Headrest manufacturing method

Abstract

To provide a headrest for vehicle seat capable of suppressing a hard spot from being formed and a method of manufacturing the same.SOLUTION: A frame 10 of a headrest 1 has a pair of main parts 10c, 10d. A tension tape 13 is adjusted between the pair of main parts 10c, 10d. A skin 11 is constituted in a bag body to house the main parts 10c, 10d of the frame 10 and a coupling part, and the tension tape 13 inside. A pad 12 is formed by injecting a fluid raw material from a raw material injection hole 11d of the skin 11 to bury the main parts 10c, 10d of the frame 10 and the coupling part, and the tension tape 13. The raw material injection hole 11d of the skin 11 is provided at a position facing a tension part 13c of the tension tape 13 at an interval in a Z direction.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention provides Manufacturing method for headrest of vehicle seat Regarding. [Background technology]

[0002] A headrest is attached to the upper part of a vehicle seat to protect the neck and head of a seated occupant. The headrest includes a frame made of a bent metal pipe, a pad that covers the periphery of the frame, and a cover that covers the outer surface of the pad.

[0003] Here, a foam-in-skin molding method is sometimes used to manufacture headrests. The foam-in-skin molding method is a method for manufacturing a headrest by placing a bag-shaped skin and a portion of a frame in a mold and injecting a padding material into the bag. When a headrest is manufactured using the foam-in-skin molding method, the injected material may impinge on a portion of the skin ahead of the injection direction while still under high pressure, resulting in excessive penetration into that portion. In this way, the portion where the padding material has penetrated too much becomes harder than the other portions of the skin (a hard spot occurs), resulting in a decrease in quality.

[0004] To address these problems, Patent Documents 1 to 4 disclose configurations in which a mesh member is provided inside a bag formed by a skin. The techniques disclosed in Patent Documents 1 and 2 employ a configuration in which a mesh strip member is provided on the skin in a portion near the inside of a raw material injection hole in the bag provided for injecting raw material for forming the pad. In the techniques disclosed in Patent Documents 1 and 2, when injecting raw material for forming the pad during production, an intermediate member before pad formation is positioned so that the raw material injection hole faces vertically upward, and a nozzle is inserted from above through the raw material injection hole into the inside of the bag to inject the raw material.

[0005] Furthermore, the techniques disclosed in Patent Documents 3 and 4 employ a configuration in which a mesh bag-like member is disposed so as to surround the outlet of a nozzle inserted into a bag formed by a skin. In the techniques disclosed in Patent Documents 3 and 4, when injecting raw material for forming a pad during manufacturing, an intermediate member before pad formation is positioned so that the raw material injection hole faces horizontally (approximately horizontally rearward), and the nozzle is inserted from the horizontal direction through the raw material injection hole into the inside of the bag to inject the raw material.

[0006] Patent Documents 1 to 4 state that the raw material discharged from the injection nozzle passes through a mesh-like member (a strip-like member, a bag-like member), thereby reducing the injection pressure and preventing the raw material from penetrating too much into a part of the epidermis. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent No. 3451562 [Patent Document 2] Patent No. 6796001 [Patent Document 3] Patent No. 6431812 [Patent Document 4] Patent No. 6660948 Summary of the Invention [Problem to be solved by the invention]

[0008] However, with the techniques disclosed in Patent Documents 1 to 4, when the raw material for forming the pad is injected, it is conceivable that the mesh-like member may be torn by the nozzle tip, or the mesh-like band-like member may become separated from the skin. That is, with the techniques disclosed in Patent Documents 1 and 2, the nozzle is inserted into the raw material injection hole from above, but if the nozzle is inserted at a different angle or too deeply, the mesh-like band-like member may be torn by the nozzle tip, or may become separated from the skin.

