Embedded net injection molding headrest and injection molding process

Abstract

The embedded net injection molding headrest comprises a frame body of a square frame structure and net cloth, the outer edge of the net cloth is attached to the inner edge of the frame body, and the frame body is of a double-layer structure and comprises an inner frame on the inner side and an outer frame wrapping the outer end face of the inner frame; the inner frame and the outer edge of the mesh cloth are connected into a whole in a mesh embedding injection molding mode, and the outer frame and the inner frame are connected into a whole in an insert injection molding mode. According to the embedded net injection molding headrest and the injection molding process, the frame body and the net cloth are connected into a whole in an embedded net injection molding mode, the structural strength is high, and the service life is long; by means of modular production, the labor cost is saved, the production efficiency is extremely high, the tension, the shape and the appearance of screen cloth of each headrest are highly consistent, and better quality control and consistency are achieved; the embedded-net injection-molded headrest is smooth in line in appearance, and has a sense of wholeness and a sense of science and technology in style.

Description

Technical Field

[0001] This invention relates to the field of headrest technology, specifically to a mesh-embedded injection-molded headrest and the injection molding process. Background Technology

[0002] Headrests are common components in chairs used to support the user's head, and they come in various shapes and materials, such as foam headrests, leather headrests, and mesh headrests. Among them, mesh headrests are widely favored by consumers for their comfortable elastic support and breathability. Traditional mesh headrests consist of a square frame and mesh fabric, and are manufactured by hand-stretching the mesh. A groove is cut around the outer edge of the frame. Workers need to cut the mesh fabric to the appropriate size, sew a ring of inserts around the edge of the mesh fabric, and when installing the mesh fabric to the frame, one hand needs to insert the inserts along the edge of the frame into the groove, while the other hand pulls and stretches the mesh fabric until it is fully stretched and the inserts are fully embedded in the groove, completing the mesh fabric assembly of a single headrest.

[0003] Traditional hand-stretched mesh headrests (hereinafter referred to as hand-stretched mesh headrests) have many defects in the production process: First, the production process of hand-stretched mesh headrests is extremely dependent on manual labor. Workers need to insert the inserts into the grooves with one hand and tighten the mesh with the other, which is very complicated and labor-intensive, resulting in low production efficiency and high labor costs. Furthermore, the quality control of hand-stretched mesh headrests is poor, and products made by different workers, or even by the same worker at different times, will vary. In addition, the stress of the headrest is concentrated at the inserts and grooves. After long-term use, the inserts may loosen or even fall off, causing uneven tension in the mesh and localized depressions, affecting support and comfort. In terms of appearance, the connection marks between the inserts and the frame are exposed on the outer edge of the frame, resulting in poor overall integrity, which does not conform to modern aesthetics and cannot meet the needs of users with high requirements for product aesthetics.

[0004] Therefore, how to provide a headrest that can be efficiently and modularly produced, has stable quality, and conforms to mainstream aesthetics has become the main problem that needs to be solved. Summary of the Invention

[0005] In view of the aforementioned defects or deficiencies in the existing technology, it is desirable to provide an embedded mesh injection molded headrest and injection molding process. This process integrates the frame and mesh fabric into a single unit, resulting in a headrest with high structural strength. The mesh fabric is also less prone to detaching from the frame during long-term use, leading to a longer service life. Modular production not only saves labor costs, providing a significant cost advantage in mass production, but also achieves extremely high production efficiency. Furthermore, it ensures high consistency in the mesh fabric tension, shape, and appearance of each headrest, resulting in stable quality and better quality control and consistency. Moreover, the embedded mesh injection molded headrest has no exposed threads or buckles, featuring smooth lines and a more cohesive and technologically advanced style, attracting consumers with high aesthetic demands.

[0006] The effects of this invention are achieved as follows: In a first aspect, this application provides a mesh injection molded headrest, including a square frame structure and a mesh fabric. The outer edge of the mesh fabric is attached to the inner edge of the frame, and the frame has a double-layer structure, including an inner frame on the inner side and an outer frame wrapped around the outer end face of the inner frame. The inner frame and the outer edge of the mesh fabric are connected as a whole by mesh injection molding, and the outer frame and the inner frame are connected as a whole by insert injection molding.

[0007] Furthermore, the frame includes horizontally arranged support sections on the top and bottom sides and vertically arranged support sections on the left and right sides. The horizontal support sections are bent backward, and the vertical support sections are bent forward, causing the top and bottom sides of the mesh fabric to bend backward, and the left and right sides of the mesh fabric to bend forward. This not only provides a comfortable support experience, but also ensures that the mesh fabric is evenly tensioned by the four sides of the frame, making the support force provided by the mesh fabric more uniform and less prone to local collapse.

[0008] Furthermore, both the horizontal and vertical support sections are inclined, and the inclination of the horizontal and vertical support sections is close to the inclination of the mesh on the corresponding side. This makes the distribution of support points of the frame on the mesh more scientific, resulting in higher structural strength, less likelihood of local collapse during use, greater durability, and less likelihood of wrinkles forming at the edges of the mesh, leading to a more refined appearance.

[0009] Secondly, this application provides an injection molding process suitable for mesh-embedded injection molded headrests, characterized by comprising the following steps: S1. Molding inner frame: The mesh fabric is installed on the inner frame injection molding machine. After the fixed mold and moving mold of the inner frame injection molding machine are closed, the material is input into the injection cavity through the gating mechanism and impregnates the mesh fabric in the injection cavity. After the material solidifies, the inner frame is formed. S2. Cutting the mesh fabric: After removing the inner frame from the inner frame injection molding machine, cut off the excess mesh fabric along the outer edge of the inner frame; S3. Molding the outer frame: The inner frame is installed on the outer frame injection molding machine. After the front mold and the rear mold of the outer frame injection molding machine are closed, the material is input into the molding cavity through the gating mechanism and wraps the inner frame inside the molding cavity. After the material solidifies, the outer frame is formed. The outer frame and the inner frame together form the frame body.

