abnormal noise. In addition, since the opening that allows swinging of the headrest body is formed by post-processing by cutting the skin material, not only is this cutting process extremely time-consuming, but the hole edge of the opening is uniform. It is difficult to form beautifully and requires skillful technique.

[0005]

SUMMARY OF THE INVENTION According to the present invention, the headrest body is smoothly swung, and no abnormal noise is generated even when the headrest body is swung, and the headrest pillar protrudes. It is an object of the present invention to provide a swing headrest capable of beautifully finishing the periphery of the hole edge of a material.

Further, according to the present invention, a long hole for allowing swinging and swinging of the headrest body is formed in advance on the bottom surface of the skin material, and the skin material is inserted into the mold so that the cushion pad is integrated. It is an object of the present invention to provide a method for manufacturing a head swing headrest integrated with a skin material, which can surely prevent the foamed resin from leaking to the outside of the skin material even when the foam molding is performed, and can be easily molded as a whole.

[0007]

According to a first aspect of the present invention, there is provided a headrest frame having a headrest frame having a headrest pillar projecting outside and a built-in head swinging mechanism, the headrest frame having a predetermined three-dimensional shape. In the swing headrest that is housed inside the skin material formed in, the headrest pillar is projected to the outside from a long hole that opens at the bottom surface of the skin material, and the cushion pad is integrally foam-molded inside the skin material, A long cylindrical rising part is provided around the axis from which the headrest pillar protrudes to allow the headrest body to swing in the front-back direction of the seat by rising from the bottom surface of the headrest frame, and the projecting end face of the rising part and the long hole of the skin material. By aligning and fixing the periphery of the hole of the elongated hole to the projecting end face of the rising portion.

In the swing headrest according to claim 2 of the present invention, the projecting flange portion is provided so as to project laterally from the projecting end side of the rising portion, and the projecting flange portion of the rising portion and the long hole of the skin material are positioned. It is constructed by aligning and fixing the periphery of the hole of the elongated hole to the plane of the projecting flange portion.

According to a third aspect of the present invention, in the method for manufacturing the foam material integrated swing-molded head swing headrest, the headrest frame is provided with the headrest pillar projecting to the outside so as to have a built-in head swing mechanism, and the headrest frame is predetermined. It is housed inside a three-dimensionally formed skin material, and the headrest pillar is projected to the outside from a long hole that opens at the bottom surface of the skin material, and the cushion pad is integrated inside the skin material within the mold. In foam molding, a long tubular rising part is integrally formed that rises from the bottom surface of the headrest frame around the axis where the headrest pillar protrudes and allows the headrest body to swing in the front-back direction of the seat. The headrest frame is housed inside the skin by aligning the tip surface of the Attach the headrest frame to the skin by protruding the drest pillar from the long hole of the skin to the outside, and further project the headrest pillar from the mold through the pillar insertion hole of the molding die, and rise around the hole edge of the long hole. By mounting the skin material that houses the headrest frame in the mold of the mold by clamping and supporting it with the tip surface of the mold and the inner surface of the mold, the resin is filled with foamed resin at a different position on the skin. The cushion pad is foamed integrally with the surface material by being injected into the interior of the material.

According to a fourth aspect of the present invention, in the method for manufacturing the foam material swing-molded head swing headrest, the protruding flange portion is integrally formed by projecting laterally from the projecting end side of the rising portion, and the long hole is formed. The periphery of the edge is clamped and supported by the flat surface of the protruding flange portion and the inner surface of the mold.

According to a fifth aspect of the present invention, in the method for manufacturing a head swing headrest integrally formed with a skin material, the periphery of the long hole is provided around the projecting end surface of the rising portion or the plane of the overhanging flange portion and the mold. It is configured to be compressed and supported by a projecting die surface so as to be clamped.

[0012]

In the swing headrest according to claim 1 of the present invention, the headrest pillar is projected to the outside so that the swing mechanism is built in the headrest frame, and the headrest pillar stands up from the bottom surface of the headrest frame around the axis on which the headrest pillar projects. Since the long tubular rising portion is provided to allow the headrest body to swing in the front-back direction of the seat, the rising portion can be guided by the headrest stay as the headrest body swings and swings. Therefore, not only can the headrest main body be swung stably, but also the headrest stay does not rub against the cushion pad, so that no abnormal noise is generated. In addition, since the protruding end surface of the rising portion and the long hole of the skin material are aligned and the hole edge of the long hole is applied to the protruding end surface of the rising portion and fixed, the headrest pillar protrudes beautifully around the hole edge of the covering material. Can be finished.

