JPS63315094A - Production of headrest - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] (Industrial application field) The present invention relates to a method for manufacturing a headrest.

(Prior Art) A headrest is mainly composed of a core body provided with a mounting stay, a cushion body made of polyurethane foam or the like that encloses the core body, and an outer skin that encloses the core body. In recent years, it has been proposed to provide these mechanisms in the core body, as in Publication of Utility Model Publication No. 57-15736, in order to make the height of the headrest and the angle of the head support surface variable according to the sitting height of the occupant, driving posture, etc. There is.

On the other hand, various methods have been proposed as methods for manufacturing this headrest, but in the case of the one in which various functions are built into the core as in the above-mentioned Utility Model Publication No. 57-15736, predetermined methods are used as described in the same publication. A manufacturing method is often used in which a pad (cushion body) provided with a recessed portion for the interior of the core body is coated with an outer skin, and the core body is internally fixed within the cushion body. However, this method requires a separate process of manufacturing the cushion body, and furthermore, attaching the outer skin to the cushion body, and also requires a process of assembling the core cushion. In this case, the adhesion between the core body and the 27292 body tends to be insufficient.

Therefore, as an alternative method, as in JP-A No. 62-5821, a bag-shaped skin is set in a foaming mold, a core body having a stay is held at a predetermined position within the skin, and polyurethane etc. are used in the remaining skin. A method has been proposed in which the skin and core are integrated by injecting and foaming a liquid foaming raw material. In this method, as the foaming raw material is foamed, the resulting foam covers the core and expands the skin into a predetermined shape, so that the core is tightly held within the foam. Moreover, since the core and the skin are adhesively fixed through the foam, this method is advantageous in terms of man-hours compared to the above-mentioned method, and the core can be firmly fixed.

(Problems to be Solved by the Invention) However, as described above, in this method, the core is encapsulated as the liquid foaming raw material is foamed, so if there is an opening in the core containing various mechanisms, the core Liquid foaming raw materials that are in the process of foaming enter the foam and solidify, often interfering with the functions of various mechanisms. However, in cases where it is necessary for the core body and the stay to be relatively movable, such as in the vertical adjustment function of the headrest, it is necessary to provide an opening for inserting the stay in the core body, and at the same time, it is necessary to provide an opening for inserting the stay in the core body. It is inevitable that a gap will be created between the edge and the stay. On the other hand, if a gap is not provided, relative displacement between the core body and the stay will be impossible, or an extremely large force will be required for the displacement. In addition, in order to hold the core in a predetermined position within the skin, a stay is protruded from a hole provided in the skin, and foam molding is performed while holding the stay in a predetermined position. Since the stick is in close contact with the stay so as to cover it, it becomes more difficult to move the stay up and down. Furthermore, the foaming raw material is often produced from the gaps between the holes provided in the skin and the steel, which may cause contamination of the outer surface of the skin.

(Means for Solving the Problems) Therefore, the present invention aims to provide a novel method for manufacturing a headrest that solves the above-mentioned various problems. In a method for manufacturing a headrest, in which a foam raw material is injected into an inner skin, the resulting foam covers the core body, and the core body and the skin body are integrated with the foam. A cylindrical body made of a structural foam is attached to a stay in the epidermis, and after the epidermis is placed in a foam mold, the stay is lifted to hold the core in a predetermined position within the epidermis, and the cylindrical foam The method of manufacturing a headrest includes sandwiching the body between a core and an epidermis, and then injecting a foaming material.

(Function) The cylindrical body made of foam attached to the stay is compressed and sandwiched between the core and the inner surface of the skin by lifting the stay. That is, both end surfaces of the cylindrical body made of foam are in close contact with the periphery of the stay insertion opening in the core body and the stay insertion hole in the skin, and the opening in the core body and the hole in the skin are separated from the remaining intra-skin cavity. It will be closed accordingly. However, since the cylindrical body is composed of a foam with an open cell structure, the residual air within the skin and the foaming gas released during foaming of the liquid foaming material can easily escape through the cylindrical body to the outside of the skin. do. However, since the liquid foaming raw material has increased its own viscosity due to creaming due to polymerization reaction, some of it impregnates the outer surface of the cylindrical body, but due to the resistance due to the cell structure of the cylindrical body and the hardening of the foaming raw material, It hardens without penetrating the inner surface of the object. As mentioned above, since the cylindrical foam is impregnated with the foaming raw material and hardened while being sandwiched between the core and the skin, it becomes integrated with the resulting foam. Therefore, a predetermined gap is maintained around the stay from the stay insertion hole provided in the skin to the stay insertion opening in the core body, and the vertical movement of the stay is not hindered. Various functions will also be secured.

