JPH09206163A - Production of perforated head rest - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a process for production capable of facilitating setting of even a fabric skin to an expansion mold and normalizing expansion molding integrally with the skin. SOLUTION: This process for producing a perforated head rest comprises disposing the base part 41 of an insert 4 into the skin 3 for the head rest formed by sewing to a hollow annular shape, then injecting a foaming raw material into the skin 3 and executing the expansion molding integrally with the skin embedded with the base part 41 of the insert. At the time of the expansion molding, a slide core 13 relating to the foaming mold 1 is shifted to the central part A of the mold and the perforating part O of the skin 3 is inserted therein. The sliding core 13 is then moved outward and the skin 3 is so set that the stitch line of the skin 3 exits in the spacing δformed by the outward movement of the sliding core 13. The foaming raw material is thereafter injected into the skin 3 and is subjected to expansion molding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a perforated headrest among vehicle headrests.

[0002]

2. Description of the Related Art Among headrests attached to seat backs of automobiles, there is a headrest type headhole. Up to now, the following two types of manufacturing methods have been mainly adopted as the manufacturing method of the perforated headrest. Set the insert base in the foaming mold, pour foaming raw material, foam and harden it, and take out the insert and headrest base integrally molded product with a skin such as fabric in a later process to make it into a bag, and a bag After arranging the insert base in the outer skin, set it in the foaming mold and pour foaming raw material from the injection port provided in the outer skin to foam and harden to make an integrated product of the headrest base body, outer skin and insert. It is a manufacturing method. And in the above manufacturing method,
There were those that used resin-molded skins such as leather type made of vinyl chloride resin, and those that used sewn fabric skins.

However, in the conventional manufacturing method and the manufacturing method, it is common to use a resin-molded skin, and a fabric skin is used to form an integrally molded product of the skin, the insert and the headrest base body. The manufacturing method was extremely rare. Because, using the above fabric skin,
The procedure for manufacturing the outer skin, the insert, and the headrest base body as an integrally molded product is usually such that the fabric outer skin is sewn according to the design shape, the insert is inserted into the sewn outer skin, and the sewn outer skin incorporating the insert is of the foam type. It is set on the (inclinable side), the mold is closed, and the foaming raw material is injected into the skin to integrally mold the skin, but the following problems were involved.

[0004]

That is, since the skin used is a fabric sewn product, it is impossible to shape the outer shape of the final product at the stage of setting the skin to the foaming mold. In addition, when the perforated portion was fitted in, the skin was tight and it was difficult to fit in the foamed mold. This directly linked to poor workability and increased man-hours for setting the epidermis. Further, in many cases, the skin is arranged with wrinkles, and the foam-molded product in that state is unusable. Furthermore, there were many problems such as the skin being caught when the foaming mold was opened and closed.

The present invention solves the above-mentioned problems and provides a method of manufacturing a perforated headrest capable of easily forming a foam mold even in the case of a fabric skin and normally performing foam molding integrally with the skin. The purpose is to do.

[0006]

In order to achieve the above object,
The gist of the present invention according to claim 1 is that a base material of an insert is provided in a headrest skin that is formed into a hollow ring by sewing, and then a foaming raw material is injected into the skin to embed the insert base material. In the method of manufacturing a perforated headrest for foam molding, when foam molding, the slide core relating to the foam mold is moved to the center of the mold, the perforated part of the skin is fitted and inserted, and then the slide core is removed. Characterized in that the outer skin is set so that the seam line of the outer skin is located in the gap formed by the outward movement of the slide core, and then the foaming raw material is injected into the outer skin to form the foam. It is in the method of manufacturing a perforated headrest. According to a second aspect of the present invention, there is provided a method of manufacturing a perforated headrest according to the first aspect, wherein the fixed die side is provided with a slide core, and the retractable die side is in a state where the slide core is moved outward. It is characterized in that foam molding is performed by using a foam mold provided with a lock part that fits with.