[0009] In the techniques disclosed in Patent Documents 3 and 4, the nozzle is inserted laterally into the raw material injection hole, but it is believed that the mesh bag-like member inside the bag is hanging down due to its own weight when the nozzle is inserted. If the nozzle is inserted in this state, the tip of the nozzle may tear the mesh bag-like member or the part fixed to the skin may come off.

[0010] As described above, if the mesh-like member (strip-like member, bag-like member) breaks or the part fixed to the skin comes off when inserting the nozzle, the injection pressure of the raw material from the nozzle may not be alleviated and may collide with part of the skin, causing a hard spot.

[0011] The present invention can suppress the occurrence of hard spots. Headrest manufacturing method The purpose is to provide the following. [Means for solving the problem]

[0026] A method for manufacturing a headrest according to one aspect of the present invention is a method for manufacturing a headrest to be attached to a vehicle seat, and includes the following steps.

[0027] (i) a step of fixing a tension member having a tension portion stretched between the pair of main frame portions to at least one of the pair of main frame portions, the tension portion having a tension portion stretched between the pair of main frame portions, for a frame having a pair of main frame portions spaced apart from each other in a first direction and each extending in a second direction intersecting the first direction; (ii) a step of setting a bag body formed by processing the skin into a bag shape, the pair of main frame portions and the tension member housed inside the bag body, in a forming mold; (iii) injecting a flowable raw material into the bag body from a specific location on the skin that faces the tension member at an interval in a third direction that intersects both the first direction and the second direction, to form a pad in which the pair of main frame portions and the tension member are embedded.

[0028] In the headrest manufacturing method according to the above aspect, with the bag (a member formed by processing the skin into a bag shape) and a portion of the frame housed inside the bag set in a mold, the tensioning member is tensioned so as to face, at a distance, the portion of the skin where the raw material for forming the pad is injected (the injection portion), so even when a nozzle is inserted through the injection portion, there is no risk of the tensioning member being torn or detached by the tip of the nozzle. Furthermore, in the step of forming the pad, the injected raw material hits the tensioning member and the flow is dispersed, preventing the raw material from reaching part of the skin while maintaining high injection pressure and preventing the occurrence of hard spots.

[0029] Furthermore, as described above, in Patent Documents 1 to 4, the mesh member is fixed to the periphery of the raw material injection hole in the skin, and it is conceivable that the injected raw material will hit the mesh member, and the portion of the skin around the raw material injection hole will be pulled inward by the injection pressure along with the mesh member, resulting in a concave state in the completed headrest, degrading the appearance quality.

[0030] In contrast, in the headrest manufacturing method according to the above aspect, the tensioning member is fixed to a highly rigid frame, so that when the raw material for forming the pad is injected, there is no risk of the injection point and the surrounding area being pulled inward into the bag body, and the above-mentioned problems with appearance quality do not occur.

[0031] In the method for manufacturing a headrest according to the above aspect, the tensioning member may be a strip-shaped member having one main surface formed of an adhesive surface, and in the fixing step, the tensioning member may be fixed to the pair of main frame portions by attaching the adhesive surface to each of the pair of main frame portions.

[0032] In the headrest manufacturing method according to the above aspect, a strip-shaped member (ribbon-shaped member) having one main surface made of an adhesive surface is used as the tensioning member to be fixed to each of a pair of main frame portions in the frame. Therefore, compared to fixing by sewing or the like, no complicated work is required when fixing the tensioning member to the frame, and the amount of labor required during manufacturing can be reduced.

[0033] In the method for manufacturing a headrest according to the above aspect, the fixing step may involve winding the tension member at least once between the pair of main frame portions with the adhesive surface facing inward, arranging one end edge portion of the tension member in the winding direction so as to overlap another portion different from the one end edge portion, and attaching the tension member at the overlapping portion using the adhesive surface.

[0034] In the headrest manufacturing method according to the above aspect, a strip-shaped member having one main surface formed as an adhesive surface is wound around a pair of main frame portions at least once and fixed thereto, thereby increasing the fixing strength of the strip-shaped member relative to the frame.