In the swing headrest according to claim 2 of the present invention, since the overhanging flange portion is provided on the projecting end side of the rising portion, the rising portion which serves as the swing swing guide of the headrest body can be reinforced, and the headrest made of the skin material. The periphery of the hole of the long hole through which the pillar is inserted can be applied to the flat surface of the protruding flange portion to be securely fixed.

In the method for manufacturing a foam material integrated foam molding swing headrest according to claim 3 of the present invention, a long hole for projecting the headrest pillar to the outside is provided in advance on the bottom surface of the skin material, and the circumference of the hole of the long hole is provided. Is supported between the rising portion of the headrest frame and the inner surface of the mold, and the cushion pad is foam-molded integrally with the skin material by assembling the skin material containing the headrest frame in the mold. Not only can the resin be prevented from entering the inside of the headrest frame, but it can also be prevented from leaking from the elongated hole of the skin material to the surface side. Also, since the cushion pad is foam-molded integrally with the skin material and the hole edge around the long hole from which the headrest protrudes is also fixed to the projecting end face of the rising portion, the entire headrest can be manufactured efficiently and the hole edge of the long hole can be manufactured. The surroundings can also be beautifully finished with a terminal.

In the method for manufacturing the swing head swing with integrated skin material according to the fourth aspect of the present invention, the periphery of the hole of the skin material can be supported with a wide pressure between the flat surface of the protruding flange portion and the inner surface of the mold. Therefore, it is possible to reliably prevent the foamed resin from entering the inside of the headrest frame and leaking from the long hole of the skin material to the surface side.

According to a fifth aspect of the present invention, in the method for manufacturing a head swing headrest integrally formed with a skin material, the periphery of the hole of the skin material is provided with a projecting surface of the mold and a projecting end surface of the rising portion or a flat surface of the protruding flange portion. Since it is compressed by and is supported by pinching,
The periphery of the hole edge of the skin material can be more surely clamped and supported.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIGS. 1 to 6, the head swing frame shown in FIG. 1 has a head rest pillar 10a projecting outward and a head swing mechanism portion 10b housed therein as shown in FIG. It is assembled using 11. In order to manufacture a swing headrest using the headrest frame 11, the headrest frame 11 is housed inside a skin material 12 formed in a predetermined three-dimensional shape and is assembled together with the skin material 12 inside a molding die 20. With the headrest frame 11 accommodated, the cushion pad 13 is integrally foam-molded inside the skin material 12 by the foaming die 20 to be manufactured as a swing headrest.

The swing mechanism 10b can be assembled by either a ratchet type having a ratchet on the axis of the headrest pillar or the above-mentioned friction type. The headrest frame 11 may be blow molded from a varison such as polypropylene. As the skin material 12, a trim cover in which a genuine leather, a synthetic leather, a fabric, and the like and a backing material are laminated in one body through a cushion layer can be used. Further, the cushion pad 13 may be foam-molded with a foam resin such as urethane foam. The swing mechanism portion 10b is integrally attached to the headrest frame 11 by being fixed in contact with the inside at a predetermined position other than the movable portion.

The skin material 12 includes a headrest frame 1
A resin injection hole 12b for injecting a foamed resin into the skin material 12 is provided on the bottom surface, along with a long hole 12a that is inserted through the headrest pillar 10a that projects from 1. Also,
As shown in FIG. 2, an elongated tubular rising portion 11a is integrally formed on the headrest frame 11 so as to rise from the bottom surface around the axis of the headrest pillar 10a. The rising portion 11a is formed in a long tubular shape in the front-rear direction that allows swinging and swinging of the headrest body. In addition, a protruding flange portion 11b is formed on the rising portion 11a so as to project laterally from the projecting end side. The headrest frame 11 has a rising portion 11a and a long hole 12a.
And the flat surface of the overhanging flange portion 11b is applied around the hole edge of the elongated hole 12a, and the headrest pillar 10a is projected to the outside from the elongated hole 12a to form the skin material 12.
It is pre-assembled inside the.