According to the first aspect of the invention, when the slide core is moved to the center of the mold and the perforated portion of the skin is fitted therein, the outer shape of the slide core becomes smaller than that of the perforated portion. Easy to fit. Then, if the slide core is moved outward, the perforated portion is easily set by the slide core. If the gap formed by the outward movement of the slide core is also located near the seam line of the epidermis, the seam line is in a state where the seam allowances are double overlapped and sewn. Therefore, the foam of the part does not bulge and deform even by foam molding. According to the invention as set forth in claim 2, when the lock part which is fitted to the slide core in the outwardly moved state is provided on the foldable side, the movement of the slide core can be stopped, so that the stable hole is formed. Allows manufacturing of open headrests.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of a method of manufacturing a perforated headrest according to the present invention will be described in detail below. Figure 1
FIG. 9 shows an embodiment of the headrest of the present invention. FIG. 1 is a longitudinal sectional view in which the slide core is in a contracted state and the perforated portion of the epidermis is fitted therein in the mold open state, and FIG. 1 is a longitudinal sectional view of the slide core extended and moved from the state of FIG.
FIG. 4 is a plan view showing the positional relationship between the skin and the slide core of FIG.
2 is a plan view showing the positional relationship between the epidermis of FIG. 2 and the slide core, FIG. 5 is a vertical cross-sectional view of the state in which the collapsible mold is closed from the state of FIG. 2, and FIG. 6 shows the state of FIG. FIG. 7 is a perspective view of a perforated headrest that has been taken out by demolding after foam molding, and FIG. 8 is a partial sectional view of a perforated headrest near the gap in the foam molding stage. Is.

First, before explaining the method of manufacturing a perforated headrest, the foaming mold 1 used for this will be outlined. The foam mold 1 includes a fixed mold 11 and a collapsible mold 12 as shown in FIG.
, The fixed mold 11 is divided into a lower mold 11a and an upper mold 11b,
The foldable mold 12 also has a structure in which a lower mold 12a and an upper mold 12b are separated. The lower fixed mold 11a is provided with a slide core 13, and the slide core 13 is moved back and forth by the operation of an actuator (the air cylinder 2 is adopted in this embodiment). When the rod 21 of the air cylinder 2 retracts, the slide core 13 moves outward (FIGS. 1 and 2). Then, when the mold is closed while the slide core 13 is moved outward, a cavity c of a perforated head rest is formed in the foaming mold 1 (FIG. 5).

The method of manufacturing a perforated headrest begins with the preparation of the headrest skin 3. The epidermis 3
Is made of a fabric skin or the like, and here, the four skin pieces 3a to 3d are once made into tubular skins 31 to 34, and then these are sewn to make a hollow ring (see FIG. 7). A seam line 35 as shown in FIG. 3 is formed at each corner portion where the four tubular skins 3 are connected to each other. An insert 4 including a ring-shaped base portion 41 and a pair of stays 42, one end of which is fixed to the base portion 41, is prepared in accordance with the outer skin 3. Then, first, the base portion 41 of the insert 4 is arranged inside the skin, and the stay 42 is projected to the outside of the skin.

Next, the air cylinder 2 is operated to confirm the state where the slide core 13 is moved to the center A of the mold and brought into contact with the vertical column fixing portion 111, and then the slide core 13 is moved.
(And vertical column fixing portion 111) O perforated portion O of the skin 3
(Fig. 1). The outer shape of the slide core 13 is the skin 3.
Since it is smaller than the perforated part O, it fits smoothly. The skin 3 is inserted while the insert 4 is assembled. The upright pillar fixing portion 111 is a raised portion that stands up in an H shape in plan view,
It is located in the central portion A on the stationary die side (Fig. 3). And
The slide core 13 is arranged so as to fit in the concave portion α of the vertical column fixing portion 111. When the slide core 13 spreads outward, it almost fills up the perforated portion O of the fitted skin 3, and when the slide core 13 comes into contact with the upright pillar fixing portion 111, it naturally becomes smaller than the previously spread state. , Becomes deflated. Therefore, as shown in FIG. 3, a gap δ is generated between the skin 3 and the slide core 13, and it becomes easy to fit the skin 3 into the slide core 13 (and the vertical column fixing portion 111). In addition, the outer peripheral side surface 111a of the vertical pillar fixing portion 111 is
It is a mold surface that forms the cavity c.