[0010] Furthermore, the fixed mold includes a fixed mold core with a raised bottom, and the bottom of the fixed mold core has a recessed area forming an annular upper injection groove. The moving mold includes a moving mold core with a recessed top, and the top of the moving mold core has a recessed area forming an annular lower injection groove. In step S1, the moving mold core presses the mesh fabric upwards against the fixed mold core, and the upper and lower injection grooves combine to form an injection cavity. The fixed mold core not only compresses and evenly tensions the mesh fabric, but also stably clamps the mesh fabric between the fixed mold core and the moving mold core, resulting in more precise positioning and ensuring stable product quality.

[0011] Furthermore, the upper injection groove has a stepped structure. In step S1, after the inner frame is injected by the injection molding machine, the inner frame has a stepped structure that is thicker on the outside and thinner on the inside. This ensures that the outer frame thickness is not too large, and shrinkage pits are less likely to occur after the material cools down, resulting in a smooth outer frame surface and improving the consistency and aesthetics of the frame.

[0012] Furthermore, the bottom of the upper and / or lower injection molding tanks is provided with several columnar openings. In step S1, after the material solidifies, the openings form several combined holes on the inner frame. This allows the inner and outer frames to be more tightly joined, thereby further improving the structural strength of the frame.

[0013] Furthermore, the rear mold is provided with several columnar mounting parts. In step S3, the inner frame is placed on the rear mold, and the mounting parts are snapped onto the inner frame through the combination holes. The combination holes not only enhance the connection strength between the inner and outer frames, but also partially engage with the mounting parts, allowing the inner frame to be positioned more precisely on the rear mold, ensuring the quality of the injection-molded product.

[0014] Furthermore, a positioning component is provided between the fixed mold and the moving mold. The positioning component includes multiple positioning pins vertically positioned on the fixed mold core or the moving mold core. In step S1, the mesh fabric is fixed to the fixed mold or the moving mold by inserting the positioning pins. The installation operation is simple, and the mesh fabric is limited by multiple positioning pins, so it will not move during the injection molding process, and has good stability.

[0015] Furthermore, a positioning component is provided between the fixed mold and the moving mold. The positioning component includes an annular positioning protrusion and a positioning groove. The positioning protrusion is located in one of the fixed mold and the moving mold, and the positioning groove is located in the other of the fixed mold and the moving mold. In step S1, the positioning protrusion presses the mesh fabric tightly against the groove wall of the positioning groove. This not only further and more accurately positions the mesh fabric, ensuring stable product quality after processing, but also further compresses and tensions the mesh fabric around its perimeter with the annular positioning protrusion, resulting in uniform tension. This makes the mesh fabric less prone to localized loosening and deformation after injection molding, providing stronger support and durability.

[0016] Furthermore, positioning protrusions are set on the edge of the fixed mold core, and corresponding recesses are formed on the moving mold core to form positioning grooves. Multiple positioning pins are set on the positioning protrusions. This not only further improves the positioning accuracy, but also ensures that the mesh fabric is stretched more forcefully and evenly, guaranteeing the quality of the processed product; it also ensures that the mesh fabric located on the inner side of the injection cavity remains taut, and makes it less prone to wrinkles in the mesh fabric between the fixed mold core and the moving mold core, ensuring that the processed product has a beautiful appearance.

[0017] Furthermore, the positioning protrusions are composed of multiple positioning blocks arranged at intervals along a ring. The gap between two adjacent positioning blocks forms a clearance opening. In step S1, the wrinkles formed at the edge of the mesh fabric accumulate at the clearance opening. This prevents the wrinkles generated on the mesh fabric from accumulating towards the center of the mesh fabric, ensuring that the mesh fabric between the fixed mold core and the moving mold core remains flat and guaranteeing a beautiful product appearance after processing.

[0018] Furthermore, the mesh thickness is 0.6-0.9mm, and the gap width between the positioning protrusions and the positioning grooves is 0.3-0.5mm. This not only provides greater tension to keep the mesh in the middle fully taut, but also effectively prevents the mesh from shifting during injection molding, further improving positioning accuracy, ensuring product quality, and effectively preventing material leakage from the gap between the positioning protrusions and the positioning grooves during injection molding, thus improving processing accuracy.

[0019] Furthermore, the front mold includes a front mold core with a raised bottom, and a ring-shaped upper molding groove is formed by a recessed bottom of the front mold core. The rear mold includes a rear mold core with a recessed top, and a ring-shaped lower molding groove is formed by a recessed top of the rear mold core. In step S3, the inner frame is engaged with the rear mold core through the lower molding groove. When the front and rear molds are closed, the rear mold core presses the mesh fabric between the inner frames upwards against the front mold core. The upper and lower molding grooves combine to form a molding cavity. The upper and lower molding grooves are not only used to position the inner frame, but the molding cavity formed after combination is used to injection mold the outer frame on the outside of the inner frame, avoiding the exposed mesh wire ends on the inner frame. The frame formed after injection molding has stronger structural strength and a more exquisite appearance. By using two sets of injection molding machines to process the inner and outer frames respectively, processing efficiency is ensured, while also ensuring that the product has extremely high quality control and consistency.

[0020] Furthermore, the upper shaping groove and the lower shaping groove are of a stepped structure, such that when the upper shaping groove and the lower shaping groove are combined, a "convex"-shaped shaping cavity is formed. The upper shaping groove includes an upper positioning portion with a smaller depth on the inner side and an upper shaping portion with a larger depth on the outer side, and the lower shaping groove includes a lower positioning portion with a smaller depth on the inner side and a lower shaping portion with a larger depth on the outer side; in step S3, when the front mold and the rear mold are closed, the inner side of the inner frame is clamped between the upper positioning portion and the lower positioning portion, and the outer side of the inner frame is located between the upper shaping portion and the lower shaping portion. This further improves the positioning accuracy of the inner frame between the front mold core and the rear mold core, avoids loosening of the inner frame due to impact during the injection molding process, and an outer frame is injection-molded between the upper shaping portion and the lower shaping portion, effectively ensuring the quality of the product.

