JPH05115332A - Manufacture of head rest or the like - Google Patents

Abstract

PURPOSE:To provide a manufacturing method of a head rest the like with excellent appearance and quality by preventing a skin from waving in shape. CONSTITUTION:A pair of split dies having a cavity for molding a head rest or the like is opened and a core body for reinforcement is arranged with a support in the split dies. Thereafter, the split dies are closed, then, a foam resin material is injected to fill a gap between the core body for reinforcement and the surfaces of the dies, and a cushion member is formed in the core body for reinforcement by foaming integrally. In a production method of such a type, the core body 1 for reinforcement is a hollow body with one side 11 thereof almost projecting while the other side 12 facing the side 11 is almost recessed or almost planar and one reinforcing part 13 or more (for example, a pair of first and second protrutions 14 and 15 sticking inwardly with tips thereof welded) is formed between the side 11 and the other side 12.

Description

【発明の詳細な説明】Detailed Description of the Invention

【０００１】[0001]

【産業上の利用分野】本発明は車両（特に自動車）用ヘ
ッドレスト、アームレスト等の製造方法に関し、更に詳
しく言えば、外観の優れたヘッドレスト等を製造する方
法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a headrest, an armrest and the like for vehicles (particularly automobiles), and more particularly to a method of manufacturing a headrest and the like having an excellent appearance.

【０００２】[0002]

【従来の技術】ヘッドレスト等の補強用芯体は、通常、
横断面が傘状をしたものが用いられている（特開昭５７
−２０３４０７号公報、特開昭６３−１５１４１３号公
報、実開昭５５−１６６５５６号公報等）。また、近年
はヘッドレストを図１に示すシートバック５の上部前方
に収納するために、このヘッドレストの横断面形状を前
面側を凸状面とし、後面側を略凹面状若しくは平面状と
するものも知られている。この場合、通常、このヘッド
レスト形状に合わせて補強用芯体も略同形状とされる。2. Description of the Related Art Reinforcing cores such as headrests are usually
An umbrella-shaped cross section is used (JP-A-57 / 57).
-203407, JP-A-63-151413, JP-A-55-166556, etc.). Further, in recent years, in order to store the headrest in the upper front part of the seat back 5 shown in FIG. 1, the headrest may have a cross-sectional shape in which the front surface side is a convex surface and the rear surface side is a substantially concave surface or a flat surface. Are known. In this case, usually, the reinforcing core is also made to have substantially the same shape according to the shape of the headrest.

【０００３】[0003]

【発明が解決しようとする課題】しかし、前記補強用芯
体の凹面状又は平面状の面は、補強用芯体を包むことに
なるクッション部を成形する時に、発泡樹脂原料の発泡
による圧力により変形し、たわみ易い。この現象は、補
強用芯体の面がより深い凹面状（全体として三日月状）
になればなる程著しい。従って、ヘッドレスト等の脱型
後、発泡圧に対しての型による反力が無くなるので、該
補強用芯体の形状はほぼ復元し、該補強用芯体を包んで
いるクッション部が局部的に変形する。そのため、表面
の一部は波を打った形状となり、外観に優れず、品質が
低下することとなる。However, the concave or flat surface of the reinforcing core is formed by the pressure generated by the foaming of the foamed resin raw material when forming the cushion portion that encloses the reinforcing core. Deforms and bends easily. The phenomenon is that the surface of the reinforcing core is deeper concave (generally crescent shaped).
The more it becomes, the more remarkable it becomes. Therefore, after the headrest or the like is removed from the mold, the reaction force generated by the mold against the foaming pressure disappears, so that the shape of the reinforcing core body is substantially restored, and the cushion portion enclosing the reinforcing core body is locally localized. Deform. Therefore, a part of the surface has a wavy shape, which is not good in appearance and deteriorates in quality.

【０００４】本発明は、上記欠点を克服するものであ
り、表面が波を打った形状となるのを防止し、外観及び
品質の優れたヘッドレスト等の製造方法を提供すること
を目的とする。The present invention overcomes the above-mentioned drawbacks, and an object of the present invention is to provide a method for manufacturing a headrest or the like which has an excellent appearance and quality by preventing the surface from becoming wavy.

