JP2002210271A - Headrest skin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a headrest skin having excellent quality not allowing generation of a recessed part. SOLUTION: This headrest skin for a headrest of a skin-integrally-formed mold 5 is formed in a bag shape. The headrest skin is formed in the bag shape by stitching plural skin pieces 11-15. All the skin pieces 11-15 are formed by cutting a skin material with a double-layer structure wherein a fabric skin 1a and a closed-cell foam sheet 1b disposed in the rear face of the fabric skin 1a are connected and integrated, in prescribed shape.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a headrest skin of a type integrally formed with a skin, among headrests mounted on an upper end of a seat back of a vehicle or the like.

[0002]

2. Description of the Related Art A conventional headrest of an integral skin-molding type, and a headrest skin of an integral skin-molding type using a fabric skin on a design surface side, has a three-layer structure of a fabric skin, a urethane slab, and a urethane film. It has been used exclusively. The skin material is cut into a predetermined shape, and a plurality of cut skin pieces are sewn together to form a bag-shaped headrest skin. Here, a film such as a urethane film is to prevent the penetration of the foaming material into the urethane slab and the fabric skin side during foam molding. However, if the film thickness is increased, the skin piece becomes harder and it is difficult to sew. However, it is said that a thin material is preferable.

[0003]

However, the headrest skin has the following problems. Film 1
When f is reduced, it is difficult to obtain a film 1f having no holes O at all due to a manufacturing problem. Of course, in the headrest manufacturing line, measures such as using the film 1f in which the portion where the hole O is opened in the inspection is removed in advance, but since the size of the hole O is in microns,
It was difficult to find all holes O. When the skin pieces using the film 1f having the holes O were mixed, the headrest product became defective. A recess u is formed in the fabric skin 1a on the design surface side only at the place where the hole O is present, and the fabric is depressed (FIG. 7). The mechanism by which the concave portion u occurs is considered to be as shown in FIG. A headrest skin with a hole O is set in the foaming mold 5 (a in the figure), and when the foaming material is injected, the headrest skin is compressed and crushed by the foaming pressure (b in the figure). At this time, the hole O
In the part, the foaming raw material impregnates and hardens the open-cell type urethane slab 1c. During subsequent demolding, the compressed and crushed headrest skin expands, but the portion O _{1 of} the pores solidified by impregnation with the foaming material.
Cannot be expanded, and remains in a recessed state, and the recess u
Can be done.

An object of the present invention is to solve the above-mentioned problems, and an object of the present invention is to provide a headrest skin which is excellent in quality and does not have the above-described recess.

[0005]

In order to achieve the above object,
The gist of the invention according to claim 1 is that, in a headrest skin formed in a bag shape for a headrest of an integrally formed skin type, all of these skin pieces formed in a bag shape by sewing a plurality of skin pieces. The headrest skin is obtained by cutting a two-layer structure skin material obtained by binding and integrating a fabric skin and a closed-cell type foam sheet disposed on the back of the fabric skin into a predetermined shape. is there. The gist of the invention according to claim 2 is that, in a headrest skin formed in a bag shape for a headrest of an integrated skin type, all of the skin pieces formed in a bag shape by sewing a plurality of skin pieces. A headrest characterized in that a three-layered skin material in which a fabric skin, a urethane slab and a closed-cell type foam sheet are combined and integrated with the urethane slab as an intermediate layer is cut into a predetermined shape. On the skin. Here, the "urethane slab" refers to a sheet-like body made of an open-cell type urethane foam.

According to the first and second aspects of the present invention, when a bag-shaped headrest skin is formed, even if a urethane foaming material is injected at the time of foaming and the foaming pressure is increased, a closed-cell foam sheet is provided inside. Is disposed, so that the foaming raw material is prevented from entering the foam sheet by the cell partition walls. Even if the foam sheet is slightly damaged, it is thicker than the film, and the remaining thickness stops the invasion of the foaming material. Therefore, there is no room for foaming material to enter,
There are no recesses.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The headrest skin of the present invention will be described in detail below. (1) Embodiment 1 FIGS. 1 and 2 show one form of a headrest skin according to the present invention. FIG. 1 is a plan view of a skin piece constituting the headrest skin, and FIG. 2 is a partial cross-sectional perspective view of the headrest skin. FIG.

