KR101636681B1 - Integral forming headrest with different hardness and manufacturing method for the same - Google Patents

Abstract

The present invention relates to an integral-foaming type headrest with different hardness and a manufacturing method thereof. The integral-foaming type headrest with different hardness including: a headrest outer skin; a cushion member attached to an inner side of the outer skin before foaming a foaming material and made of a material with high elongation and low rebounding elasticity; a diaphragm member attached to the inner side of the cushion member to prevent the foaming material from permeating into the cushion member; a stay frame fixating the headrest to a seat; and the foaming material covering the stay frame and filled inside the outer skin of the headrest by foaming. Accordingly, the cushion member can be stably attached not only to the outer skin, but also to a curved part to satisfy the soft performance of the headrest even though the thickness of the cushion member is 10 mm or thicker. In addition, the cushion member is able to promote sewing convenience, thus the mass production of the integral-foaming type headrest is possible.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to an integral foam headrest,

The present invention relates to an integral foamed headrest and a method of manufacturing the same. More particularly, the present invention relates to an integral foamed headrest having a cushion portion and a body portion of a headrest having a different degree of hardness, And a manufacturing method thereof.

Generally, the headrest is designed to support the head of a driver or a passenger in a driver's seat or a passenger seat of a vehicle so that the head can be rested while preventing the head from being tilted backward in a sudden accident or an accident.

In a conventional headrest, the headrest is manufactured by inserting or injecting flexible polyurethane, which is a foamed material excellent in cushioning property, into a skin material sewn by a cloth having air permeability. As shown in Fig. 1, such a headrest is made by sewing a skin material in the same fashion as a headrest using cloths, inserting a stay frame having a finishing material for finishing the inside thereof, And a soft urethane foamed liquid is injected into the inside of the skin material through an injection port in the outer shell. The urethane foam liquid injected into the skin material hardens after a certain period of time and maintains the shape of the headrest.

In order to ensure the user's comfort as well as the safety of the user in the event of a car accident, the headrest is integrated with the stay frame so that the cushioning function is strengthened at a portion where the user's head contacts, And the safety is secured at the same time. In the case of the above-mentioned conventional art, since the foam is integrally foamed with the skin material and the stay frame, the manufacturing method is simple and the production cost is reduced. However, There is a problem that the stability and comfort of the user are reduced because the same hardness as that of the other portions is provided even at the portion where the user's head abuts.

In order to solve such a problem, as shown in Fig. 2A, a headrest manufacturing method of a recently separated assembly method has been proposed. The method of manufacturing a headrest of the separable assembly method is a method in which a soft urethane (hereinafter referred to as "main body") is foam molded and then a cushion member is separately detached and assembled to a portion where a user's head abuts. Generally, the flexible polyurethane for headrest has a density of 0.040 to 0.065 g / cm < ^{3 &} gt ;.

However, according to the above-described conventional separation and assembly method, a soft cushion member can be disposed at a portion where the user's head abuts to improve the comfort and safety of the user, compared to the conventional method of manufacturing the integral foam headrest. However, There has been a problem in that it takes a long time and a lot of time and cost to finish the foamed headrest main body part, the incision of the main body part, the insertion of the cushioning member, and the attachment of the tape to the cushioning member. Further, since the tape must be attached to the cushion member, as shown in Fig. 2 (b), a floating phenomenon such as a portion A occurs between the outer shell and the cushion member or a headrest covering the outer shell is bent, There is a problem that there is a high possibility that defects such as occurrence of a part of the user's head contact with the head are likely to occur. In addition, the separate assembly type system does not have a satisfactory effect even if the cushion member is used at 15 mm or more.

Meanwhile, in recent years, in order to provide comfort and softness in addition to stability in the area where the user touches the head of an automobile, a soft property as a cushion member is required to be higher. In order to satisfy such a high soft property, a cushion member of 10 mm or more There is a need.

However, there is a problem that it is very difficult to attach a cushion member of 10 mm or more in the conventional integral foam headrest. That is, according to the conventional method of manufacturing an integral foamed headrest, when the cushion member is attached at 5 mm or more, the difference in elongation of the fabric (fabric, artificial leather, natural leather) and the cushion member is large, So that not only the appearance can not be obtained, but also a stable cushioning function can not be performed.

