JP3171705B2 - Method of manufacturing retractable headrest - Google Patents

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 headrest having a pillow and a stay protruding from the bottom surface of the pillow, the headrest being attached to an upper portion of an automobile seat by the stay. The present invention relates to a method of manufacturing a tiltable headrest whose angle can be adjusted.

[0002]

2. Description of the Related Art The foldable headrest can adjust the angle of the pillow according to the occupant's physique and taste, so that the pillow can always be set at the correct angle or the desired angle, and is excellent in safety and comfort. .

[0003] FIG. 8 shows one that is used as a retractable headrest. The foldable headrest is provided with a pillow 80 in which a cushion pad of urethane foam or the like is covered with a skin, a stay 82 made of a metal pipe having an upper part buried in the pillow 80, and an upper part of the stay 82. And an angle adjusting device 84 housed in the pillow 80.

[0004] Conventionally, there are the following methods for manufacturing a retractable headrest having the above-described structure. First, a plastic hollow body for surrounding and sealing the angle adjusting device on the upper portion of the stay is formed by blow molding (hollow molding) of plastic. Next, the upper part of the angle adjustment device and the stay sealed with the plastic hollow body is arranged in a foaming mold, and a cushion pad material such as a urethane foam material is injected into the mold. Then, foam is formed around the plastic hollow body to form a cushion pad integrated with the plastic hollow body, the angle adjusting device, and the stay.

[0005] After that, the periphery of the stay projection on the bottom surface of the cushion pad and the bottom surface of the plastic hollow body is punched by a hot blade to form a rotation space of the stay when the angle is adjusted. Finally, cover the surface of the cushion pad with a skin to obtain a retractable headrest.

However, in the above-mentioned manufacturing method, the angle adjusting device on the upper portion of the stay is previously provided so that the cushion pad material does not enter into the angle adjusting device during foam molding of the cushion pad and the angle adjusting device becomes defective. Must be surrounded and sealed with a plastic hollow body, and additionally, the periphery of the stay projection on the bottom surface of the plastic hollow body and the bottom surface of the cushion pad must be punched with a hot blade, which is troublesome. In addition, there is a problem that the outer skin has to be put on after work, and the work takes time.

Further, when the bottom surface of the plastic hollow body and the bottom surface of the cushion pad are punched by the hot blade as described above,
There is also a problem that smoke is generated and the smoke adheres to the outer surface of the stay and discolors the plating on the outer surface of the stay. Furthermore, after the angle adjusting device was once sealed with a plastic hollow body, the operation of the angle adjusting device could not be confirmed until the punching by the hot blade after the cushion pad molding was completed. Therefore, even if a malfunction occurs in the angle adjustment device during sealing etc.,
The cushion pad is formed using the angle adjusting device having the problem, and there is much waste.

[0008]

SUMMARY OF THE INVENTION Accordingly, the present invention has been made to solve the above-mentioned problems, and provides a method for manufacturing a foldable headrest with a simple operation and without causing discoloration of a stay. It is.

[0009]

SUMMARY OF THE INVENTION The present invention has a pillow having a cushion pad covered with a skin and a stay protruding from the bottom surface of the pillow, and an angle adjusting device for the pillow is provided on an upper portion of the stay. In the method of manufacturing a retractable headrest stored in a pillow, a box-shaped hollow core body having only a bottom surface opened and an outer peripheral edge of the opening serving as a flange is inserted into a bag-shaped outer skin having an open bottom surface. Then, the opening periphery of the skin is overlapped with the flange bottom surface of the hollow core to form a cushion pad forming space between the hollow core and the inner surface of the skin, and then cushion material is injected into the cushion pad forming space. The cushion pad is formed by foaming, and then the angle adjusting device on the upper portion of the stay is inserted into the hollow core through the opening on the bottom surface of the hollow core together with the upper portion of the stay. Finally, the stay insertion hole is formed. Plates, characterized in that fixed to the flange of the hollow core bottom through the stay.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a perspective view showing one embodiment of a method for manufacturing a retractable headrest according to the present invention, showing a state where a hollow core is inserted into a skin. FIG. 2 is a cross-sectional view showing the same embodiment after the hollow core body is inserted. FIG. 3 is a cross-sectional view of a foaming mold during cushion pad molding in the embodiment. FIG. 4 is a sectional view showing the cushion pad after molding in the same example. FIG. 5 is a perspective view showing the same embodiment when the angle adjusting device is inserted. FIG.
It is sectional drawing which follows the -6 line. FIG. 7 is a sectional view of the foldable headrest obtained in the embodiment.