[0021] Furthermore, the front mold further includes a plurality of clamping blocks. A plurality of movable grooves are recessed on the front mold core, elastic members are arranged in the movable grooves, and the clamping blocks are slidably connected to the front mold core up and down through the movable grooves. The elastic force of the elastic members acts on the clamping blocks. In step S3, the clamping blocks press the rear mold downward under the elastic force of the elastic members. This makes the closure between the front mold core and the rear mold core closer, ensuring the quality of the product; moreover, the elastic force of the elastic members provides a buffering force for the mold closing operation of the front mold and the rear mold, effectively reducing mold wear and extending the service life; not only that, when the front mold and the rear mold are separated, the clamping blocks push the rear mold core and the outer frame downward under the elastic force of the elastic members, making the demolding operation smoother.

[0022] The inlaid mesh injection-molded headrest and injection molding process provided by the present application connect the frame body and the mesh fabric into a whole by means of inlaid mesh injection molding, making the inlaid mesh injection-molded headrest have a higher structural strength, and the mesh fabric is not easily loosened from the frame body during long-term use, and has a longer service life. Compared with the existing hand-stretched mesh headrests, the inlaid mesh injection-molded headrests are directly formed by means of injection molds. Although the cost of designing and manufacturing the molds is high, the manufacturing process of the headrests does not rely on manual labor, saving labor costs, and thus having an absolute cost advantage in mass production. The mold production of inlaid mesh headrests has extremely high efficiency and does not depend on manual proficiency. Moreover, with the aid of mold production, the mesh fabric tension, shape, and appearance of each headrest are highly consistent, and the quality is stable. Therefore, compared with hand-stretched mesh headrests, it has better quality control and consistency. Not only that, the outer edge of the mesh fabric is fitted to the inner edge of the frame body, so that there are no redundant threads and buckles exposed on the inlaid mesh injection-molded headrest in terms of appearance, and the lines are smooth, making it more integral and technological in style, attracting more consumers with high requirements for product appearance; Moreover, by setting the frame body as a double-layer structure, the inner frame and the mesh fabric on the inner side are inlaid and injection-molded, and an outer frame is formed by insert injection molding on the outer layer of the inner frame, so that the mesh fabric threads on the inner frame are wrapped and covered by the outer frame, further enhancing the overall sense of the inlaid mesh injection-molded headrest in terms of appearance, ensuring the quality, and also making the frame body have stronger structural strength; Furthermore, the inner frame injection molding machine uses multiple positioning pins to install the mesh fabric. Installation is simple; just align the mesh fabric with the positioning pins and insert it. The mesh fabric is easily installed, and the multiple positioning pins limit its movement during injection molding, ensuring good stability. During mold closing, the fixed mold core not only compresses and evenly tensions the mesh fabric, but also stably holds it between the fixed and moving mold cores, resulting in more precise positioning and consistent product quality. Moreover, there's no need to pre-cut the mesh fabric to a preset shape before injection molding. The mold directly tensions the mesh fabric and injects it into the injection cavity to form the inner frame. The inner frame is then removed from the injection molding machine, and excess mesh fabric is trimmed along the edges to fit the inner frame, significantly simplifying cutting and assembly operations. The upper and lower molding grooves not only position the inner frame but also, when combined, form a molding cavity for injection molding the outer frame. This allows the outer frame to enclose the inner frame, preventing exposed mesh wire ends. The resulting frame has stronger structural strength and a more aesthetically pleasing appearance. By using two sets of injection molding machines to process the inner and outer frames respectively, processing efficiency is ensured, while also ensuring that the products have extremely high quality control and consistency. Attached Figure Description

[0023] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 A three-dimensional structural diagram of the mesh-embedded injection-molded headrest provided in an embodiment of this application; Figure 2 A schematic diagram of the back structure of the mesh-embedded injection-molded headrest provided in an embodiment of this application; Figure 3 A cross-sectional structural diagram of the mesh-embedded injection-molded headrest provided in an embodiment of this application; Figure 4 A three-dimensional structural diagram of an inner frame injection molding machine provided in an embodiment of this application; Figure 5 This is a schematic diagram of the connection structure between the fixed mold and the moving mold provided in an embodiment of this application; Figure 6 This is an enlarged structural diagram of region A provided in an embodiment of this application; Figure 7 This is a three-dimensional structural diagram of the mold provided in an embodiment of this application; Figure 8 A schematic diagram illustrating the state changes of the inner frame injection molding machine before the fixed mold and moving mold are closed, as provided in an embodiment of this application. Figure 9 A schematic diagram illustrating the state changes of the inner frame injection molding machine after the fixed mold and moving mold are closed, as provided in an embodiment of this application. Figure 10 A schematic diagram illustrating the state changes of the inner frame ejection mechanism provided in this application embodiment as it ejects the injection-molded inner frame; Figure 11 A three-dimensional structural diagram of an injection molding machine with an outer frame provided in an embodiment of this application; Figure 12 This is a schematic diagram of the connection structure between the front mold and the rear mold provided in an embodiment of this application; Figure 13 This is an enlarged structural diagram of region B provided in an embodiment of this application; Figure 14 A three-dimensional structural diagram of the front mold provided in the embodiments of this application; Figure 15 This is a schematic diagram of the connection structure between the clamping block and the front mold provided in an embodiment of this application; Figure 16 A schematic diagram illustrating the state changes of the outer frame injection molding machine before the front and rear molds are closed, as provided in an embodiment of this application. Figure 17 A schematic diagram illustrating the state changes of the outer frame injection molding machine after the front and rear molds are closed, as provided in an embodiment of this application. Figure 18 A schematic diagram illustrating the state changes of the outer frame ejection mechanism provided in this application embodiment as it ejects the injection-molded outer frame; Figure 19 This is a schematic diagram of the injection molding process provided in the embodiments of this application.