In addition, although attempts have been made to increase the softness by increasing the thickness of the sponge for the outer jacket, not only the sewing ability due to the thickening of the outer shell becomes difficult, but also the appearance defects are caused by the characteristics of the integral foam headrest. In the case of the headrest, the hygroscopicity of the cushion member sucks the raw material and hardens, thereby causing the phenomenon that the soft property of the cushion member is largely lowered.

In order to prevent this, a sponge may be disposed inside the cushion member so as to prevent moisture from being absorbed by the foam. In this case, however, a sponge for preventing moisture absorption at the bent portion of the headrest There is a problem in that the bending portion (B) is generated by the pressurization and the soft property is greatly deteriorated at the portion, and there is a feeling that the occupant has a protruding feeling when leaning his head, there was.

The automobile headrest can be manufactured in various shapes, and in particular, when the headrest is made of a curved headrest as shown in FIG. 3A, the above-described problem becomes large.

Korean Utility Model Registration No. 20-0261184 (Urethane foam molding integrated automobile epidermal headrest)

SUMMARY OF THE INVENTION It is an object of the present invention to provide a cushion of soft and soft cushioning member in a cushion portion of a headrest to which a head of a user is abutted at the time of manufacturing a headrest, Part is formed of a conventional foam material and is made into a single foam type without having a separate finishing process while having a small diameter in one headrest and can be easily manufactured and secure the comfort and stability of the user. A foamed headrest and a method of manufacturing the same are provided.

Another object of the present invention is to provide a cushioning device which can stably be adhered not only to the outer skin but also to the bending portion even if a cushioning member having a thickness of 10 mm or more is provided in order to satisfy the soft performance of the headrest, And to provide a method of manufacturing the same.

In order to achieve the above-described object, the integral foamed headrest according to the present invention has a headrest shell, and a body made of a material having high elongation and low rebound resilience, which is attached to the inside of the shell prior to foaming molding of the foamed material A diaphragm member attached to the inside of the cushion member so as to prevent the foam material from penetrating the cushion member; a stay frame that fixes the headrest to the seat; and a stay frame surrounding the stay frame, And a foaming material filled in the foaming material by foam molding.

The cushion member is characterized by comprising a memory foam having a high elongation and a rebound resilience of 5% to 15% or a sponge having a high elongation and a rebound resilience of 50% or less. The higher the density, the higher the hardness of the ordinary sponge, but the memory foam has a high density and a low hardness and a high elongation.

Here, the diaphragm member is made of a heat-resistant material and has a thickness of 20 to 50 탆.

Here, the headrest shell is made of natural leather or artificial leather, and the cushion member is sewn on only the rim portion of the cushion member without being attached to the headrest shell.

A method of manufacturing an integral foamed headrest having a two-dimensional gauge according to the present invention includes the steps of preparing a cushion member which is disposed at a portion where a user's head abuts and is made of a memory foam or a sponge having a high elongation and low rebound resilience, Attaching the cushion member to the inside of the outer shell of the headrest; inserting the stay frame into the headrest shell having the cushion member attached thereto and inserting the headrest shell into the headrest mold; A step of joining the end cover to the cushion member and the rest cover, and a step of foam-molding the cushion member and the headrest integrally by injection molding a foam material into the head rest shell and foam molding.

Here, the cushion member is attached to the cushion member and the headrest shell by heating and applying a solid state adhesive to the cushion member and the headrest shell after positioning the cushion member in a proper position on the shell of the headrest.

Here, the preparation of the cushion member may further include a step of disposing a diaphragm member between the cushion member and the foam member to be foam-molded and preventing the foam member from penetrating the cushion member by attaching the diaphragm member to the cushion member .

Here, the attachment of the diaphragm member may be performed by heating or heating the diaphragm member and the cushion member or the headrest shell after applying or attaching a solid state adhesive to the cushion member or the outer shell of the headrest, And is attached without positional deviation.

Here, the attachment of the cushion member to the headrest shell is performed by heating and bonding the cushion member to the headrest shell at a high temperature for a short period of time in a vertical thermal bonding apparatus, and attaching the cushion member and the headrest shell to the transfer apparatus A step of pulling the molten metal to the outside of the vertical thermal bonding apparatus and pressing the molten metal to complete bonding and cooling.