First, as shown in FIG.
0, the hollow core 10 and the skin 20 are inserted as shown in FIG.
A cushion pad formation space 21 is formed between the inner surfaces. The hollow core body 10 is a box-shaped body whose periphery is surrounded by a wall surface and only the bottom surface is opened, and the outer periphery of the opening 12 is a flange 14 and is made of plastic. A hook 16 is formed on the outer surface of the upper portion and side portions of the hollow core body 10.
The hook 16 is for increasing the bonding force between the cushion pad and the hollow core body 10 described later, and is not limited to this shape. For example, it may be a hook-shaped one or a protruded one with an enlarged tip. Further, a screw hole 19 for fixing a plate, which will be described later, is formed in the flange 14 of the hollow core body.
A notch 18 for injecting a cushion pad material is formed. The notch 18 is not limited to a semicircle as in this embodiment, and may be a hole when the width of the flange 14 is large. The box shape of the hollow core body 10 is not limited to that of this embodiment, but may be a flat cylindrical shape.

A sealing member 11 made of a soft foam having a shape substantially equal to that of the flange 14 is adhered to the bottom surface of the flange 14 of the hollow core. The sealing material 11 is bonded by an adhesive tape or an adhesive.
The sealing material 11 has a bottom surface 13 opposite to the flange 14.
Is also provided with an adhesive tape or an adhesive. Reference numeral 15 denotes a notch for injecting a cushion pad material, which is formed in accordance with the notch 18 for injecting a cushion pad material formed in the hollow core body 10. 17 is a screw insertion hole for fixing the plate. The sealing material 11
Is to improve the seal between the flange 14 and the peripheral edge of the opening of the skin 20 at the time of forming the cushion pad, which will be described later, and to reliably prevent leakage of the cushion pad forming material. It may not be necessary if good sealing properties can be obtained depending on the material of the skin 20 or the skin 20.

The skin 20 is formed in a bag shape with an open bottom surface, and a cushion pad raw material injection hole 26 and a screw insertion hole 28 for fixing a plate are formed on the periphery 24 of the opening. The opening 22 on the bottom surface of the skin 20 has a size that allows the hollow core 10 to be inserted. In addition, the opening peripheral edge 24 is the hollow core 1
The sealing material 11 is superimposed on the bottom surface of the flange 14 via the sealing material 11 and adhered to the sealing material bottom surface 13 with an adhesive tape or the like. At this time, the cushion pad material injection hole 26 of the skin 20 is located at the same position as the cushion pad material cutouts 15 and 18 of the sealing material 11 and the hollow core 10.

The skin 20 may be a plastic product formed by blow molding or the like, or a two- or three-layer skin component piece in which a soft foam sheet or a plastic film is laminated on the back surface of the fabric. May be.

Next, as shown in FIG. 3, the hollow core body 10 and the skin 20 combined as described above are
Place within. Then, from the nozzle 33 of the foam injection machine inserted into the cushion pad raw material injection port 26 of the skin 20,
A cushion pad material 32 such as a urethane foam material is injected into a cushion pad forming space 21 in the skin 20 and foamed. Thereby, the cushion pad 30 is formed between the hollow core body 10 and the skin 20 as shown in FIG.
The headrest pillow 34 is obtained. The cushion pad 30 and the hollow core 10 are securely connected by the adhesiveness generated when the cushion pad raw material 32 is foamed, and by the engagement between the hook 16 of the hollow core 10 and the cushion pad 30.

Thereafter, as shown in FIG. 5, the angle adjusting device 50 provided on the upper portion of the stay 40 is inserted into the hollow core 10 through the opening 12 on the bottom surface of the hollow core 10 together with the upper portion of the stay. The stay 40 is formed of a metal pipe bent in a U-shape similarly to the stay 82 shown in FIG.

As shown in FIG. 6, which shows a cross section of the angle adjusting device 50, the upper portion 42 of the stay 40 is sandwiched between plastic plates 52, 52 made of polyacetal or the like, and the plastic plates 52, 52 are metal panels 54, 54. Between the metal panels 54, 54 and the plastic plate 5
2, 52 are fastened with bolts 56 and nuts 58. The angle adjusting device 50 is provided on the upper part 4 of the stay.
Rotation is made back and forth around the axis 2, and at this time, the positioning is performed steplessly by the frictional force between the stay upper portion 42 and the plastic plates 52, 52.

Openings 55 are formed in the bottom surfaces of the metal panels 54, 54 so that the stay 40 does not hit when the angle adjusting device 50 rotates. The outer peripheral edge of the opening 55 constitutes a flange-shaped mounting portion 57, and the mounting portion 57 is overlapped on the flange 14 of the hollow core 10 via the opening peripheral edge 24 of the skin 20 and the sealing material 11. It has become. Further, a screw insertion hole 59 for fixing the plate is formed in the mounting portion 57 as shown in FIG.