[0035] Furthermore, in the headrest manufacturing method according to the above aspect, one edge portion of the belt-shaped member is attached using the adhesive surface at the portion where it overlaps with the other portion, so that even if the injection pressure of the raw material for forming the pad acts on the belt-shaped member (tensioning member), it is possible to more reliably prevent the belt-shaped member from coming off the frame or becoming displaced. In the method for manufacturing a headrest according to the above aspect, the tensioning member is a molded body formed using a resin material, and is integrally formed with the tensioning portion having a plate shape and a pair of locking portions provided at each end of the tensioning portion in the first direction and capable of being engaged with each of the pair of main frame portions, and the fixing step may include fixing the tensioning member to the pair of main frame portions by locking the pair of locking portions of the molded body to each of the pair of main frame portions. [Effects of the Invention]

[0036] In each of the above aspects, production can be performed without the need for complicated work, and the occurrence of hard spots can be suppressed. [Brief explanation of the drawings]

[0037] [Figure 1] 1 is a perspective view showing an external configuration of a headrest according to an embodiment of the present invention. [Figure 2]FIG. [Figure 3] FIG. 2 is a perspective view showing a frame and tensioning tape in the headrest. [Figure 4] FIG. 4 is a cross-sectional view taken along line IV-IV in FIG. 3. [Figure 5] FIG. 2 is a cross-sectional view showing a cross section along line VV in FIG. [Figure 6] FIG. 2 is a cross-sectional view taken along line VI-VI in FIG. [Figure 7] FIG. 10 is a cross-sectional view showing a raw material injection step in the manufacture of a headrest. [Figure 8] 10 is a front view showing a frame and tensioning tape in a headrest according to Modification 1. FIG. [Figure 9] 10 is a front view showing a frame and a tension molding in a headrest according to Modification 2. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0038] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. Note that the embodiment described below is an example of the present invention, and the present invention is not limited to the following embodiment except for its essential configuration.

[0039] In the drawings, the X direction corresponds to the "second direction," the Y direction corresponds to the "first direction," and the Z direction corresponds to the "third direction."

[0040] 1. Headrest 1 configuration The configuration of a headrest 1 according to an embodiment of the present invention will be described with reference to Figures 1 and 2. The headrest 1 is attached to a vehicle seat.

[0041] 1, the headrest 1 includes a frame 10, a cover 11, and a pad 12. The pad 12 is made of foamed resin (for example, urethane foam) and is formed to enclose a part of the frame 10. The cover 11 is formed to cover the outer surface of the pad 12.

[0042] The headrest 1 of this embodiment is a so-called saddle-shaped headrest in that, when attached to a vehicle seat, the rear portion 1a located at the top of the seat has a thinner Z-direction thickness in the pad 12 than the front portion 1b located along the front of the seat.

[0043] As shown in Fig. 2, when the headrest 1 is viewed from the bottom side, three holes 11b to 11d are provided in the lower surface 11a of the skin 11. The three holes 11b to 11d are provided in the rear portion 1a of the headrest 1. Of the three holes 11b to 11d, holes 11b and 11c are holes through which the legs of the frame 10 are inserted (frame insertion holes). Hole 11d is a hole through which the raw material for forming the pad 12 is injected into the skin 11 (injection point).

[0044] 2, the frame insertion holes 11b and 11c are provided in the rear portion 1a of the headrest 1 in the rear part in the X direction and are spaced apart from each other in the Y direction. The raw material injection hole 11d is provided in the rear portion 1a of the headrest 1 in a part forward in the X direction from the frame insertion holes 11b and 11c and in an intermediate part in the Y direction between the frame insertion holes 11b and 11c.

[0045] 2. Configuration of the frame 10 and tension tape 13 The configurations of the frame 10 and the tension tape 13 will be described with reference to FIGS.

[0046] 3, the frame 10 is integrally formed with a pair of legs 10a, 10b, a pair of main frame portions 10c, 10d, and a connecting portion 10e. The frame 10 is made of a metal pipe. The pair of legs 10a, 10b each extend in the Z direction and are spaced apart from each other in the Y direction.