Then, the rod 21 of the air cylinder 2 is contracted to move the slide core 13 outward (FIG. 2).
By the outward movement of the slide core 13, the perforated portion side of the skin 3 which has been in a relaxed state is in a tight fit state. Influenced by this, the outer shape of the epidermis is naturally shaped. The outer peripheral side surface 13a of the slide core 13 is a mold surface that forms a cavity c. When the slide core 13 moves and is arranged outward, the outer peripheral side surface 111a of the vertical column fixing portion 111 forms a hollow annular skin 3 Add the holed side of. Thus, as the slide core 13 moves outward, the shape of the epidermis is properly adjusted. The outward movement of the slide core 13 causes the contact surfaces L of the slide core 13 and the vertical column fixing portion 111 to separate from each other, thereby forming a gap δ, but the gap δ is arranged near the stitch lines 35 at the four corners. Therefore, foam molding can be performed successfully (described later).

After that, the mold is closed (FIG. 5). Foldable type 1
By closing 2 the cavity c of the perforated headrest is formed in the foaming mold 1. Here, the retractable mold 12 is provided with a convexly formed lock portion 121 (FIG. 1),
When the mold is closed, the lock portion 121 stops the movable slide core 13 from moving. A gap E is generated between the slide core 13 and the mold center portion A of the vertical column fixing portion 111 due to the outward movement of the slide core 13, and the lock portion 121 is fitted in the gap E. By fitting the lock portion 121 to the slide core 13, the slide core 13 is prevented from returning to the mold central portion A from both sides without depending on only the force of the air cylinder 2.
In this way, the slide core 13 is fixed, and the cavity c having a stable shape is formed in the foaming mold 1.

After that, the foaming raw material G is injected into the skin 3 using the slit 36 (FIG. 6). The injection of the foaming raw material G is performed by a known plate-shaped jig 6 (for example, JP-A-7-31759).
It is performed by inserting a jig described in the publication) into the slit 36. The foaming raw material G is transferred from the injection machine 7 through the funnel 8 to the skin 3
A predetermined amount is injected into the inside.

Subsequently, the perforated headrest is foam-molded at a predetermined temperature. As the foam hardening progresses, the desired headrest with a hole O in the center is completed. By the way, if there is the gap δ as described above, the gap δ becomes bad not only in the general molding process but also in the foam molding process. Therefore, it has hitherto been unthinkable to adopt a mold structure that creates the gap. It was This is because if there is the gap δ, the design surface swells toward the gap δ in foam molding, resulting in a defect that the convex portion f is formed (FIG. 9). However, the present inventors have confirmed that when the sewn skin 3 is used and the gap δ is located near the seam line 35, the above-mentioned bulging failure does not occur. At the seam line 35, the two seam allowances 37 and 38 overlap each other in the upright state, and since these are tightly sewn to each other, it is as if the core material was applied (FIG. 8). Furthermore, since it is a perforated headrest, the four seam lines 35 are ring-shaped and work in a direction in which deformation is suppressed. Therefore,
Even if there is some gap δ, the convex portion f that affects the quality cannot be formed. Incidentally, the sewing line 35 is normally in a state of being retracted into the epidermis as shown in FIG. 8 in order to sew up tightly with the sewing thread n, and rather, since there is a gap δ, this portion is extruded and corrected, It may be convenient.

After the foaming and hardening are completed, the foamed body 5 which fits the cavity c is formed (FIG. 7). After that, by cooling and demolding, a desired perforated headrest with a skin in which the insert 4 base portion 41 is embedded is obtained.

The method of manufacturing the perforated headrest of this embodiment is one mode, and another mode is, for example, FIG.
Slide core 13 that spreads in all directions like 0 (here,
It is represented by a schematic shape. It is also possible to use a foaming type that adopts (1). The slide core 13 is squeezed in FIG. 10 (a) which is moved to the center part A of the mold, and after the skin 3 is fitted therein,
The outer skin 3 can be set by moving the slide core 13 outward to change it to the state of FIG. The air cylinder 2 is used to move the slide core 13.
Besides, an actuator such as an electromagnetic valve, and a spring or the like can be used. As the material for the skin 3, a fabric skin or the like is used. Specifically, the fabric skin is lined with a solid polyurethane film, or the fabric skin is integrally laminated with a urethane foam sheet or a polyurethane film. Is used. Alternatively, a cut pile fabric in which synthetic fibers such as acrylic and polyamide are used as pile yarns and cotton, rayon and the like are used as the ground sutures may be used. A resin coating is applied to the cut pile fabric for the purpose of preventing the pile fabric from coming off the pile. The sewing specifications of the seam line 35 are not particularly limited, but it is more preferable if the seams are sewn by overlock sewing. In overlock stitching, the sewing thread n of the seam is doubled over the entire seam, so that even if the skin 3 and the foam 5 act to bulge toward the gap δ by the foaming pressure of foam molding, the seam is difficult to open, and the convex The formation of the part f is effectively suppressed.