[0024] The reference numerals in the attached drawings are as follows: 1-Frame, 1a-Horizontal support, 1b-Vertical support, 110-Inner frame, 111-Assembly hole, 120-Outer frame, 2-Mesh fabric, 3-Fixed mold, 310-Fixed mold core, 311-Upper injection groove, 320-Positioning protrusion, 321-Positioning pin, 322-Positioning block, 323-Allowing opening, 330-Opening part, 4-Moving mold, 4a-Moving mold frame, 4b-Moving mold frame base plate, 4c-Ejector pin fixing plate, 410-Moving mold core, 411-Lower... Injection groove, 420-positioning groove, 430-ejector pin, 5-front mold, 510-front mold core, 511-upper molding groove, 512-upper positioning part, 513-upper molding part, 514-moving groove, 520-clamping block, 530-elastic element, 6-rear mold, 6a-rear mold base, 6b-rear mold base plate, 6c-push rod fixing plate, 610-rear mold core, 611-lower molding groove, 612-lower positioning part, 613-lower molding part, 620-mounting part, 630-push rod. Detailed Implementation

[0025] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0026] Please refer to the attached document. Figure 1-19This application provides a mesh injection molded headrest, including a square frame structure 1 and a mesh fabric 2. The outer edge of the mesh fabric 2 is attached to the inner edge of the frame 1. The frame 1 has a double-layer structure, including an inner frame 110 on the inner side and an outer frame 120 wrapped around the outer end face of the inner frame 110. The inner frame 110 and the outer edge of the mesh fabric 2 are connected as a whole by mesh injection molding. The outer frame 120 and the inner frame 110 are connected as a whole by insert injection molding.

[0027] In this embodiment, the frame 1 and the mesh fabric 2 are connected as a whole through embedded injection molding, giving the embedded injection molded headrest high structural strength. The mesh fabric 2 is also less likely to loosen from the frame 1 during long-term use, resulting in a longer service life. Compared to existing hand-stretched mesh headrests, the embedded injection molded headrest is directly formed using injection molds. Although designing and manufacturing the molds incurs costs, the headrest manufacturing process does not rely on manual labor, saving labor costs and thus providing a significant cost advantage in mass production. Mold production of embedded mesh headrests is highly efficient and does not depend on manual skill. Furthermore, mold production ensures that the mesh tension, shape, and appearance of each headrest are highly consistent, resulting in stable quality and better quality control and consistency compared to hand-stretched mesh headrests. Moreover, the outer edge of the mesh fabric 2 fits snugly against the inner edge of the frame 1, eliminating any excess threads or exposed fasteners on the embedded injection molded headrest. The smooth lines create a more cohesive and technologically advanced look, attracting consumers with high aesthetic demands.

[0028] During the mesh injection molding process, since the material used is molten PP or nylon, the molten material will penetrate the mesh fabric 2, resulting in some mesh wire ends still being exposed on the inner frame 110 after cooling and solidification. Therefore, by setting the frame 1 as a double-layer structure, the inner frame 110 and the mesh fabric 2 are embedded and injection molded, and the outer frame 120 is formed by injection molding the outer insert of the inner frame 110, so that the mesh wire ends on the inner frame 110 are wrapped and covered by the outer frame 120, which further improves the overall appearance of the mesh injection molded headrest, ensures quality, and also makes the frame 1 have stronger structural strength.

[0029] Please refer to the attached document. Figure 1-3In some embodiments of this application, the frame 1 includes horizontally arranged horizontal support portions 1a on the upper and lower sides and vertically arranged vertical support portions 1b on the left and right sides. The horizontal support portions 1a are bent backward, and the vertical support portions 1b are bent forward, causing the upper and lower sides of the mesh fabric 2 to bend backward, and the left and right sides of the mesh fabric 2 to bend forward. This makes the mesh fabric 2 not only protrude forward relative to the horizontal support portions 1a, thereby better supporting and conforming to the user's head, but also bend backward relative to the vertical support portions 1b on both sides, so that the user's head can be naturally placed in the middle of the mesh fabric 2. This not only provides a comfortable support experience, but also makes the mesh fabric 2 evenly tensioned by the four sides of the frame 1, so that the support force provided by the mesh fabric 2 is more uniform, and the mesh fabric 2 is not prone to local collapse after long-term use.

[0030] Please refer to the attached document. Figure 1-3 In some embodiments of this application, both the horizontal support 1a and the vertical support 1b are inclined, and the inclination of the horizontal support 1a and the vertical support 1b is close to the inclination of the mesh fabric 2 on the corresponding side. This makes the distribution of support points of the frame 1 on the mesh fabric 2 more scientific, resulting in higher structural strength, less likelihood of local collapse during use, and greater durability. Furthermore, it reduces the likelihood of wrinkles forming at the edges of the mesh fabric 2, resulting in a more aesthetically pleasing appearance.

[0031] Please refer to the attached document. Figure 4-17 This application also provides an injection molding process suitable for mesh-embedded injection molded headrests, characterized by including the following steps: S1. Molding inner frame 110: The mesh fabric 2 is installed on the inner frame injection molding machine. After the fixed mold 3 and the moving mold 4 of the inner frame injection molding machine are closed, the material is input into the injection cavity through the gating mechanism and impregnates the mesh fabric 2 in the injection cavity. After the material solidifies, the inner frame 110 is formed. S2. Cutting the mesh fabric 2: After taking the inner frame 110 out of the inner frame injection molding machine, cut off the excess mesh fabric 2 along the outer edge of the inner frame 110. S3. Molding outer frame 120: The inner frame 110 is installed on the outer frame injection molding machine. After the front mold 5 and the rear mold 6 of the outer frame injection molding machine are closed, the material is input into the molding cavity through the gating mechanism and wraps the inner frame 110 inside the molding cavity. After the material solidifies, the outer frame 120 is formed. The outer frame 120 and the inner frame 110 together form the frame 1.