【０００５】[0005]

【課題を解決するための手段】本発明のヘッドレスト等
の製造方法は、成形用キャビティを有する一対の割型を
開き、該割型内に支柱を備える補強用芯体を配設し、そ
の後、該割型を閉じ、該割型に設けられた注入口より発
泡樹脂原料を注入、充填し、クッション部を一体に発泡
成形してなるヘッドレスト等の製造方法において、前記
補強用芯体は、一面が略凸面状で且つ該一面と対向する
他面が略凹面状若しくは略平面状である中空体であり、
該一面と該他面間には１以上の補強部が形成されている
ことを特徴とする。ここで、「ヘッドレスト等」とは、
ヘッドレスト以外にもアームレスト等をも含み、またク
ッション部の表面を覆う表皮の有無も問わない。更に、
この表皮を有する場合は、パリソンを用いて型内にて一
体的に形成してもよいし、後工程にて縫製等により装着
してもよい。According to a method of manufacturing a headrest or the like of the present invention, a pair of split molds having a molding cavity is opened, a reinforcing core body provided with a column is disposed in the split molds, and thereafter, In the method for manufacturing a headrest or the like, in which the split mold is closed, a foamed resin raw material is injected and filled through an injection port provided in the split mold, and the cushion portion is integrally foam-molded, the reinforcing core is one side Is a hollow body having a substantially convex surface and the other surface facing the one surface is a substantially concave surface or a substantially flat surface,
One or more reinforcing portions are formed between the one surface and the other surface. Here, "headrest etc." means
In addition to the headrest, an armrest and the like are included, and the presence or absence of an epidermis covering the surface of the cushion portion is not required. Furthermore,
When this skin is provided, it may be integrally formed in the mold using a parison, or may be attached by sewing or the like in a later step.

【０００６】[0006]

【作用】本発明のヘッドレスト等の製造方法において使
用する補強用芯体は、一面が略凸面状で且つ該一面と対
向する他面が略凹面状若しくは略平面状である中空体で
あり、該一面と該他面間には１以上の補強部が形成され
ているものである。従って、発泡樹脂原料が発泡する工
程においてこの両面がほとんどたわむことがないので、
脱型時に元の位置に戻るための変形を生じることが少な
いか又はほとんどない。The reinforcing core body used in the method for manufacturing a headrest or the like of the present invention is a hollow body having one substantially convex surface and the other surface facing the one surface having a substantially concave or substantially planar shape. One or more reinforcing portions are formed between one surface and the other surface. Therefore, in the process of foaming the foamed resin raw material, both sides hardly bend,
There is little or no deformation to return to the original position when demolding.

【０００７】[0007]

【実施例】以下、実施例により本発明を、図に基づいて
具体的に説明する。本実施例で用いる補強用芯体１は、
図２（正面図）及び図１（図２のＡ−Ａ矢視断面図を示
す芯体を含む。）に示すように、全体に横長（幅約２２
５ｍｍ、高さ約１４０ｍｍ、最大厚み約５５ｍｍ）で、
その横断面形状は、三日月状、即ち、一面（人頭部受け
面、以下前面という。）１１が凸状面をし、その反対側
の他面（以下、後面という。）１２が凹面状をしてお
り、金属製又はポリプロピレン等の硬質樹脂製の中空体
を示している。EXAMPLES The present invention will be described below in detail with reference to the drawings based on examples. The reinforcing core 1 used in this example is
As shown in FIG. 2 (front view) and FIG. 1 (including a core body showing a cross-sectional view taken along the line AA of FIG. 2), the whole is horizontally long (width about 22).
5mm, height about 140mm, maximum thickness about 55mm),
The cross-sectional shape thereof is a crescent shape, that is, one surface (human head receiving surface, hereinafter referred to as the front surface) 11 is a convex surface, and the other surface on the opposite side (hereinafter referred to as the rear surface) 12 is a concave surface. It shows a hollow body made of metal or a hard resin such as polypropylene.