(Example) The present invention will be described below based on an example. FIG. 1 shows a skin 30 with a core body 10 inside which a cylindrical body 20 is attached to a stay 15, and one foaming mold 40 which is a split type. FIG. 2 is a cross-sectional view of the mold 40, the skin 30, and the cylindrical body 20 cut through the center of the stay 15 and perpendicular to the cut surface of the foam mold 40. .

The skin 30 is made of plastic such as soft vinyl chloride resin and molded into a desired bag shape, and has an injection port 31 at the bottom #3 (upper part in the figure since it is inverted) for injecting the liquid foaming raw material. A hole 32 is provided through which the attachment stay 15 is inserted. Note that instead of being made of plastic, the skin 30 may be a skin made of a woven fabric laminated with a plastic film, a foam sheet, or the like, and sewn with the woven fabric as the outer surface.

The core body 10 is made of a hollow body such as plastic, which has a built-in vertical adjustment mechanism (not shown) for the stay 15, etc.
It has a side opening 11 for inserting the stay at its bottom side, and one end of the attachment stay 15 is connected to the internal mechanism through the opening 11. Note that the stay 15 may be formed from a substantially U-shaped mesh pipe, and the center portion thereof may be built into the core body 10. Although the vertical adjustment mechanism and the like within the core body 10 are omitted since they are not the gist of the present invention, the mechanism disclosed in Japanese Patent Application No. 15489/1989 filed by the applicant of the present invention is utilized.

The cylindrical body 20 is made of a foam having an open cell structure, preferably a compressible and deformable soft foam such as a soft polyurethane foam, and has a center hole 21 in the center through which the stay 15 can be inserted and slid. The thickness is sufficient to cover the stay insertion hole 32 provided in the skin 30 and the stay insertion opening 11 provided in the core IO at both end surfaces.

The cylindrical body 20 is attached to a stay 15 provided on the core body 10, and the core body 10 with the cylindrical body attached is installed in the outer skin 30 so that the stay 15 protrudes from the insertion hole 32. When the outer skin 30 is made of a plastic skin, it is preferable to apply the interior during molding of the outer skin 30. For example, when molding the skin 30 by blow molding, the core body 10 with the cylindrical body 20 attached thereto can be held in a parison, and the core body 10 and the like can be placed inside at the same time as the skin 30 is molded. However, even if it is a plastic skin, it is not limited to this, and a part of the hollow skin made by the above-mentioned blow molding, other slushy molding, rotary molding, etc., preferably the bottom part on the mounting side of the headrest, is cut to a predetermined length, Core body 10 equipped with the aforementioned cylindrical body 20
The cracks may be removed from the interior. Further, in the case of a skin made of woven fabric or the like, a bag-like skin with an opening for inserting the core body may be sewn in advance, and the opening may be sewn after the core body 10 etc. are placed inside.

On the other hand, the foaming mold 40 is a split mold (one not shown), and each split surface 41 is provided with one half of a desired headrest cavity 42 in a concave shape, and a stay-holding mold that communicates with the cavity from the outside of the mold. - Groove 43 is provided.

44 is a concave groove for inserting an injection nozzle for liquid foaming raw material, and when the foaming mold 40 is closed, the cavity 42 along with the groove 43 for holding the stay can be inserted from outside the mold.
A through hole is formed leading to the. Note that the injection nozzle insertion hole 44 does not necessarily need to be provided on the mold parting surface 41, and may be provided at another position. However, the outer skin 3 with the core body 10 inside
Needless to say, the injection port 31 provided in the skin 30 faces the nozzle insertion hole 44 when the mold 40 is placed in the foam mold 40 and the mold 40 is closed. 45 is stay 15
This is a claw for positioning the stay at a predetermined height, and is provided in line with the stay holding groove 43.

