JP3439886B2 - Vehicle headrest and method of manufacturing the same - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle headrest excellent in productivity and exhibiting a sufficient soft feeling, and a manufacturing method thereof.

[0002]

2. Description of the Related Art A vehicle headrest is known in which a molded core made of foamed synthetic resin is integrally incorporated into a sewing cover in a state in which an embedded base of a stay metal fitting is embedded therein. In this type of conventional vehicle headrest, a sewing cover is set in the mold with the upper part of the stay fitting placed inside, and the synthetic foam resin solution is injected into this sewing cover, and this synthetic foam resin solution reacts. Then, a molded core body made of a foamed synthetic resin is molded inside the sewing cover. However, in such a conventional vehicle headrest, the foam synthetic resin stock solution may impregnate the sewing cover or leak from the seam during the foaming process, and as a result, the surface is hardened and the quality is deteriorated. There was a problem.

For the purpose of preventing impregnation of the foam synthetic resin stock solution into the sewing cover, an inner bag made of an expandable film is arranged inside the sewing cover, and the foam synthetic resin stock solution is injected inside the inner bag. A method of foaming (see, for example, JP-A-6
No. 2-156915) or a part of the insert part is formed with a recess for temporarily storing the expanded synthetic resin stock solution, and the expanded synthetic resin stock solution is once foamed and then overflowed. A method has been proposed in which the sewing cover is filled with water (see, for example, Japanese Patent Laid-Open No. 6-143300), but it is possible to prevent the foaming synthetic resin stock solution from completely impregnating the sewing cover or leaking the liquid from the seam. There was a problem that it was difficult to prevent. In addition, the molded core body made of expanded synthetic resin inside the sewing cover has a substantially same degree of foaming, but there is a problem that a sufficient soft feeling cannot be obtained because the surface layer portion integrated with the sewing cover is cured. However, in order to solve this, it is necessary to previously provide a wadding layer or a slab foam layer on the back side of the sewing cover, which causes a problem of poor productivity.

[0004]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional problems and can completely prevent impregnation of a synthetic synthetic resin foam solution into a sewing cover and liquid leakage from a seam. , A headrest for a vehicle that can obtain a sufficient soft feeling without preliminarily providing a wadding layer or a slab foam layer on the back side of the sewing cover, and that is excellent in productivity and can significantly reduce costs. It was completed for the purpose of providing the manufacturing method.

[0005]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention has a molded cover made of a foamed synthetic resin inside a sewing cover, in which an embedded base portion of a stay fitting is embedded. In the headrest that is integrally packaged as a state, the molded core comprises a high-density middle core that fills the inside of the inner bag and a low-density outer core that fills between the inner bag and the sewing cover. , The high-density inner core and the low-density outer core are the textures or stitches of the cloth or knitted fabric arranged in the inner bag .
The first invention is a vehicle headrest, characterized in that it is connected by a connecting portion made of a foamed synthetic resin that fills pores . A large number of pores for the fabric and stitches
The inner bag and the embedded base of the stay metal fitting are arranged and set, and the undiluted synthetic resin foam solution is injected into the inner bag. By foaming while flowing out between the inner bag and the sewing cover through the pores, a high-density core body that fills the inside of the inner bag inside the sewing cover and a low-density outer core that fills between the inner bag and the sewing cover. A second aspect of the present invention is a method of manufacturing a vehicle headrest, which comprises molding a molded core body made of a foamed synthetic resin that is linked to the core body by a linking portion that fills the pores.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION In the first aspect of the present invention, a high-density core body filling the inside of the inner bag and a low-density outer core body filling the space between the inner bag and the sewing cover are made of the same raw material. Although not limited thereto, the inner bag is provided with pores, and the high-density middle core body and the low-density outer core body are connected by a connecting portion made of a foamed synthetic resin filling the pores. As long as the inner bag is made of any material, the molded core is surely integrated with the inner bag, and the foam synthetic resin material is injected into the inner bag opening 1 Since it only has to be performed from a location, it is more preferable because it is convenient in manufacturing.

Embodiments of the present invention will be described below with reference to the drawings. The drawing shows a headrest for an automobile using polyurethane foam as a foamed synthetic resin. In the figure, reference numeral 1 denotes a sewn cover 2 made of a fabric material sewn into a predetermined shape, and a molded core made of a foamed synthetic resin. 4 is a stay metal fitting in which an embedded base portion is embedded, and the above configuration is basically the same as that of the conventional foam synthetic resin headrest of this kind.

The present invention is characterized by the structure of the molded core body 4 made of a foamed synthetic resin serving as a cushion layer. That is, the molded core body 4 according to the present invention has a high-density middle core body 4a that fills the inside of the inner bag 3 so that the inner and outer foaming degrees of the inner bag 3 are different, the inner bag 3 and the sewing cover 2. The outer core body 4b has a low density and fills the space between the outer core body 4b and the upper part of the stay metal fitting 1 which is an insert part. The surface is in close contact with and integrated with the sewing cover 2. As a result, the outer surface portion against which the occupant's head hits exerts an appropriate elasticity as a headrest by the low-density outer core body 4b, and the center portion has the high-density middle core body 4b.
With a, sufficient strength is maintained.