[0008] The headrest skin 1 is a bag-shaped skin for a headrest of an integrally formed skin type, and is formed in a bag shape by sewing a plurality of skin pieces 11 to 15. For all of the skin pieces 11 to 15, a skin material having a two-layer structure in which a fabric skin 1a and a closed-cell foam sheet 1b disposed on the back of the fabric skin are joined and integrated with an adhesive 1j is used. The skin material is cut into each skin piece shape (FIG. 1). 1 and 3
Reference numeral 6 indicates the position of the stitch for convenience.

[0009] The fabric skin 1a is a skin formed of cloth. By using the fabric skin 1a on the design surface side, a texture and a sense of quality are imparted to a headrest as a vehicle interior product. The back surface of the fabric skin 1a is lined with a closed-cell type foam sheet 1b to form a fabric base laminate.

The closed cell type foam sheet 1b is a closed cell foam sheet having a predetermined thickness. Here, the foam sheet 1b is a foamed polyethylene sheet, and in the present embodiment, a sheet having a thickness of 0.5 mm to 3 mm is used. When the closed cell type is used, the open cell type impregnates and infiltrates the foam sheet 1b when the urethane raw material is injected into the bag-shaped skin and the skin is integrally foamed and molded. It is. Closed cell type foam sheet 1b
If so, it is possible to prevent impregnation and penetration of the foaming material into the foam sheet 1b during foam molding. What forms the closed-cell type is polyethylene, polyvinyl chloride, polypropylene, polystyrene, ABS, acrylic resin, silicone, hard rubber, and the like. In the closed cell type foam sheet 1b, it is preferable that all cells are separated from the other cells by partition walls. However, it is needless to say that all cells need not be so, and the ratio of closed cells is a certain percentage. Should be exceeded. Incidentally, it is more preferable to use a foamed polyethylene sheet having a density of about 0.033 ± 0.020 g / cm ³ . This is because such a foamed polyethylene sheet (foam sheet 1b) can also eliminate wrinkles SW which have been a problem in the conventional headrest skin 1 (described later).

As described above, the headrest skin 1 is attached to the fabric sheet 1a by the foam sheet 1b.
Is a two-layer laminated skin material integrally bonded by an adhesive 1j. The adhesive 1j includes a thermoplastic resin-based adhesive, a thermosetting resin-based adhesive, an elastomer-based adhesive, a mixed-type adhesive, and the like. If the fabric skin 1a and the foam sheet 1b can be combined and integrated, the type is selected. It doesn't matter.
The skin material, which is a cloth base laminate, is cut into a predetermined shape to form a plurality of skin pieces 11 to 15, and the adjacent skin pieces 11 are formed.
By suturing the peripheral portions 11a to 15a, the bag-shaped headrest skin 1 is obtained. Reference numeral 6 is a stitch line. Regardless of the production process, each skin piece 11-
A bag-shaped skin sewn so that the fifteen foam sheets 1b face the inside of the bag is completed, and becomes a regular headrest skin 1 (FIG. 2).

The headrest skin 1 thus produced is set in a foaming mold with the foam sheet 1b inside C, and a headrest as shown in FIG. 2 is formed. Code 4
Is a urethane foam integrally formed with the headrest skin 1, reference numeral 7 is an injection port of a urethane raw material, reference numeral 8 is a stay insertion hole provided on the bottom side S of the headrest skin, reference numeral 9 is an insert, and reference numeral 91 is a stay. Is shown. When the headrest skin 1 is used, the foam sheet 1b is bonded by foam molding to bond the polyethylene foam sheet 1b and the urethane foam 4 after the injection urethane raw material.
Corona treatment or the like is appropriately performed on the side. This is because the foamed polyethylene sheet 1b and the urethane foam 4 are difficult to adhere to each other as they are. In the present embodiment, an adhesive is used to bond and integrate the fabric skin and the foam sheet, but it may be based on a heat treatment or the like.