[0047] Main portion 10c is continuous with leg portion 10a at the upper end portion in the Z direction of leg portion 10a and extends in the X direction. Main portion 10d is continuous with leg portion 10b at the upper end portion in the Z direction of leg portion 10b and extends in the X direction, and is spaced apart from main portion 10c in the Y direction.

[0048] The connecting portion 10e is bent so as to have a U-shape when viewed from the front in the X direction. One end of the connecting portion 10e is continuous with the front end of the main portion 10c, and the other end of the connecting portion 10e is continuous with the front end of the main portion 10d. The connecting portion 10e is provided in a position that hangs down in the Z direction from the portion that is continuous with the main portions 10c and 10d.

[0049] The tension tape 13 is formed, for example, using a nonwoven fabric as a base material, and is a strip-shaped (ribbon-shaped) member (nonwoven fabric base adhesive tape) with one main surface (the lower main surface in the Z direction) configured as an adhesive surface. As shown in Fig. 3, the tension tape 13 is stretched between the main portion 10c and the main portion 10d of the frame 10.

[0050] The tension tape 13 used does not have a release layer containing silicone resin or the like formed on the surface of the substrate (the main surface opposite to the adhesive surface) in order to prevent the raw material for forming the pad from being repelled by the tension tape 13 when forming the pad 12, which will be described later.

[0051] As shown in Fig. 4, tension tape 13 has attachment portions (fixing portions) 13a and 13b and tension portion 13c. Attachment portion 13a is adhesively fixed to the outer peripheral surface of main portion 10c with its adhesive surface. Attachment portion 13b is adhesively fixed to the outer peripheral surface of main portion 10d with its adhesive surface. Tension portion 13c is continuous with attachment portions 13a and 13b and is tensioned between main portions 10c and 10d.

[0052] 3. Positional relationship between the raw material injection hole 11d of the skin 11 and the tension tape 13 The positional relationship between the raw material injection hole 11d of the skin 11 and the tension tape 13 will be described with reference to FIGS.

[0053] 5, tensioned portion 13c of tension tape 13 is arranged in the X direction including a position facing in the Z direction from raw material injection hole 11d (raw material injection location) provided on lower surface 11a of skin 11, as indicated by arrow A. In this embodiment, tensioned portion 13c is arranged so as to encompass substantially the entire longitudinal area of ​​main portions 10c, 10d in the X direction (main portion 10c is not shown in FIG. 5).

[0054] The raw material injection hole 11d in the skin 11 and the tensioned portion 13c of the tensioning tape 13 are spaced apart from each other. The distance in the Z direction between the raw material injection hole 11d and the tensioned portion 13c is set to be larger than the insertion depth of a nozzle used to inject raw material when forming the pad 12. That is, the distance is set so that the tip of the nozzle inserted through the raw material injection hole 11d when forming the pad 12 does not reach the tensioned portion 13c. For example, when the nozzle is inserted X mm into the raw material injection hole 11d, the distance in the Z direction between the raw material injection hole 11d and the tensioned portion 13c is set to (X + α) mm. In this case, "α" is determined taking into consideration the insertion depth of the nozzle during manufacturing and manufacturing variations in each part of the headrest 1. As an example, when the nozzle insertion depth is assumed to be 32 to 33 mm, the distance in the Z direction between the raw material injection hole 11d and the tensioned portion 13c is set to 35 to 40 mm or more.

[0055] 6, tensioned portion 13c of tensioning tape 13 is stretched in the Y direction between main portion 10c and main portion 10d of frame 10. Furthermore, raw material injection hole 11d is provided on underside 11a of skin 11 in the Y direction, midway between main portion 10c and main portion 10d of frame 10. Therefore, tensioned portion 13c of tensioning tape 13 is also arranged in the Y direction, including a position facing raw material injection hole 11d provided in skin 11 in the Z direction, as shown by arrow B.