The inner bag 3 is constructed so as to have pores 3a through which the expanded synthetic resin stock solution can permeate, and the expanded synthetic resin stock solution supplied into the bag passes through the pores 3a at a foaming pressure during foaming. It is for flowing out to the outside of the inner bag 3 so as to foam and fill between the sewing cover 2 and the inner bag 3. As shown in FIG. Those made of a synthetic resin film or non-woven fabric such as vinyl chloride resin in which a large number of pores 3a are arranged, or as shown in FIG. 3, cloths or stitches made of pores 3a through which a foamed synthetic resin stock solution can pass. And knitted fabrics are used.

Next, a method of manufacturing the vehicle headrest as described above will be described. First, as shown in FIG. 4, a sewing cover 2 made of a fabric material sewn into a predetermined shape is formed together with an upper portion of the stay metal fitting 1 in a molding die. 10, 10
The inner bag 3 having the pores 3a through which the undiluted urethane solution can permeate is set in the center of the sewing cover 2 so that the opening 3b is outside the mold. Then, the raw material injection head 11 is inserted from the opening 3b of the inner bag 3 to inject and mold the foamed synthetic resin stock solution, and the foamed synthetic resin stock solution is subjected to foaming treatment by a conventional method. As the viscosity increases, the liquid expands and at the same time, a part of the expanded synthetic resin stock solution in the process of foaming flows out of the inner bag 3 through the pores 3a due to the expansion force. Then, the undiluted foamed synthetic resin liquid in the middle of foaming that has continued to foam further fills this space between the sewing cover 2 and the inner bag 3, and the upper portion of the stay metal fitting 1, the sewing cover 2 and the urethane foam are integrally formed by foam molding. Will be molded.

In the molded core body 4 of the headrest thus formed, the pores 3a of the inner bag 3 limit the exudation of the expanded synthetic resin stock solution to the outside of the bag. Is a high-density core body 4a, while the outside of the inner bag is a low-density outer core body 4b formed by further foaming a small amount of the undiluted synthetic resin stock solution that has flowed out through the pores 3a. In addition to being molded to a density, the pores 3 of the inner bag 3 are
The low-density outer core body 4b that has flowed out between the inner bag 3 and the sewing cover 2 through a is foamed in the inner bag 3 in a state where the viscosity has already risen. There is no impregnation or liquid leakage from the seams, and the fabric and seams of the sewing cover 2 do not harden, so that no special wadding layer or slab foam layer is provided on the back side of the sewing cover 2 in advance. Even so, a sufficient soft feeling can be obtained.

[0012]

As is apparent from the above description, the first
According to the invention of claim 1, the impregnation of the expanded synthetic resin stock solution into the sewing cover and the leakage of the liquid from the seam are completely prevented, and it is possible to obtain a sufficient softness without preliminarily providing a wadding layer or a slab foam layer on the back side of the sewing cover. You can get a feeling, and also
A second aspect of the present invention is capable of mass-producing the vehicle headrest as described above efficiently and achieving a significant cost reduction. Therefore, the present invention, as a vehicle headrest and a method for manufacturing the same that eliminates the conventional problems, is extremely important in contributing to industrial development.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view showing an example of a vehicle headrest of the present invention.

FIG. 2 is a perspective view showing an example of an inner bag according to the present invention.

FIG. 3 is a perspective view showing another example of the inner bag according to the present invention.

FIG. 4 is a process explanatory view showing a state before foaming in the method for manufacturing a vehicle headrest of the present invention.

FIG. 5 is a process explanatory view showing a state during foaming in the method for manufacturing a vehicle headrest of the present invention.

[Explanation of symbols]

1 stay bracket 2 sewing cover 3 inner bag 4 Molded core 4a high-density core 4b Low density outer core 4c connection part

Claims (2)

(57) [Claims] 1. A headrest in which a sewn cover (2) has a molded core body (4) made of foamed synthetic resin enclosed and integrated therein with an embedded base portion of a stay metal fitting (1) embedded therein. The molded core body (4) is a high-density middle core body (4a) that fills the inside of the inner bag (3), and the inner bag (3) and the sewing cover.
(2) consisting of a low-density outer core (4b) that fills the space between the high-density middle core (4a) and a low-density outer core (4b) in the inner bag (3). Micropores (3a) that are used as a texture or stitch of a woven fabric or knitted fabric
A vehicle headrest characterized in that it is connected by a connecting portion (4c) made of foamed synthetic resin that fills the vehicle. 2. A sewing cover is provided in the forming die, and a cloth is provided therein.
The inner bag in which a large number of pores such as fabrics and knits such as fabrics and knits are arranged and set, and the embedded base of the stay metal fitting is arranged and set, and the synthetic foam resin is injected into the inner bag, and the synthetic foam resin is formed. The undiluted solution is filled in the inner bag by allowing the undiluted solution to react inside the inner bag and causing a part of it to flow between the inner bag and the sewing cover through the pores with the foaming pressure to fill the inside of the inner bag with high density. A vehicle headrest, characterized in that a molded core body made of a foamed synthetic resin in which a core body, a lower density outer core body filling the space between the inner bag and the sewing cover are connected by a connecting portion filling the pores is formed. Manufacturing method.