[0032] In this embodiment, the headrest is manufactured using a modular production method, which saves labor costs while achieving high production efficiency. Before injection molding, there is no need to pre-cut the mesh fabric 2 to a preset shape. The mold directly stretches the mesh fabric 2 and injects it into the injection cavity to form the inner frame 110. The inner frame 110 is then removed from the inner frame injection molding machine, and excess mesh fabric 2 is trimmed along the edges to fit the shape of the mesh fabric 2 to the inner frame 110, thus greatly simplifying the cutting and assembly operations. Using two sets of injection molding machines to process the inner frame 110 and the outer frame 120 respectively ensures extremely high product quality control and consistency.

[0033] The gating mechanisms used on the inner frame injection molding machine and the outer frame injection molding machine are common runner and gate structures on molds in the prior art, and will not be described in detail in this embodiment.

[0034] Please refer to the attached document. Figure 7-9 In some embodiments of this application, the fixed mold 3 includes a fixed mold core 310 with a raised bottom, and the bottom of the fixed mold core 310 is recessed to form an annular upper injection groove 311. The moving mold 4 includes a moving mold core 410 with a recessed top, and the top of the moving mold core 410 is recessed to form an annular lower injection groove 411. In step S1, the moving mold core 410 presses the mesh fabric 2 upward against the fixed mold core 310, and the upper injection groove 311 and the lower injection groove 411 combine to form an injection cavity.

[0035] In this embodiment, during the mold closing process, the fixed mold core 310 can not only squeeze and evenly tension the mesh fabric 2, but also the mesh fabric 2 is stably clamped between the fixed mold core 310 and the moving mold core 410, resulting in more accurate positioning and ensuring stable product quality.

[0036] The fixed mold core 310 and the moving mold core 410 are shaped to fit the preset shape of the headrest mesh fabric 2, that is, they present an arc-shaped structure with the front and rear sides curving upwards and the left and right sides curving downwards. The upper injection groove 311 and the lower injection groove 411 are also inclined according to the preset shape of the frame 1.

[0037] Please refer to the appendix. Figure 11 The inner frame injection molding machine is also equipped with an inner frame ejection mechanism. The moving mold 4 includes a moving mold frame 4a at the top for mounting the moving mold core 410 and a moving mold frame base plate 4b at the bottom. An ejector pin fixing plate 4c is provided between the moving mold frame 4a and the moving mold frame base plate 4b. The ejector pin fixing plate 4c is driven to move up and down by a hydraulic or pneumatic mechanism. Multiple vertical ejector pins 430 are fixedly connected to the top of the ejector pin fixing plate 4c. The ejector pins 430 pass upward through the moving mold core 410, and the top surface of the ejector pins 430 and the bottom of the lower injection groove 411 are connected to a complete plane. After the inner frame injection molding machine completes the injection molding, the moving mold 4 and the fixed mold 3 separate, the inner frame ejection mechanism is activated, and the ejector pin fixing plate 4c slides upward, so that the ejector pins 430 can be ejected upward, thereby lifting the inner frame 110 upward until it is separated from the moving mold 4, making it convenient for the operator to remove the injection-molded product.

[0038] Please refer to the attached document. Figure 9 In some embodiments of this application, the upper injection groove 311 has a stepped structure. In step S1, after the inner frame is injected by the injection molding machine, the inner frame 110 has a stepped structure that is thick on the outside and thin on the inside.

[0039] In this embodiment, to ensure overall strength and product aesthetics, the outer thickness of the frame 1 is relatively large. However, if the outer frame 120 surrounding the inner frame 110 is too thick, the material in the thicker areas will shrink after cooling during injection molding, causing sink marks to easily form on the surface of the outer frame 120, affecting its appearance. Therefore, by injection molding the inner frame 110 into a stepped structure, the thickness of the outer frame 120 is not excessive, making it less prone to sink marks after material cooling. This results in a smooth surface for the outer frame 120, improving the consistency and aesthetics of the frame 1.

[0040] Please refer to the attached document. Figure 5 Appendix Figure 7 and appendix Figure 11 In some embodiments of this application, the bottom of the upper injection molding tank 311 and / or the lower injection molding tank 411 is provided with a plurality of columnar openings 330. In step S1, after the material solidifies, the openings 330 form a plurality of combined holes 111 on the inner frame 110.

[0041] In this embodiment, by setting the opening 330 to form a combined hole 111 on the inner frame 110, when the inner frame 110 is put into the outer frame injection molding machine for the second injection, the material flows into the combined hole 111. After solidification, part of the outer frame 120 is formed in the combined hole 111, thereby making the inner frame 110 and the outer frame 120 more tightly connected, thereby further improving the structural strength of the frame 1.

[0042] Preferably, the bottom of both the upper injection groove 311 and the lower injection groove 411 is provided with an opening 330. When the mold is closed, the two openings 330 that are opposite each other are joined together, so that the combined hole 111 formed on the inner frame 110 after injection molding is a through hole, thereby making the outer frame 120 and the inner frame 110 more tightly joined, and further improving the structural strength of the frame 1.

[0043] Please refer to the attached document. Figure 12-13 In some embodiments of this application, the rear mold 6 is provided with a plurality of columnar mounting members 620. In step S3, the inner frame 110 is placed on the rear mold 6, and the mounting members 620 are snapped onto the inner frame 110 through the combination holes 111. The combination holes 111 are not only used to improve the connection strength between the inner frame 110 and the outer frame 120, but also partially engage with the mounting members 620, so that the inner frame 110 can be more accurately positioned on the rear mold 6, ensuring the quality of the injection-molded product.

[0044] Preferably, the rear mold 6 includes an annular lower molding groove 611, and a plurality of mounting parts 620 are disposed in the lower molding groove 611. When the inner frame 110 is snapped into the rear mold 6 through the lower molding groove 611, the mounting parts 620 are snapped into the combination hole 111.

[0045] Please refer to the attached document. Figure 7-8, in some embodiments of the present application, a positioning component is provided between the fixed mold 3 and the moving mold 4. The positioning component includes multiple positioning pins 321 vertically arranged on the fixed mold core 310 or the moving mold core 410. In step S1, the mesh cloth 2 is fixed to the fixed mold 3 or the moving mold 4 by inserting and connecting through the positioning pins 321.