(2) Embodiment 2 This embodiment is a headrest skin as shown in FIGS. FIG. 3 is a plan view of a skin piece constituting the headrest skin, FIG. 4 is a partial cross-sectional perspective view of the headrest skin 1, and FIG. 5 is a schematic explanatory cross-sectional view of a method of manufacturing a skin material used for the headrest skin. .

The headrest skin 1 is a bag-shaped headrest skin 1 for a headrest of an integrally formed skin type, and is formed in a bag shape by sewing a plurality of skin pieces 11 to 15. All of the skin pieces 11 to 15 are a three-layered skin material in which the fabric skin 1a, the urethane slab 1c, and the closed-cell foam sheet 1b are combined and integrated by heat treatment using the urethane slab 1c as an intermediate layer. Used. The skin material is cut into each skin piece shape.

The fabric skin 1a is a skin formed of a cloth, as in the first embodiment. Fabric skin 1
A back surface of a is lined with a urethane slab 1c and a closed cell type foam sheet 1b to form a fabric base laminate.

The urethane slab 1c is a sheet made of an open-cell urethane foam and has a thickness of about 0.5 mm to 3.0 mm. It is basically the same as that used for the conventional headrest skin 1. The urethane slab 1c is arranged on the back surface of the fabric skin 1a.

The closed cell type foam sheet 1b is a closed cell foam sheet having a predetermined thickness, and is also a foamed polyethylene sheet as in the first embodiment. The thickness of the foam sheet 1b is 0.5 mm to 3 mm.

As described above, for the headrest skin 1, a skin material of a three-layer laminate structure is used, in which the urethane slab 1c is used as an intermediate layer and the fabric skin 1a and the foam sheet 1b are integrally joined together. . The method of forming a three-layer laminate structure can be achieved by a flame treatment (heat treatment) or the like (FIG. 5). For example, the fabric skin 1a is placed and moved on the conveyor K heading rightward in FIG. 5, and the urethane slab 1c is pressed and introduced by the roller R1 on the way. Then, the flame FL is sprayed on the urethane slab surface to be integrally joined before the introduction.
Urethane slab 1c by spraying flame FL
Melts and softens, and the temperature rises to facilitate bonding. After being pressed by the roller R1, the fabric skin 1a and the urethane slab 1c are integrated. Thereafter, the foam sheet 1b is pressed by the roller R2 and introduced into the integrated product of the fabric skin 1a and the urethane slab 1c on the conveyor going rightward. The flame FL is sprayed on the urethane slab 1c surface just before the roller R2. Urethane slab 1c
Is melted and softened, and after being pressed by the roller R2, a skin material having a three-layer structure in which the fabric skin 1a, the urethane slab 1c, and the foam sheet 1b are combined and integrated.

The skin 1 for a headrest uses the skin material having the three-layer structure. The skin material, which is a cloth base material laminate, is cut into a predetermined shape to form a plurality of skin pieces 11 to 15, and the peripheral portions 11 a to 15 a of the adjacent skin pieces 11 to 15 are sewn together to form a bag-shaped headrest skin 1. Becomes Regardless of the production process, the foam sheet 1b of each of the skin pieces 11 to 15 becomes a bag-like skin sewn so as to face the inside of the bag, and the regular headrest skin 1 is completed.
(FIG. 4). The fabric skin 1a, foam sheet 1b, and the like of this embodiment are basically the same as those of the first embodiment, and a detailed description thereof will be omitted. The same reference numerals as those in the first embodiment denote the same or corresponding parts. It should be noted that an adhesive or the like may be used to obtain a skin material having a three-layer laminate structure. However, if the skin material is made by flame treatment as described above, workability is excellent and more preferable.

(3) Effect In the headrest skin 1 configured as described above, since the closed-cell type foam sheet 1b is arranged in the bag (inside), the foam sheet 1b is set in a foaming mold and a foaming material is injected. Even when foam molding is performed, the foaming material does not impregnate or permeate into the foam sheet 1b. Therefore, there is no possibility that the concave portion u is formed as in the related art. This solves the problem of the concave portion u that could not be avoided when the film 1f was used.