[0056] 4. Manufacturing method of headrest 1 A method for manufacturing the headrest 1 will be described with reference to FIGS.

[0057] <Frame formation step> A metal pipe is bent to form a frame 10 having leg portions 10a and 10b, main portions 10c and 10d, and a connecting portion 10e as shown in FIG.

[0058] <Tape installation step> Next, as shown in Fig. 4, a nonwoven fabric adhesive tape is attached to the main portions 10c and 10d of the frame 10. This completes the fixation of the tension tape 13 having the tension portion 13c stretched between the main portion 10c and the main portion 10d.

[0059] <Skin coating step> 7, the skin 11 processed into a bag shape is placed over the frame 10 so as to cover the main portions 10c, 10d and the connecting portion 10e of the frame 10. By placing the skin 11, which has been processed into a bag shape, over the frame 10 in this manner, the raw material injection hole 11d provided in the skin 11 and part of the tensioning portion 13c of the tensioning tape 13 face each other.

[0060] In addition, when the surface 11 is placed on the frame 10, the frame 10, the surface 11, and the material supply hole 11d are arranged so that the distance between the material supply hole 11d and the tension portion 13c in the Z direction is 35 to 40 mm or more. Installation A tape 13 is provided.

[0061] And the frame 10, the skin 11, and Installation The tape 13 is inserted into the inner space (cavity) 100 a of the mold 100 .

[0062] Although detailed illustration is omitted, the forming die 100 is configured by combining a plurality of (for example, two) dies.

[0063] <Raw material filling step> Nozzle 101 is inserted into mold 100, and raw material for forming the pad (e.g., urethane) is injected (arrow C1) from tip opening 101a into inner space 100a (inside skin 11). Nozzle 101 is inserted inward from raw material injection hole 11d by, for example, about 32 to 33 mm.

[0064] The raw material for forming the pad discharged from the tip opening 101a of the nozzle 101 advances toward the area facing the raw material injection hole 11d (the area indicated by arrow D), but the flow is dispersed (arrow C2) by the tensioned portion 13c of the tensioning tape 13 provided along the way. This reduces the injection pressure of the raw material, suppresses localized penetration of the raw material into the area indicated by arrow D in the skin 11, and prevents the occurrence of hard spots.

[0065] The injection of the raw material for forming the pad is carried out until it reaches a predetermined volume, that is, the volume inside the skin 11. This causes the skin 11 to adhere tightly to the inner surface 100b of the molding die 100 without any gaps.

[0066] Finally, the headrest 1 is removed from the mold 100, thereby completing the production of the headrest 1.

[0067] 5.Effects In the headrest 1 and its manufacturing method according to this embodiment, the tensioning tape 13 is stretched between the main portions 10c and 10d of the frame 10. The region between the main portions 10c and 10d, where the tensioning portion 13c of the tensioning tape 13 is stretched, is set to include a position facing the raw material injection hole 11d in the skin 11 at a distance. Therefore, in the headrest 1 and its manufacturing method, even when a nozzle is inserted through the raw material injection hole 11d when injecting raw material for forming the pad 12, there is no risk of the tensioning tape 13 being torn or detached by the tip of the nozzle. Therefore, in the headrest 1 and its manufacturing method, when the raw material for forming the pad is injected, the tensioning portion 13c of the tensioning tape 13 prevents the raw material from reaching a part of the skin 11 at a high injection pressure, and the occurrence of localized hard spots in the skin 11 is prevented.

[0068] Furthermore, in the technologies disclosed in Patent Documents 1 to 4, a mesh member is fixed around the raw material injection hole in the skin, and when the raw material for forming the pad is injected, the raw material hits the mesh, and the injection pressure may pull the mesh member and the area around the raw material injection hole in the skin toward the inside of the bag. In this case, the raw material injection hole and the area around it may be recessed in the completed headrest, resulting in a deterioration in appearance quality.