[0046] In this embodiment, the inner frame injection molding machine installs the mesh cloth 2 through multiple positioning pins 321. When installing the mesh cloth 2, it only needs to be aligned with the positioning pins 321 and inserted. The installation operation is simple, and the mesh cloth 2 is limited by multiple positioning pins 321 and will not move during the injection molding process, so the stability is relatively good.

[0047] Please refer to the appendix Figure 7-9 , in some embodiments of the present application, a positioning component is provided between the fixed mold 3 and the moving mold 4. The positioning component includes an annular positioning protrusion 320 and a positioning groove 420. The positioning protrusion 320 is provided on one of the fixed mold 3 and the moving mold 4, and the positioning groove 420 is opened on the other of the fixed mold 3 and the moving mold 4; in step S1, the positioning protrusion 320 presses the mesh cloth 2 against the groove wall of the positioning groove 420.

[0048] In this embodiment, by providing the positioning protrusion 320 and the positioning groove 420 that are engaged with each other, not only can the mesh cloth 2 be further accurately positioned, making the mesh cloth 2 not easy to move during the injection molding process and ensuring the quality stability of the processed product. And when the positioning protrusion 320 is inserted into the positioning groove 420, the four sides of the mesh cloth 2 are further squeezed and tensioned by the annular positioning protrusion 320, with uniform tension, making the mesh cloth 2 after injection molding not easy to produce local relaxation and deformation, and having stronger support and durability.

[0049] Please refer to the appendix Figure 7-8 , in some embodiments of the present application, the positioning protrusion 320 is provided on the edge of the fixed mold core 310, and a corresponding depression is formed on the moving mold core 410 to form the positioning groove 420. Multiple positioning pins 321 are provided on the positioning protrusion 320.

[0050] In this embodiment, by providing the positioning protrusion 320 on the edge of the protruding fixed mold core 310, that is, when the fixed mold 3 and the moving mold 4 are clamped, the mesh cloth 2 is bent in a "V" shape under the extrusion of the positioning protrusion 320 and the fixed mold core 310, which not only further improves the positioning accuracy, but also can tension the mesh cloth 2 more powerfully and evenly to ensure the quality of the processed product. And when the mesh cloth 2 is under tension, with the area surrounded by the positioning pins 321 as the boundary, the inner mesh cloth 2 is tightened after being squeezed, while the outer mesh cloth 2 remains loose, and wrinkles are likely to occur at the boundary between the tightened part and the loose part; therefore, by providing the positioning pins 321 on the positioning protrusion 320, it is ensured that the inner mesh cloth 2 located in the injection cavity position remains tightened, and the mesh cloth 2 between the fixed mold core 310 and the moving mold core 410 is not easy to produce wrinkles, ensuring the beautiful appearance of the processed product.

[0051] Of course, in other embodiments of this application, the positioning protrusion 320 may also be provided on the moving mold core 410, and the positioning groove 420 may be provided on the fixed mold core 310.

[0052] Please refer to the attached document. Figure 7 In some embodiments of this application, the positioning protrusion 320 is composed of a plurality of positioning blocks 322 arranged in a ring at intervals, and the interval area between two adjacent positioning blocks 322 forms a clearance opening 323. In step S1, the folds formed by the edge of the mesh fabric 2 accumulate in the clearance opening 323.

[0053] In this embodiment, after the mesh fabric 2 between the positioning pins 321 is tensioned, the mesh fabric 2 near the positioning pins 321 is prone to wrinkles. By forming a relief opening 323 between the positioning blocks 322 to accommodate the wrinkles, the wrinkles generated on the mesh fabric 2 are not easy to accumulate towards the middle side of the mesh fabric 2. That is, the mesh fabric 2 between the fixed mold core 310 and the moving mold core 410 can remain flat, ensuring that the processed product has a beautiful appearance.

[0054] Please refer to the attached document. Figure 9 In some embodiments of this application, the thickness of the mesh fabric 2 is 0.6-0.9 mm, and the gap width between the positioning protrusion 320 and the positioning groove 420 is 0.3-0.5 mm. The gap between the positioning protrusion 320 and the positioning groove 420 is narrower than the thickness of the mesh fabric 2, meaning the mesh fabric 2 can be more firmly clamped between the positioning protrusion 320 and the groove wall of the positioning groove 420. This not only provides greater tension to keep the mesh fabric 2 fully taut, but also effectively prevents the mesh fabric 2 from shifting during injection molding, further improving positioning accuracy and ensuring product quality. Furthermore, the tight fit between the positioning protrusion 320, the mesh fabric 2, and the positioning groove 420 effectively prevents material leakage from the gap between the positioning protrusion 320 and the positioning groove 420 during injection molding, improving processing accuracy.

[0055] Please refer to the attached document. Figure 12-13 In some embodiments of this application, the front mold 5 includes a front mold core 510 with a raised bottom, and a ring-shaped upper molding groove 511 is formed in the bottom recess of the front mold core 510. The rear mold 6 includes a rear mold core 610 with a recessed top, and a ring-shaped lower molding groove 611 is formed in the top recess of the rear mold core 610. In step S3, the inner frame 110 is engaged with the rear mold core 610 through the lower molding groove 611. When the front mold 5 and the rear mold 6 are closed, the rear mold core 610 presses the mesh 2 between the inner frames 110 upwards against the front mold core 510. The upper molding groove 511 and the lower molding groove 611 combine to form a molding cavity.

[0056] In this embodiment, the upper shaping groove 511 and the lower shaping groove 611 are not only used to position the inner frame 110, but also form a shaping cavity after combination for injection molding an outer frame 120 on the outer side of the inner frame 110, so that the outer frame 120 can wrap the inner frame 110, avoiding the exposure of the wire leads on the inner frame 110. After injection molding, the formed frame body 1 has stronger structural strength and a beautiful appearance. By using two injection molding machines to process the inner frame 110 and the outer frame 120 respectively, while ensuring the processing efficiency, the product also has extremely high quality control and consistency.