Further, when a foamed polyethylene sheet or the like is used as the foamed sheet 1b, the appearance quality is improved. In the case of manufacturing a headrest, a wrinkle SW having an uneven shape as shown in FIG. Wrinkles SW occur when the pattern of the headrest skin 1 is too large or too small for the size (volume) of the foaming mold. Therefore, the pattern was adjusted several times to create a pattern that seemed optimal. Although mass production is performed through such an operation, wrinkles SW still occur at a rate of what percentage. This is affected by the softness of the urethane slab 1c, the variation in sewing, the variation in the elongation of the bag-like skin, the variation in the foaming pressure, the variation in the injection amount of the urethane foaming material, the variation in the urethane shrinkage, environmental conditions, and the like. It is considered that the twist YZ occurs (a in FIG. 6) and the wrinkle SW occurs. It is not yet possible to completely sew the headrest skin 1 with a machine. Sewing relies on human senses, and it is impossible to completely eliminate variations in sewing. Regarding the variation in the elongation of the bag-like epidermis, a two-dimensional one is sewn three-dimensionally in the first place, and is inflated to form. If the elongation balance is poor, excessive force will work and twist YZ
Occurs. Even if the paper pattern is adjusted in units of 1 mm, the conventional method is a molding method with unstable quality which is affected by sewing accuracy and the like. On the other hand, when a foamed polyethylene sheet is used as the foamed sheet 1b as in the present invention, even if the pattern and sewing accuracy are deviated by about 1 mm to 2 mm, the quality is stable without being influenced by the deviation. The foamed polyethylene sheet 1b and the like have a lower stiffness (rigidity) than the soft urethane slab 1c.
There is a certain degree of shape retention. It is possible to produce a stable headrest skin that is not affected by slight variations in sewing and is free from wrinkles SW.

In the present invention, the present invention is not limited to the embodiment described above, and various modifications can be made within the scope of the present invention depending on the purpose and application. The shape, size, number, material, and the like of the headrest skin 1, fabric skin 1a, foam sheet 1b, urethane slab 1c, adhesive 1j, skin pieces 11 to 15, and the like can be appropriately selected according to the application.

[0023]

As described above, the headrest skin according to the present invention does not have any recesses and does not have any wrinkles due to twisting and the like which have conventionally occurred.

[Brief description of the drawings]

FIG. 1 is a plan view of a skin piece constituting a headrest skin in a first embodiment.

FIG. 2 is a partial sectional perspective view of the headrest skin of FIG. 1;

FIG. 3 is a plan view of a skin piece constituting a headrest skin in a second embodiment.

FIG. 4 is a partial sectional perspective view of the headrest skin 1;

FIG. 5 is a schematic explanatory sectional view of a method for manufacturing a skin material used for the headrest skin 1;

FIG. 6 is an explanatory diagram showing a wrinkle occurrence state.

FIG. 7 is an explanatory sectional view around a concave portion.

FIG. 8 is an explanatory cross-sectional view showing a process of generating a concave portion.

[Explanation of symbols]

 Reference Signs List 1 skin for headrest 11-15 skin piece 1a fabric skin 1b foam sheet 1c urethane slab 1f film 1j adhesive

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B60R 21/055 B60R 21/055 N // A47C 7/38 A47C 7/38 F term (Reference) 3B084 CA00 DD04 3B096 AB08 4F100 AK04 AK51C AT00B BA02 BA03 BA07 BA10A BA10B CB00 DG01A DG11A DJ01B DJ02B DJ03C GB33 JL00

Claims (2)

[Claims] 1. A headrest skin formed in a bag-like shape for a headrest of an integral skin-molding type, wherein all of the skin pieces formed into a bag-like shape by sewing a plurality of skin pieces together with a fabric skin. A headrest skin, which is obtained by cutting a two-layered skin material into a predetermined shape by combining and integrating a closed-cell type foam sheet disposed on the back surface of the fabric skin. 2. A headrest skin which is formed in a bag shape for a headrest of an integrated skin type, wherein all of the skin pieces formed in a bag shape by sewing a plurality of skin pieces are made of a fabric skin and urethane. What is claimed is: 1. A skin for a headrest, wherein a skin material having a three-layer structure in which a slab and a closed-cell type foam sheet are combined and integrated with the urethane slab as an intermediate layer is cut into a predetermined shape.