In the method of manufacturing the perforated headrest thus constructed, the outer shape of the slide core 13 is made smaller by the mold center portion A, and then the perforated portion O of the outer skin 3 is fitted into the slide core 13. The skin 3 can be fitted easily. The conventional trouble that the skin 3 is tight and difficult to fit in the foam mold 1 is solved. And the slide core 13
When is moved outward, the inner portion of the annular skin 3 is shaped by the slide core 13 and the vertical pillar fixing portion 111, so that the skin 3 is set properly. The situation in which wrinkles are placed on the skin 3 does not occur. Of course, under the condition that the outer skin 3 is correctly set on the fixed mold 11, there is no problem that the mold is closed and bite. In addition, slide core 1
Since the gap δ formed by the movement of 3 is arranged in the vicinity of the seam line 35, it is possible to suppress the foam body 5 from expanding toward the gap δ in foam molding as described above. To be done. Further, the slide core 13 moved outward by the air cylinder operation receives the foaming pressure only by the force of the air cylinder 2 as it is, but when the lock portion 121 is provided, the slide core 13 slides together with the air cylinder 2. Core 1
It is possible to prevent the receding and blurring of No. 3 and smoothly perform foam molding.

In the present invention, the present invention is not limited to the above-described embodiment, but can be variously changed within the scope of the present invention depending on the purpose and application. The shape, size, etc. of the foaming mold 1, the air cylinder 2, the skin 3, the insert 4, etc. are appropriately selected according to the application.

[0020]

As described above, according to the method of manufacturing a perforated headrest of the present invention, it is possible to easily set a perforated headrest into a foam type even if it is a sewn skin, and to finish the perforated headrest with stable quality. It is possible to exert an excellent effect on improving workability and yield.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view in which a slide core is in a contracted state under a mold open state, and a perforated portion of a skin is fitted therein.

FIG. 2 is a vertical cross-sectional view in which the slide core is extended and moved from the state of FIG.

FIG. 3 is a plan view showing a positional relationship between a skin and a slide core shown in FIG.

FIG. 4 is a plan view showing a positional relationship between a skin and a slide core shown in FIG.

FIG. 5 is a vertical cross-sectional view in which the collapsible mold is closed from the state of FIG.

6 is a partially enlarged vertical cross-sectional view of injecting a foaming raw material into the epidermis after ensuring the state of FIG.

FIG. 7 is a partial cross-sectional perspective view of the perforated headrest that has been taken out by demolding after foam molding.

FIG. 8 is a partial cross-sectional view of a perforated head rest near the gap in the foam molding stage.

9 is a partial cross-sectional view of a prior art headrest compared to FIG.

FIG. 10 is a plan view showing another form of a slide core.

[Explanation of symbols]

 1 Foaming type 11 Fixed type 12 Inclinable type 121 Lock part 13 Slide core 3 Skin 4 Insert 41 Base part A type central part G Foaming raw material O Hole opening part δ Gap

Claims (2)

[Claims] 1. A hole for carrying out foam molding integrally with a skin in which a foaming raw material is injected into the skin and a foaming raw material is injected into the skin for headrest, which is formed into a hollow annular shape by sewing. In the method of manufacturing a drest, in foam molding, the slide core related to the foam mold is moved to the center of the mold, the perforated portion of the skin is fitted and inserted into the mold, and then the slide core is moved outward to move the slide core. A method for manufacturing a perforated headrest, characterized in that the outer skin is set so that the seam line of the outer skin is positioned in the gap formed by the outward movement of the outer skin, and then the foaming raw material is injected into the outer skin to form the foam. 2. A foam mold using a foam mold in which a slide core is provided on the fixed mold side, and a lock part for fitting with the slide core in an outwardly moved state is provided on the retractable mold side. The method for manufacturing a perforated headrest according to claim 1, wherein molding is performed.