【０００８】また、この前面１１と後面１２間には、４
つの補強部１３が、ピッチ４５ｍｍで等間隔になるよう
に且つ略中央高さに形成されている。この補強部１３
は、内側に突出する第１突出部１４と、この後面１２に
も、内側に突出し第１突出部１４に対向する位置に形成
される第２突出部１５とからなり、そして第１突出部１
４の先端と第２突出部１５の先端とが溶着された構成
（溶着部は１６）となっている。尚、この前面１１に凹
部１４ａが、後面１２にも凹部１５ａが形成されてい
る。Between the front surface 11 and the rear surface 12, 4
The one reinforcing portion 13 is formed at a pitch of 45 mm and at equal intervals and at a substantially central height. This reinforcement 13
Is composed of a first protrusion 14 that protrudes inward, and a second protrusion 15 that is also formed on the rear surface 12 at a position that protrudes inward and faces the first protrusion 14, and the first protrusion 1
The tip of No. 4 and the tip of the second protruding portion 15 are welded (welded portion is 16). The front surface 11 is formed with a recess 14a, and the rear surface 12 is also formed with a recess 15a.

【０００９】そして、本実施例にて製造されるヘッドレ
スト（幅約２８０ｍｍ、高さ約１７０ｍｍ、最大厚み約
７３ｍｍ、クッション部の前面側厚さ１５ｍｍ、後面側
厚さ３ｍｍ）は、図１に示すように、前記補強用芯体１
と、補強用芯体１を略相似形状に取り囲む発泡ウレタン
製クッション部３と、補強用芯体１に固定され且つ相手
シートにヘッドレストを脱着可能に取り付けるための支
柱４と、からなる。尚、頭部を受ける前面側厚さは通常
１０〜２０ｍｍ程度とされる。また、本実施例において
は、クッション部３の表面を覆う表皮は構成されていな
い、いわゆる裸ヘッドレストとしたが、多くは（特に最
終製品としては）、表皮が被覆される。この表皮の材質
としては、樹脂、織布又は樹脂フィルムをラミネートし
た織布等を使用でき、またこの形成方法も公知のパリソ
ンを用いた一体成形方法又は後工程の縫製による方法等
を用いることができる。The headrest manufactured in this embodiment (width approximately 280 mm, height approximately 170 mm, maximum thickness approximately 73 mm, cushion part front side thickness 15 mm, rear side thickness 3 mm) is shown in FIG. So that the reinforcing core 1
And a cushion portion 3 made of urethane foam that surrounds the reinforcing core 1 in a substantially similar shape, and a column 4 that is fixed to the reinforcing core 1 and that detachably attaches a headrest to a mating seat. The thickness of the front side that receives the head is usually about 10 to 20 mm. Further, in this embodiment, a so-called bare headrest is used in which the skin covering the surface of the cushion portion 3 is not formed, but in most cases (especially as a final product), the skin is covered. As the material of the outer skin, a resin, a woven fabric, a woven fabric laminated with a resin film, or the like can be used, and this forming method is also a known integral molding method using a parison or a sewing method in a later step. it can.

【００１０】次に、前記補強用芯体１を用いたヘッドレ
ストの製造方法は、以下の通りである。まず、図４に示
すように、割型８１が開かれた状態において、補強用芯
体１が支持装置７によって所定の位置空間にセットさ
れ、その後割型８１を閉じる。次いで、図５に示すよう
に、この補強用芯体１と型面との空隙に、割型に設けら
れた注入口８２よりウレタン原料３ａを注入、充填し、
クッション部を一体に発泡成形して、本ヘッドレストを
製造した。本ヘッドレストにおいては、補強用芯体を包
んでいるクッション部の変形がほとんど認められず、そ
の結果、表皮においても波打ち形状が、目視上ほとんど
認められなかった。従って、外観に優れ且つ高品質なヘ
ッドレストを製造できた。Next, a method of manufacturing a headrest using the reinforcing core 1 is as follows. First, as shown in FIG. 4, in the state where the split mold 81 is opened, the reinforcing core 1 is set in a predetermined position space by the support device 7, and then the split mold 81 is closed. Next, as shown in FIG. 5, the urethane raw material 3a is injected and filled into the space between the reinforcing core 1 and the mold surface from the injection port 82 provided in the split mold,
The headrest was manufactured by integrally foam-molding the cushion portion. In this headrest, almost no deformation of the cushion portion wrapping the reinforcing core was observed, and as a result, almost no wavy shape was visually observed in the epidermis. Therefore, it was possible to manufacture a high-quality headrest having an excellent appearance.