According to the present invention having the above-described configuration, a soft soft cushion member is disposed on the cushion portion of the headrest to which the user's head abuts during the manufacture of the headrest, and the headrest main body portion is formed of a conventional foam member, The headrest can be manufactured in an integral foamed form without having a separate finishing process while having different hardnesses, so that it is easy to manufacture, the assembly cost can be reduced, manufacturing cost can be reduced, and user comfort and stability can be ensured.

In addition, even if a cushion member having a thickness of 10 mm or more is provided to satisfy the gradually increasing soft performance of the headrest, the cushion member can be stably adhered to the outer shell and stably installed at the bent portion. It is possible to provide a one-piece foamed headrest having a high degree of flexibility and a method of manufacturing the same.

In addition, when manufacturing a headrest made of leather such as natural leather or artificial leather, it is possible to provide the integral foam headrest having the above-mentioned dimen- sion.

Brief Description of the Drawings Fig. 1 is a view showing a headrest manufactured by an integral foaming method according to the prior art.
FIGS. 2A and 2B are views showing a headrest manufactured by a conventional separation assembly method.
Fig. 3A is a view showing an example of a curved headrest, and Fig. 3B is a view showing a bending phenomenon at a bent portion.
4 is a cross-sectional view showing an integral foam headrest according to the present invention.
5 is a cross-sectional view showing a bent portion of a headrest according to the present invention.
6 is an image showing a cross section of the integral foamed headrest according to the present invention after foaming.
7 is a view schematically showing a thermal bonding apparatus for attaching a cushion member of a headrest according to the present invention.
8A and 8B are cross-sectional views showing that the diaphragm member is attached to the cushioning member and / or the headrest shell.
Figs. 9A and 9B are diagrams for explaining lifting of a cushion member, Fig. 9A is a conventional headrest, and Fig. 9B is a plan view showing the arrangement of a cushion member of a headrest according to the present invention.
10 is a schematic view showing various arrangements of a cushion member according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for manufacturing an integral foamed headrest having a two-dimensional view according to the present invention and a headrest manufactured by the method will be described in detail with reference to the accompanying drawings.

4 to 10, an integral foam headrest 1 of a second aspect of the present invention includes a headrest shell 10, a cushion member 20, a stay frame 50, And a foam material 40.

The headrest sheath 10 typically uses fabrics used as the skin of the headrest. However, the sheath sheath 10 is not necessarily limited to this, and any material that is applied to the sheath of leather or the like may be used. The lower end portion of the headrest shell 10 is provided with an opening for inserting a stay frame described later.

A cushion member (20) is attached to an inner side surface of a portion of the headrest shell (10) where the head of the user abuts. The cushion member 20 is formed of a soft material so as to be able to feel a sense of comfort when the user's head comes into contact with the cushion member 20, and to mitigate the impact upon collision.

As described above, it is necessary to provide a cushion member having a thickness of 10 mm or more in order to satisfy the gradually increasing soft performance of the headrest. In this case, due to the thickness of the cushion member, it is difficult to sew the headrest shell and mass production is difficult, and there is a problem that a bent portion occurs as shown in Fig. 3B.

In order to solve the above-mentioned problems, in the present invention, it is necessary to provide a space between the outer line of the cushion member 20 and the outer skin sewing line 60 at a regular interval to enable sewing. The cushion member 20 is preferably made of a material having a high elongation and a low rebound resilience. Examples of the cushion member 20 of low rebound resilience include a memory foam or a low-elasticity sponge member.

When the cushion member 20 is formed of the memory foam, even when the memory foam is formed by a memory foam having a size of 10 mm or more, a good bending performance is exhibited in the curved portion of the headrest as shown in Fig. 5, Can be prevented.

In addition, the cushion member 20 is made of a low-elasticity soft member, so that the cushion member can be stably installed in the hetress frame. That is, when the cushion member is formed of a material having good elasticity by the conventional technique, as shown in Fig. 9A, the cushion member flares in the headrest frame and becomes a factor of failure. However, the cushion member according to the present invention has a low rebound resilience The cushion member can be stably stowed in the headrest frame at the time of manufacturing the headrest, as shown in Fig. 9B.

In the present embodiment, examples of the memory foam constituting the cushion member 20 include a memory foam having a rebound resilience of 5 to 15%. Examples of the sponge member include a sponge having a rebound resilience of 50% For example.

A diaphragm member (30) is attached to the cushion member (20) as a cushion protecting material. The diaphragm member 30 is disposed on the opposite side of the side where the cushion member 20 is attached to the headrest shell 10, that is, between the cushion member 20 and a foaming material described later.