The mold 20 comprises an upper mold 21 and a lower mold 22,
The upper mold 21 is provided with a pillar insertion hole 23 for projecting the headrest pillar 10a out of the mold and a resin injection port 24 for inserting a foaming resin injection nozzle. Further, a projecting die surface 25 is provided on the inner surface of the upper die 21 with the resin injection port 24 positioned in the surface. In the molding die 20, the headrest pillar 10 a is projected from the pillar insertion hole 23 of the upper die 21 to the outside of the die, and the skin material 12 housing the headrest frame 11 is assembled in the die. At this time, as shown in FIG. 3, the periphery of the long hole 12a from which the headrest pillar 10a protrudes is compressed and sandwiched between the flat surface of the overhanging flange portion 11b provided on the headrest frame 11 and the projecting surface 25 of the molding die 20. The skin material 12 is assembled inside the molding die 20.

After the skin material 12 is assembled and inserted into the molding die 20, a foamed resin is injected into the skin material 12 through the resin injection port 24 of the molding die 20 to foam-mold the cushion pad 13. To do. This cushion pad 1
With the foam molding of No. 3, the long hole 12a of the skin material 12 is compressed and supported around the edge of the hole by the overhanging flange portion 11b of the rising portion 11b and the projecting mold surface 25 of the molding die 20. Of course, the foamed resin does not enter the inside of the headrest frame 11 and, of course, does not leak to the surface side from the elongated hole 12a of the skin material 12. The resin injection port 2 of the molding die 20
4 and the resin injection hole 12b of the skin material 12 can be sealed with a stopper plug fitted from the resin injection port 24 of the molding die 24.

When the cushion pad 13 is integrally foam-molded with the skin material 12, the periphery of the long hole 12a projecting the headrest pillar 10a can also be fixed to the projecting flange portion 11b of the rising portion 11a. Therefore, as shown in FIG. 4, the hole edge around the elongated hole 12a protruding from the headrest pillar 10a can be finished in a uniform and beautiful manner, and the cushion pad 13 can be foam-molded so that the hole around the elongated hole 12a can be rounded. Since the headrest can be fixed to the protruding flange portion 11b of the rising portion 11a, the entire headrest can be efficiently manufactured.

In the swing headrest manufactured in this manner, the rising portion 11a is guided by the headrest stay 10a as the headrest body swings and swings, so that the headrest body can be swung in the forward and backward directions of the seat in a stable manner. Can swing. In addition, the rising portion 11
Since "a" is reinforced by the overhanging flange portion 11a, it can sufficiently retain its shape even with long-term use.

As shown in FIG. 5, the long hole 12a of the skin material 12 may be formed so as to have a width narrower than the inner peripheral edge of the rising portion 11a so as to cover the entire overhanging flange portion 11b. However, when the entire headrest frame 11 including the rising portion 11a is made of a colored synthetic resin such as black, as shown in FIG.
Can be kept in good appearance even if it is formed wider than the inner peripheral edge of the rising portion 11a.

In the above-mentioned embodiment, the overhanging flange portion 11b is integrally formed on the projecting end side of the rising portion 11a, but the rising portion 11a is formed around the hole edge of the elongated hole 12a.
It can be attached and fixed to the tip surface of the. Although the molding die 20 is provided with the projecting surface 25, the inner periphery of the elongated hole 12a can be reliably clamped and supported by the inner surface of the molding die 20 and the projecting end surface of the rising portion 11a. Mold 2 described above
Although the upper mold 21 and the lower mold 22 are exemplified as 0, in this molding mold 20, the long hole 12a of the skin material 12 is used.
It is preferable that the shaft portion of the headrest pillar 10a that protrudes out of the mold via the headrest frame 11 is locked and fixed by the clip 27 of the rising plate 26 provided on the upper mold 21.

[0026]

As described above, according to the swing headrest according to the present invention, the headrest body can be stably swung at the rising portion of the headrest frame, and the edge of the long hole projecting the headrest stay can be swayed. You can also finish the terminal beautifully around the rising edge.

In manufacturing the swing headrest with the skin material by integral foam molding, even if a long hole for projecting the headrest stay is provided in advance on the bottom surface of the skin material, the periphery of the hole of the long hole of the molding die is formed. Since the skin material is assembled in the mold of the molding die by sandwiching and supporting it between the projecting end surface of the rising portion and the inner surface of the molding die, the foamed resin enters the inside of the headrest frame or the surface side from the long hole. It can be surely prevented from leaking out. In addition, since the cushion pad can be integrally foam-molded with the skin material and the periphery of the long hole can be applied and fixed to the rising portion of the headrest frame, the headrest as a whole can be efficiently manufactured.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a molding die to which a method for manufacturing a foam-integrated foam-molded swing headrest according to the present invention is applied in a state in which a headrest frame and a skin material are assembled.