[0057] Among them, the shapes of the front mold core 510 and the rear mold core 610 fit the preset shape of the mesh fabric 2 on the headrest, that is, an arc structure with the front and rear sides bent upward and the left and right sides bent downward. And the upper shaping groove 511 and the lower shaping groove 611 are also inclined according to the preset shape of the frame body 1.

[0058] Among them, please refer to the appendix Figure 18 , an outer frame ejection mechanism is also provided on the outer frame injection molding machine. The rear mold 6 includes a rear mold frame 6a for installing the rear mold core 610 at the top and a rear mold frame bottom plate 6b at the bottom. A push rod fixing plate 6c is provided between the rear mold frame 6a and the rear mold frame bottom plate 6b. The push rod fixing plate 6c is lifted up and down by a hydraulic or pneumatic mechanism. A plurality of vertical push rods 630 are fixedly connected to the top of the push rod fixing plate 6c. The push rods 630 pass through the rear mold core 610 upward, and the top surface of the push rods 630, the bottom of the lower shaping groove 611 and the top surface of the rear mold core 610 are connected into a complete plane. After the outer frame injection molding machine finishes injection molding, the rear mold 6 and the front mold 5 are separated. After the outer frame ejection mechanism is started, the push rod fixing plate 6c slides upward, so that the push rods 630 can push upward, thereby lifting the outer frame 120 upward to separate from the rear mold 6, facilitating the staff to remove the injection molded product.

[0059] Please refer to the appendix [[ID=1十二]] Figure 17 , in some embodiments of the present application, the upper shaping groove 511 and the lower shaping groove 611 are of a stepped structure, so that the upper shaping groove 511 and the lower shaping groove 611 form a "convex"-shaped shaping cavity after combination. The upper shaping groove 511 includes an upper positioning part 512 with a smaller inner depth and an upper shaping part 513 with a larger outer depth. The lower shaping groove 611 includes a lower positioning part 612 with a smaller inner depth and a lower shaping part 613 with a larger outer depth; in step S3, when the front mold 5 and the rear mold 6 are closed, the inner side of the inner frame 110 is clamped between the upper positioning part 512 and the lower positioning part 612, and the outer side of the inner frame 110 is located between the upper shaping part 513 and the lower shaping part 613.

[0060] In this embodiment, by setting the plastic cavity into a "convex" shape structure, during the injection molding process, the inner side of the inner frame 110 is clamped between the upper positioning portion 512 and the lower positioning portion 612, thereby further improving the positioning accuracy of the inner frame 110 between the front mold core 510 and the rear mold core 610, avoiding loosening of the inner frame 110 due to impact during the injection molding process, and injecting to form the outer frame 120 between the upper plastic molding portion 513 and the lower plastic molding portion 613, effectively ensuring the quality of the product.

[0061] Please refer to the attached Figure 14-17 , in some embodiments of the present application, the front mold 5 further includes a plurality of clamping blocks 520. A plurality of movable grooves 514 are recessed on the front mold core 510. An elastic member 530 is disposed in the movable grooves 514, and the clamping blocks 520 are slidably connected to the front mold core 510 through the movable grooves 514 up and down. The elastic force of the elastic member 530 acts on the clamping blocks 520. In step S3, the clamping blocks 520 are pressed downward against the rear mold 6 under the elastic force of the elastic member 530.

[0062] In this embodiment, during the injection molding process, the clamping blocks 520 are pressed downward against the rear mold core 610 under the elastic force of the elastic member 530, making the closure between the front mold core 510 and the rear mold core 610 tighter, effectively avoiding material leakage and ensuring the quality of the product. Moreover, the elastic force of the elastic member 530 provides a buffering force for the mold closing operation of the front mold 5 and the rear mold 6, effectively reducing mold wear and extending the service life. Not only that, when the front mold 5 and the rear mold 6 are separated, the clamping blocks 520 push the rear mold core 610 and the outer frame 120 downward under the elastic force of the elastic member 530, making the outer frame 120 more smoothly ejected from the plastic cavity and the demolding operation more smooth.

[0063] Among them, preferably, three groups of clamping blocks 520 are provided on the front mold 5. The bottom ends of the clamping blocks 520 are recessed, and when the molds are closed, the recessed portions of the clamping blocks 520 and the upper plastic molding groove 511 are connected as a whole. The elastic member 530 is a spring, which not only has strong elasticity, but also the clamping blocks 520 are fixed to the front mold 5 by bolts, and the elastic member 530 is sleeved on the bolts, which is convenient for installation and can smoothly push the front mold 5 to slide up and down along the bolts.

[0064] It should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., used above to indicate orientation or positional relationships are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, unless otherwise stated, "a plurality of" means three or more.

[0065] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in this application.

Claims

1. A mesh-embedded injection-molded headrest, characterized in that, The frame includes a square frame structure (1) and a mesh fabric (2). The outer edge of the mesh fabric (2) is attached to the inner edge of the frame (1). The frame (1) is a double-layer structure, including an inner frame (110) on the inner side and an outer frame (120) wrapped around the outer end face of the inner frame (110). The inner frame (110) and the outer edge of the mesh fabric (2) are connected as a whole by mesh injection molding. The outer frame (120) and the inner frame (110) are connected as a whole by insert injection molding.

2. The mesh-embedded injection-molded headrest according to claim 1, characterized in that, The frame (1) includes a horizontal support part (1a) arranged horizontally on the upper and lower sides and a vertical support part (1b) arranged vertically on the left and right sides. The horizontal support part (1a) is bent backward and the vertical support part (1b) is bent forward, so that the upper and lower sides of the mesh fabric (2) are bent backward and the left and right sides of the mesh fabric (2) are bent forward.

3. The mesh-embedded injection-molded headrest according to claim 2, characterized in that, Both the horizontal support (1a) and the vertical support (1b) are inclined, and the inclination of the horizontal support (1a) and the vertical support (1b) is close to the inclination of the mesh (2) on the corresponding side.