The shape of the metal panels 54, 54 is such that at least a part of the outer surface is in close contact with the wall surface of the hollow core 10, so that the angle adjusting device 50 is housed in the hollow core 10 without rattling. Is preferred. In addition, the outer sides of the metal panels 54, 54 are covered with a plastic box so as to enable the storage without rattling, so that the metal panel 54 comes into close contact with the wall surface of the hollow core 10 via the plastic box. It may be.

Subsequently, as shown in FIGS. 5 and 6, a plastic or metal plate 60 in which a stay insertion hole 62 and a screw insertion hole 64 are formed is passed through the stay 40 and the bottom surface of the angle adjusting device 50 is formed. On the mounting portion 57 of The mounting portion 57 and the opening edge 2 of the skin 20
The plate 60 is fixed to the flange 14 of the hollow core body 10 with the screw 70 via the seal member 4 and the seal member 11, thereby obtaining a foldable headrest of the final product.

The foldable headrest thus manufactured is attached to the seat with the stay 40 inserted through the upper part of the seat back of the automobile. Then, depending on the physique or preference of the occupant, the upper part of the pillow 34 of the headrest is pushed back and forth, and the pillow 34 is rotated to a predetermined angle and a predetermined position with respect to the seat back.

The present invention is not limited to the above embodiment. The angle adjusting device is not limited to the one in the above-described embodiment, and may be any device that can adjust the angle of the pillow back and forth with respect to the stay. For example, a gear or the like may be used.

[0023]

As shown and described above, according to the present invention, the operation of enclosing and sealing the angle adjusting device with hollow plastic becomes unnecessary, and further, after the cushion pad is formed, the hollow plastic and the bottom surface of the cushion pad are removed. It is not necessary to perform the work of punching the headrest with a hot blade, so that the foldable headrest can be obtained very easily. Moreover,
Since the angle adjusting device is not surrounded and sealed with hollow plastic, the operation of the angle adjusting device can be checked before forming the cushion pad, and the cushion pad can be formed using only a well-operationed one. To manufacture a retractable headrest. Further, the stay can be prevented from being discolored, which is apt to occur at the time of punching by the hot blade in the related art, and a reversible headrest of good quality can be obtained.

[Brief description of the drawings]

FIG. 1 is a perspective view showing one embodiment of a manufacturing method of the present invention and showing a state where a hollow core is inserted into a skin.

FIG. 2 is a sectional view showing a state after inserting a hollow core body in the embodiment.

FIG. 3 is a cross-sectional view of a foaming mold during cushion pad molding in the example.

FIG. 4 is a cross-sectional view showing a state after cushion pad molding in the example.

FIG. 5 is a perspective view showing the same embodiment when the angle adjusting device is inserted.

FIG. 6 is a sectional view taken along line 6-6 in FIG. 5;

FIG. 7 is a cross-sectional view of the retractable headrest obtained in the embodiment.

FIG. 8 is a perspective view of a retractable headrest.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Hollow core body 14 Flange at the bottom of hollow core body 20 Skin 21 Space for cushion pad formation 22 Opening of skin 24 Opening edge of skin 30 Cushion pad 34 Pillow 40 Stay 50 Angle adjuster 60 Plate 62 Stay insertion hole

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ identification code FI // B29K 105: 04 B29L 31:58 (58) Fields investigated (Int.Cl. ⁷ , DB name) B29C 39/10 B29C 39 / 22-39/24 A47C 7/38 B60R 21/055 B60N 2/48 B68G 7/06

Claims (1)

(57) [Claims] 1. A pillow having a pillow in which a cushion pad is covered with a skin and a stay protruding from a bottom surface of the pillow, wherein an angle adjusting device for adjusting an angle of the pillow is provided on an upper portion of the stay. In the method of manufacturing a retractable headrest housed in a box-shaped hollow core having only a bottom surface opened and an outer peripheral edge of the opening serving as a flange, inserted into a bag-shaped outer skin having an open bottom surface, The peripheral edge of the opening of the skin is overlapped with the bottom surface of the flange of the hollow core to form a cushion pad forming space between the hollow core and the inner surface of the skin, and a cushion pad material is injected into the cushion pad forming space. The cushion pad is formed by foaming, and the angle adjusting device on the upper portion of the stay is inserted into the hollow core through the opening on the bottom of the hollow core together with the upper portion of the stay. Retractable manufacturing method of the headrest, characterized in that through a serial stay fixed to the flange of the hollow core base.