【００１１】尚、（１）他の実施例として、適度な間隔
（ピッチ９０ｍｍ）を備える２対の補強部を有すること
以外は前記と同じ補強用芯体を用いた場合、（２）比較
例として、補強部を全く有しないが全体としては同形状
の補強用芯体を用いた場合について、前記と同様にヘッ
ドレストを成形して、比較してみた。その結果、前記他
の実施例におけるヘッドレストでは、この補強部間に若
干の変形があり、表皮に若干Ｗ型の波打ち形状（最大深
さ；約４ｍｍ程度）を認め、厚さは８１ｍｍで、前述の
設計値７３ｍｍよりも８ｍｍの膨らみがあったが、後述
する比較例の場合と比べてその変形程度は小さかった。
一方、この比較例の場合は、全体に大きく湾曲した凸形
状のように変形し、最大変形深さ（大きさ）は約１０ｍ
ｍであり、厚さは９０ｍｍで前述の設計値よりも１７ｍ
ｍの膨らみがあった。(1) As another embodiment, in the case of using the same reinforcing core as described above except that it has two pairs of reinforcing portions having an appropriate interval (pitch 90 mm), (2) Comparative Example As a comparison, a headrest was molded in the same manner as described above and a comparison was made in the case of using a reinforcing core having the same shape as a whole but having no reinforcing portion. As a result, in the headrest of the other embodiment, there is some deformation between the reinforcing portions, a slight W-shaped wavy shape (maximum depth; about 4 mm) is recognized in the skin, and the thickness is 81 mm. The swelling was 8 mm larger than the designed value of 73 mm, but the degree of deformation was smaller than that of the comparative example described later.
On the other hand, in the case of this comparative example, the entire shape is deformed like a convex shape, and the maximum deformation depth (size) is about 10 m.
m, the thickness is 90 mm, which is 17 m more than the above design value.
There was a bulge of m.

【００１２】尚、本発明においては、前記具体的実施例
に示すものに限られず、目的、用途に応じて本発明の範
囲内で種々変更した実施例とすることができる。即ち、
前記のような補強用芯体を使用すること以外の各製造工
程は、公知の種々の工程を使用できる。補強用芯体の形
状、大きさ若しくは材質、又は補強部の大きさ、形状、
数若しくは配設場所、更に突出部の大きさ、形状等は特
に問わない。例えば、補強用芯体の一面を構成する略凸
面の形状も、前記実施例形状のもの以外に、図３に示す
ような略椀形状でもよいし、半球状その他の形状でもよ
い。また、この他面も種々の凹面形状とできるし、図３
に示すような平面状とすることもできる。突出部として
は、前記のような面の一部を窪ませて反対側に突き出す
ような形状に限定されず、窪みのない柱状、略錐状、そ
の他の形状のものでもよいし、一対の突出部の先端は接
合（溶着、熔接、接着等は問わない。）されず、当接す
るようにしてもよい。また、補強部としては、図３に示
すように、一対の突出部を有せずに、一対の面１１、１
２を連結する１つの棒状体、管状体等１３ａでもよい。The present invention is not limited to the specific examples described above, and various modifications may be made within the scope of the present invention depending on the purpose and application. That is,
Various known steps can be used for each manufacturing step other than the use of the reinforcing core body as described above. The shape, size or material of the reinforcing core, or the size, shape of the reinforcing portion,
The number or place of arrangement, and the size and shape of the protruding portion are not particularly limited. For example, the shape of the substantially convex surface forming one surface of the reinforcing core may be a bowl shape as shown in FIG. 3, a hemispherical shape, or the like other than the shape of the above embodiment. In addition, the other surface can also have various concave shapes, and FIG.
Alternatively, it may have a planar shape as shown in. The protrusion is not limited to a shape in which a part of the surface is depressed and protrudes to the opposite side as described above, and may be a columnar shape without depressions, a substantially conical shape, or another shape, or a pair of protrusions. The tips of the parts may be in contact with each other without being joined (welding, welding, bonding, etc.). Further, as the reinforcing portion, as shown in FIG. 3, the pair of surfaces 11, 1 is provided without having the pair of protruding portions.
It may be one rod-shaped body or a tubular body 13a that connects the two.