FIG. 2 is a perspective view showing a headrest frame used in the same method from the bottom surface side.

FIG. 3 is a partially enlarged cross-sectional view of the molding die shown in FIG.

FIG. 4 is a partial perspective view showing the swing headrest manufactured by the method according to the present invention from the bottom surface side.

FIG. 5 is an explanatory view showing an assembled state of a rising portion of a headrest frame and a long hole of a skin material that can be applied by the method according to the present invention.

FIG. 6 is an explanatory view showing an assembled state of a rising portion of a headrest frame and a long hole of a skin material, which is applicable by the method according to the present invention as in the case shown in FIG.

FIG. 7 is an explanatory view showing a method of manufacturing a foam material integrated foam molding swing headrest according to a conventional example.

FIG. 8 is an explanatory view showing a swinging headrest provided with a long hole for protruding a headrest pillar from the bottom surface side in the same method.

[Explanation of symbols]

10a Headrest Pillar 10b Swing Mechanism 11 Headrest Frame 11a Headrest Frame Rise Part 11b Rise Overhang Flange Part 12 Skin Material 12a Skin Material Long Hole 12b Skin Material Resin Injection Port 13 Cushion Pad 20 (21,22) Mold 23 Pillar insertion hole of the molding die 24 Resin injection port of the molding die 25 Projecting surface of the molding die

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Claims (5)

[Claims] 1. A headrest frame in which a headrest pillar is projected to the outside to incorporate a swinging mechanism, the headrest frame is housed inside a skin material formed in a predetermined three-dimensional shape, and the headrest pillar is used as a skin material. In a swing headrest that projects outward from a long hole that opens at the bottom surface of the head cushion and integrally foam-molds a cushion pad inside the skin material, raise the headrest frame from the bottom surface around the axis where the headrest pillar projects. A long tubular rising part that allows the headrest body to swing in the front-rear direction of the seat is provided, and the projecting end face of the rising part and the long hole of the skin material are aligned with each other so that the edge of the long hole surrounds the projecting end of the rising part. Swing headrest characterized by being fixed to the surface. 2. A projecting flange portion is provided so as to project laterally from the projecting end side of the rising portion, and the projecting flange portion of the rising portion and the elongated hole of the skin material are aligned so that the circumference of the elongated hole is surrounded. The swing headrest according to claim 1, wherein the headrest is fixed to the flat surface of the overhanging flange portion. 3. A headrest frame having a head swing pillar that projects to the outside and has a built-in swinging mechanism. The headrest frame is housed inside a skin material formed into a predetermined three-dimensional shape, and the headrest pillar is used as a skin material. When the cushion pad is integrally foam-molded inside the skin material inside the skin material through a long hole opened in the bottom surface of the headrest pillar, the headrest frame is rotated around the axis where the headrest pillar projects. The headrest frame is formed by integrally forming a long tubular rising part that allows the headrest body to swing in the front-rear direction of the seat by standing up from the bottom surface of the upper part and aligning the protruding end face of the rising part with the long hole of the skin material. Is housed inside the skin material, and the headrest pillar is projected outside from the long hole of the skin material so that the headrest frame The headrest pillar is projected outside the mold through the pillar insertion hole of the molding die, and the edge of the long hole is clamped and supported by the projecting end surface of the rising part and the inner surface of the molding die. As a result, the skin material containing the headrest frame is assembled in the mold, and the foamed resin is injected into the skin material through the resin injection holes provided at different positions of the skin material, and the cushion pad is integrated with the skin material. A method for manufacturing a head swing headrest integrally formed with a skin material, the method comprising: 4. A projecting flange portion is integrally formed by projecting laterally from the projecting end side of the rising portion, and the periphery of the hole edge of the elongated hole is clamped by the flat surface of the projecting flange portion and the inner surface of the mold. The method for manufacturing a head swing headrest integrally foamed with a skin material according to claim 3, wherein the headrest is supported. 5. The periphery of the long hole is compressed and held by the projecting end surface of the rising portion or the flat surface of the protruding flange portion and the projecting die surface projecting into the die of the forming die. Item 5. A method of manufacturing a head swing headrest integrally foamed with a skin material according to Item 3 or 4.