On the surface of the cushion member 20 where the raw material of the foaming material described later meets the foam material, the cushion member becomes hard at the portion impregnated with the foam material and impregnated with the cushion material. In order to prevent impregnation of the foam member with the cushion member, a method of attaching a non-sponge member or the like to the cushion member may be proposed. However, in the portion where the cushion member is bent due to the attachment of the non- There is a possibility that a bending phenomenon may occur.

In the present invention, the diaphragm member 30 is formed of a film of a thin film having a stable heat resistance without being deformed at a high temperature, for example, and a foaming material to be described later is attached to the cushion member 20 To prevent penetration. Particularly, it is preferable that the diaphragm member 30 is formed to have a thickness of 50 μm or less, preferably 20 to 50 μm, and the thickness is thin and formed to have high temperature and heat resistance. If there is no heat resistance of the film, deformation or holes are generated when heat is applied by the thermal bonding apparatus, which is a factor of defects.

Fig. 6 shows an image obtained by foaming the foamed material after attaching the above-described diaphragm member to the cushion member and then cutting the cross section thereof. As shown in FIG. 6, the headrest according to the present invention can feel the soft feeling of stability of the headrest by a cushion member made of a memory foam having a thickness of 10 mm or more, and at the same time, the foam member penetrates into the cushion member It is possible to stably prevent softening of the hest rest, thereby improving the soft characteristics of the hest rest.

A stay frame (50) is inserted into the headrest shell (10). The stay frame 50 fastens and fixes the headrest to the seat back seat of a car.

In addition, the foam material 40 is injected into the inside of the headrest shell 10. The foam material 40 is foamed after being injected with, for example, a foamed liquid such as a urethane foam liquid, and is filled inside the headrest enclosure while surrounding the stay frame 50.

Hereinafter, a method of manufacturing an integral foamed headrest having a two-dimensional gauge according to the present invention will be described.

In the method of manufacturing an integral foamed headrest having different hardnesses according to the present invention, first, the cushion member 20 to be disposed at a portion where the user's head abuts is prepared.

The provision of the cushion member is disposed between the cushion member and the foam member to be foam molded, and attaches the diaphragm member to the cushion member to prevent the foam member from penetrating the cushion member.

Here, the attachment of the diaphragm member may be performed by heating and heating the diaphragm member and the cushion member or the headrest shell after applying and attaching a solid state adhesive to the cushion member or the outer shell of the headrest, So that it is attached without positional deviation.

8A, the attachment of the diaphragm member 30 is described as being attached to cover the cushion member. However, depending on the design of the headrest, the sewing line 60 and the attachment portion of the diaphragm member coincide with each other However, in such a case, wrinkles may appear on the appearance, and defects such as bending impregnation phenomenon may occur. In this case, as shown in Fig. 8B, the diaphragm member 30 may be disposed so as to cover the cushion member and the headrest shell to eliminate wrinkles and bending impregnation of the outer shell.

Then, the cushion member 20 is attached to the headrest shell 10.

The headrest shell 10 is inverted so that the inside and the outside are reversed, and then the cushion member 20 is attached to a portion where the user's head abuts.

Here, the cushioning member is applied and attached with a solid state adhesive to position the cushioning member in a proper position on the outer surface of the headrest, and then the cushioning member and the headrest sheath are heated and attached without positional deviation.

Adhesion of the diaphragm member to the cushion member and adhesion of the cushion member to the headrest shell are liable to cause defects because the position adjustment can not be performed once the member is adhered once it has adhesive strength. Further, since the elongation rates of the members attached to each other are different from each other, wrinkles or lifting phenomena are likely to occur.

Therefore, it is preferable that the adhesive is a solid adhesive. That is, after applying a solid state adhesive using a solid state adhesive in which no adhesive force is applied before applying heat and attaching the member to be adhered to the correct position, the member is heated and attached without positional deviation .

In addition, since the headrest and the cushion member are different in elongation as described above, defects such as a deviation and a lifting phenomenon are likely to occur in a conventional thermal bonding apparatus.

In the present invention, the attachment of the cushion member to the headrest shell is first heated at a high temperature for a short time in the vertical thermal bonding apparatuses 101, 102 and adhered.

Then, in order to minimize the heat transfer to the fabric, the cushioning member and the headrest sheath adhered to each other are drawn out to the outside of the vertical thermal bonding apparatus by the transferring device 103, and are then completely bonded by pressurization.