4. An injection molding process applicable to the mesh-embedded injection molded headrest as described in any one of claims 1-3, characterized in that, Includes the following steps: S1. Molding inner frame (110): The mesh (2) is installed on the inner frame injection molding machine. After the fixed mold (3) and moving mold (4) of the inner frame injection molding machine are closed, the material is input into the injection cavity through the pouring mechanism and the mesh (2) in the injection cavity is impregnated. After the material solidifies, the inner frame (110) is formed. S2. Cutting the mesh (2): After taking the inner frame (110) out of the inner frame injection molding machine, cut off the excess mesh (2) along the outer edge of the inner frame (110). S3, Molding outer frame (120): The inner frame (110) is installed on the outer frame injection molding machine. After the front mold (5) and rear mold (6) of the outer frame injection molding machine are closed, the material is input into the molding cavity through the gating mechanism and wraps the inner frame (110) inside the molding cavity. After the material solidifies, the outer frame (120) is formed. The outer frame (120) and the inner frame (110) together form the frame (1).

5. The injection molding process according to claim 4, characterized in that, The fixed mold (3) includes a fixed mold core (310) with a raised bottom. The bottom of the fixed mold core (310) is recessed to form an annular upper injection groove (311). The moving mold (4) includes a moving mold core (410) with a recessed top. The top of the moving mold core (410) is recessed to form an annular lower injection groove (411). In step S1, the moving mold core (410) presses the mesh fabric (2) upward against the fixed mold core (310). The upper injection groove (311) and the lower injection groove (411) combine to form an injection cavity.

6. The injection molding process according to claim 5, characterized in that, The upper injection groove (311) has a stepped structure. In step S1, after the inner frame is injected by the injection molding machine, the inner frame (110) has a stepped structure with a thicker outer side and a thinner inner side.

7. The injection molding process according to claim 5, characterized in that, The bottom of the upper injection tank (311) and / or the lower injection tank (411) is provided with a number of columnar openings (330). In step S1, after the material solidifies, the openings (330) form a number of combined holes (111) on the inner frame (110).

8. The injection molding process according to claim 7, characterized in that, The rear mold (6) is provided with several columnar mounting parts (620). In step S3, the inner frame (110) is placed on the rear mold (6), and the mounting parts (620) are snapped onto the inner frame (110) through the combination hole (111).

9. The injection molding process according to claim 4, characterized in that, A positioning component is provided between the fixed mold (3) and the moving mold (4). The positioning component includes multiple positioning pins (321) that are vertically positioned on the fixed mold core (310) or the moving mold core (410). In step S1, the mesh fabric (2) is fixed to the fixed mold (3) or the moving mold (4) by inserting the positioning pins (321).

10. The injection molding process according to claim 4, characterized in that, A positioning component is provided between the fixed mold (3) and the moving mold (4). The positioning component includes an annular positioning protrusion (320) and a positioning groove (420). The positioning protrusion (320) is located in one of the fixed mold (3) and the moving mold (4), and the positioning groove (420) is located in the other of the fixed mold (3) and the moving mold (4). In step S1, the positioning protrusion (320) presses the mesh fabric (2) against the groove wall of the positioning groove (420).

11. The injection molding process according to claim 10, characterized in that, The positioning protrusion (320) is located on the edge of the fixed mold core (310), and the corresponding recess on the moving mold core (410) forms a positioning groove (420). Multiple positioning pins (321) are provided on the positioning protrusion (320).

12. The injection molding process according to claim 10, characterized in that, The positioning protrusion (320) is composed of multiple positioning blocks (322) arranged in a ring-shaped interval. The interval area between two adjacent positioning blocks (322) forms a clearance opening (323). In step S1, the folds formed by the edge of the mesh fabric (2) accumulate in the clearance opening (323).

13. The injection molding process according to claim 10, characterized in that, The thickness of the mesh (2) is 0.6-0.9 mm, and the gap width between the positioning protrusion (320) and the positioning groove (420) is 0.3-0.5 mm.

14. The injection molding process according to claim 4, characterized in that, The front mold (5) includes a front mold core (510) with a raised bottom. The bottom of the front mold core (510) is recessed to form an annular upper molding groove (511). The rear mold (6) includes a rear mold core (610) with a recessed top. The top of the rear mold core (610) is recessed to form an annular lower molding groove (611). In step S3, the inner frame (110) is snapped onto the rear mold core (610) through the lower molding groove (611). When the front mold (5) and the rear mold (6) are closed, the rear mold core (610) presses the mesh fabric (2) between the inner frames (110) upwards onto the front mold core (510). The upper molding groove (511) and the lower molding groove (611) combine to form a molding cavity.

15. The injection molding process according to claim 14, characterized in that, The upper shaping groove (511) and the lower shaping groove (611) are of a stepped structure, so that a "convex"-shaped shaping cavity is formed after the upper shaping groove (511) and the lower shaping groove (611) are combined. The upper shaping groove (511) includes an upper positioning portion (512) with a smaller inner depth and an upper shaping portion (513) with a larger outer depth. The lower shaping groove (611) includes a lower positioning portion (612) with a smaller inner depth and a lower shaping portion (613) with a larger outer depth. In step S3, when the front mold (5) and the rear mold (6) are closed, the inner side of the inner frame (110) is clamped between the upper positioning portion (512) and the lower positioning portion (612), and the outer side of the inner frame (110) is located between the upper shaping portion (513) and the lower shaping portion (613).

16. The injection molding process according to claim 14, characterized in that, The front mold (5) further includes a plurality of clamping blocks (520). A plurality of movable grooves (514) are recessed on the front mold core (510). Elastic members (530) are arranged in the movable grooves (514), and the clamping blocks (520) are slidably connected to the front mold core (510) up and down through the movable grooves (514). The elastic force of the elastic members (530) acts on the clamping blocks (520). In step S3, the clamping blocks (520) press the rear mold (6) downward under the elastic force of the elastic members (530).

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