Next, the skin 30 with the core body 10 inside as described above is attached so that the protruding stay 15 fits into the stay holding groove 43 of the foaming mold 40, and the other foaming mold 40 is closed. At this time, it is preferable that the foaming mold 40 be closed in two stages, and in the first stage of closing, the skin 30 is installed in the cavity 42, but the stay 15 is closed so as to be movable. Then, by lifting up the stay 15, the stay 15 is engaged with the pawl 45 using the notch 16 provided for engaging and fixing the stay to the seat back, etc., and then the second stage of mold closing is performed. The stay 15 is sandwiched between foam molds 40. At this time, the cylindrical foam 20 attached to the core body 10 and the stay 15 in the skin 30 is initially not subject to any restrictions, but as the stay 15 is lifted, the cylindrical foam 20 rises together, and the core body 10 is placed in a predetermined position within the skin. While being held, the cylindrical body 20 is pinched between the core body 10 and the inner surface of the skin 30, and is further compressed. Therefore, the stay insertion opening 11 of the core body 10 and the stay insertion hole 32 of the outer skin 30
are closed at both end surfaces of the cylindrical body 20, and the center hole 21 of the cylindrical body 20 is separated from the intraepidermal cavity 33. Note that the position of the stay 15 is not limited to the above-described method, and the stay 15 can be fixed by providing a claw 45 in the stay holding groove 43, etc.
may be locked in a predetermined position.

After that, a liquid foaming material injection nozzle (not shown) is inserted into the nozzle insertion hole 44, and a liquid foaming material such as flexible polyurethane foam is introduced into the skin 30 from the injection port 31 of the skin 30 that is in contact with the insertion hole 44. inject.

The injected raw material thickens due to reaction, generates carbon dioxide gas, etc., foams, and fills the epidermis.

Therefore, the air inside the skin 30 is forced out of the skin 30 due to the increase in volume of the foam that is generated. The cylindrical body 20 attached to
Since it has an open cell structure, air passes through the cylindrical body 20 and further passes through the stay insertion hole 32 to escape from the outside of the skin to the outside of the mold. On the other hand, if the skin 30 is made of woven fabric or the like, air will of course escape from the woven fabric or the like. However, since the foaming raw material has thickened as mentioned above, the cylindrical foam 2
The flow is hindered by the bubble walls of 0, and the outer surface of the cylindrical body 20 is hardened by only a slight impregnation, and the central hole 2 of the cylindrical body 20 is hardened.
It doesn't reach 1. Moreover, the shape of the cylindrical body 20 is fixed in a compressed state by the hardening.

The above is an example in which the core body 10 is provided with an internal mechanism in order to explain various functions of the present invention, but even if the core body 10 does not have an internal mechanism, the scales and functions are the same. It is easy to understand that this is the case.

(Effects) As described above, the present invention can almost eliminate the risk of liquid foam raw material coming out from the stay insertion hole in the skin by obtaining a headrest in which a core body having a stay is integrally encapsulated with a foam and a skin. It is something. Therefore, the outer surface of the skin is not contaminated, a finishing step is not required, and the yield of the product can be greatly improved. In particular, it has become possible to integrally mold even the outer skin of woven fabric, etc., which could not be prevented from penetrating the foaming raw material produced in the past. In addition, even if a vertical movement mechanism for the stay is provided in the core, it is almost impossible for the foaming material to enter the core through the stay insertion opening, and a void is ensured around the stay within the foam. Therefore, the vertical movement mechanism of the stay is not obstructed, and smooth operation of the stay can be ensured. Even though various functions are provided within the core body, it is now possible to set the core body at a desired position within the foam, increasing the degree of freedom in the design of the headrest. It was made.

[Brief explanation of the drawing]

Fig. 1 is a partially cutaway perspective view of a skin with a core inside and one of the split foaming molds, showing an embodiment of the present invention, and Fig. 2 shows the center of the stay with the skin installed in the foaming mold. Longitudinal sectional view through. Patent applicant: Inoue MBC Co., Ltd. Figure 1

Claims (1)

[Claims] In a headrest manufacturing method that integrates a core and an outer skin with a foam produced by injecting a liquid foaming raw material into an outer skin in which a core with a stay is inserted, a cylinder made of a foam with an open-cell structure is used. The core body is held in a predetermined position within the epidermis by attaching the shaped body to a stay in the epidermis, and after placing the epidermis in the foam mold and lifting the stay, the cylindrical foam is placed between the core body and the epidermis. A method for manufacturing a headrest, characterized by sandwiching the material, and then injecting a foaming material.