【００１３】[0013]

【発明の効果】以上のように、本製造方法によれば補強
部により対向する面が相互に支持しあうので、製造工程
中、補強用芯体の変形がほとんど認められず、そのため
製造されるヘッドレスト等の表面においても波打ち形状
等の変形がほとんど認められない。従って、外観及び品
質の優れたヘッドレスト等の製品が得られる。As described above, according to the present manufacturing method, since the opposing surfaces are mutually supported by the reinforcing portion, the reinforcing core is hardly deformed during the manufacturing process, and therefore the manufacturing is performed. Almost no deformation such as wavy shape is observed on the surface of the headrest or the like. Therefore, a product such as a headrest excellent in appearance and quality can be obtained.

【図面の簡単な説明】[Brief description of drawings]

【図１】実施例における補強用芯体を備えるヘッドレス
トの横断面図である。FIG. 1 is a cross-sectional view of a headrest including a reinforcing core according to an embodiment.

【図２】実施例において用いた補強用芯体の正面図であ
る。FIG. 2 is a front view of a reinforcing core body used in Examples.

【図３】突出部を有せずに１本の棒状体等からなる補強
部を使用した補強用芯体の断面図である。FIG. 3 is a cross-sectional view of a reinforcing core body using a reinforcing portion formed of a single rod-shaped body or the like without having a protruding portion.

【図４】実施例において割型内に補強用芯体をセットし
た状態を示す説明断面図である。FIG. 4 is an explanatory cross-sectional view showing a state in which a reinforcing core body is set in a split mold in the example.

【図５】実施例において発泡樹脂原料の注入状態を示す
説明断面図である。FIG. 5 is an explanatory cross-sectional view showing an injection state of a foamed resin raw material in an example.

【符号の説明】[Explanation of symbols]

１；補強用芯体、１１；一面、１２；他面、１３；補強
部、１４；第１突出部、１５；第２突出部、１４ａ、１
５ａ；先端部、１６；溶着部、３；クッション部、４；
支柱、７；支持装置、８１；割型。DESCRIPTION OF SYMBOLS 1; Reinforcing core body, 11; One surface, 12; Other surface, 13; Reinforcing portion, 14; First protruding portion, 15; Second protruding portion, 14a, 1
5a; tip part, 16; welded part, 3; cushion part, 4;
Post, 7; support device, 81; split mold.

Claims (1)

【特許請求の範囲】[Claims] 【請求項１】 成形用キャビティを有する一対の割型を
開き、該割型内に支柱を備える補強用芯体を配設し、そ
の後、該割型を閉じ、該割型に設けられた注入口より発
泡樹脂原料を注入、充填し、クッション部を一体に発泡
成形してなるヘッドレスト等の製造方法において、 前記補強用芯体は、一面が略凸面状で且つ該一面と対向
する他面が略凹面状若しくは略平面状である中空体であ
り、該一面と該他面間には１以上の補強部が形成されて
いることを特徴とするヘッドレスト等の製造方法。1. A pair of split molds having a molding cavity are opened, a reinforcing core body provided with struts is disposed in the split molds, and then the split molds are closed, and a casting provided on the split molds. In a method of manufacturing a headrest or the like in which a foamed resin raw material is injected from an inlet, filled, and a cushion part is integrally foam-molded, the reinforcing core body has a substantially convex one surface and the other surface facing the one surface. A method for manufacturing a headrest or the like, which is a hollow body having a substantially concave surface or a substantially flat surface, wherein one or more reinforcing portions are formed between the one surface and the other surface.