Then blow air to cool quickly.

On the other hand, the method for manufacturing a two-headed fully foamed headrest according to the present invention is also applicable to a headrest of a leather product.

When the headrest shell is made of natural leather, it is preferable that the cushion member is attached to a sponge having a shell structure, and then the fabric is joined to the fabric by sewing a rim portion. Because of the nature of the leather, it is characterized by hardness when attached with sponge.

Then, the headrest casing to which the cushion member is attached is inverted back to its inside and outside.

Then, the stay frame 50 is inserted into the headrest shell with the cushion member attached thereto, and the headrest shell is fixed to the headrest mold.

Then, the end cover is joined to the headrest shell to block the opening formed in the lower end of the headrest shell.

Then, a foaming material is injected into the headrest shell and foam-molded. At this time, the foam material expanding at the time of foam molding of the foam material presses the diaphragm member, so that the diaphragm member can be attached to the headrest shell while preventing the foam material from penetrating the cushioning member.

Then, the headrest is demolded after a certain period of time has elapsed after the foam material has hardened.

As a result, a soft soft cushion member is disposed on the cushion portion of the headrest to which the user's head abuts during the manufacture of the headrest, and the headrest main body portion is formed of a conventional foam member so as to have different hardness The cushioning member and the headrest sheath can be manufactured as a single-piece foam.

The method of manufacturing a headrest according to the present invention is a method of manufacturing a headrest by which manufacturing can be simplified and assembly costs can be reduced to reduce manufacturing cost and a soft cushion member is disposed at a portion where a user's head abuts and other headrest body portions are foamed It is possible to ensure the comfort and stability of the user.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. It will be apparent to those of ordinary skill in the art.

1: integral foam headrest
10: Headrest shell
20: Cushion member
30: diaphragm member
40: foam material
50: stay frame
60: sewing line

Claims (9)

A headrest shell,
A cushion member made of a material having a high elongation and a low rebound resilience, which is attached to the inner side of the envelope before foaming molding of the foam material;
A diaphragm member made of a heat resistant material and having a thickness of 20 to 50 탆 and attached to the inside of the cushion member to prevent the foam material from penetrating the cushion member,
A stay frame for fixing the headrest to the seat,
And a foam member surrounding the stay frame and being filled inside the headrest shell by foam molding.
The method according to claim 1,
Wherein the cushion member comprises a memory foam having a high elongation and a rebound resilience of 5 to 15% or a sponge having a rebound resilience of 50% or less.
delete The method according to claim 1,
Wherein the headrest shell is made of natural leather, and the cushion member is sewn on only the rim portion of the cushion member without being adhered to the headrest shell by an adhesive.
Preparing a cushion member which is disposed at a portion where the user's head abuts and is made of a memory foam or a sponge having a high elongation and a low rebound resilience;
A step of attaching a diaphragm member to the cushion member and preventing the foam member from penetrating the cushion member, the foam member being disposed between the cushion member and the foam member to be foam molded,
Attaching the cushion member to the inside of the outer shell of the headrest,
Inserting a stay frame into the headrest shell having the cushion member attached thereto and inserting the headrest shell into the headrest mold,
Coupling an end cover to the headrest shell;
Molding the cushion member and the headrest by integrally foaming the foam material by injecting the foam material into the headrest shell,
The attachment of the diaphragm member
The cushion member or the headrest shell is heated and heated so that the cushion member or the headrest shell is adhered without any positional deviation after the cushion member or the headrest shell is positioned and positioned in the cushion member or the outer shell of the headrest by applying and attaching a solid state adhesive Wherein the method comprises the steps of:
6. The method of claim 5,
Wherein the cushioning member is applied and attached with a solid state adhesive to place the cushioning member in a proper position on the outer surface of the headrest, and then the cushioning member and the headrest sheath are heated and attached without positional deviation. Wherein the method comprises the steps of:
delete delete 7. The headrest according to claim 6, wherein the attachment of the cushion member to the headrest shell comprises:
Heating and heating at a high temperature for a short period of time in a vertical thermal bonding apparatus,
And a step of pulling out the cushion member and the headrest shell to which the cushion member is adhered and the outer shell of the headrest to the outside of the vertical thermal bonding apparatus by a transferring device and pressing them to complete bonding and cooling. A method of manufacturing a headrest.

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