[0069] However, in the headrest 1 and its manufacturing method according to this embodiment, the tensioning tape 13 is fixed not to the skin 11 but to the frame 10, which is more rigid than the skin 11. Therefore, even if the injection pressure of the raw material for forming the pad acts on the tensioning tape 13 when the raw material is injected, no problems with appearance quality arise, as in the techniques disclosed in Patent Documents 1 to 4 above.

[0070] Furthermore, in the headrest 1 and its manufacturing method according to this embodiment, the fixing portions 13a and 13b of the tensioning tape 13 are fixed to the main portions 10c and 10d, respectively. Therefore, in the headrest 1 and its manufacturing method, when the raw material for forming the pad is injected, the tensioning tape 13 is prevented from coming off the frame 10 or from becoming misaligned with respect to the main portions 10c and 10d even if the raw material is subjected to injection pressure. Therefore, in the headrest 1 and its manufacturing method, the occurrence of hard spots in the skin 11 can be more reliably prevented.

[0071] Furthermore, in the headrest 1 and its manufacturing method according to this embodiment, tensioning tape (strip-shaped member) 13 having one main surface configured as an adhesive surface is used as the tensioning member, so no complicated work is required when fixing the tensioning tape 13 to the main portions 10c, 10d of the frame 10, and the number of steps during manufacturing can be reduced, thereby reducing manufacturing costs.

[0072] Furthermore, the headrest 1 according to the present embodiment and the manufacturing method thereof are so-called saddle-type headrests, which have a structure in which the thickness in the Z direction at the rear portion 1a is thinner than the thickness in the Z direction at the front portion 1b. Even in the case of such a structure, the flow of injected raw material for forming the pad is dispersed by the tensioning tape 13, and the injection pressure of the raw material is alleviated by the tensioning tape 13, so that the raw material is prevented from reaching a part of the skin 11 while still under high injection pressure, thereby suppressing the occurrence of hard spots.

[0073] As described above, the headrest 1 according to this embodiment and the method for manufacturing the same can be manufactured without requiring complicated work, and can also suppress the occurrence of hard spots.

[0074] [Variation 1] The headrest according to the first modification will be described with reference to FIG. 8. In FIG. 8, the frame 10 and the Installation Only the tape 23 is shown in the figure. In Fig. 8, the members denoted by the same reference numerals as those in the above embodiment have the same configuration as those in the above embodiment.

[0075] 8, in the headrest according to this modification, a tensioning tape 23 is also stretched between the main portion 10c and the main portion 10d of the frame 10. Like the tensioning tape 13 in the above embodiment, the tensioning tape 23 is a tape having one main surface configured as an adhesive surface, and as an example, is a nonwoven fabric-based adhesive tape.

[0076] The tensioning tape 23 is wound at least once between the main portion 10c and the main portion 10d. The tensioning tape 23 is attached by its adhesive surface in the areas where it abuts against the main portion 10c and the main portion 10d (attachment portions 23a, 23b). In the headrest according to this modification, the attachment portions 23a, 23b of the tensioning tape 23 also correspond to the "fixing portion."

[0077] Furthermore, tension tape 23 has two tensioning portions 23c and 23d in the portion between attachment portion 23a and attachment portion 23b in the Y direction. Two tensioning portions 23c and 23d are attached to each other by their adhesive surfaces. Two tensioning portions 23c and 23d are arranged to cover an area including a position facing raw material injection hole 11d (injection point) provided in skin 11.

[0078] Of the two tensioning portions 23c, 23d, the lower tensioning portion 23d in the Z direction has an overlapping portion 23e where one edge portion and the other edge portion of the tensioning tape 23 overlap. In the overlapping portion 23e, the edge portions are attached to each other by the adhesive surface.

[0079] In a headrest including tensioning tape 23 configured as described above, as with headrest 1 according to the above embodiment, during the manufacture of the headrest, the flow of raw material for forming the pad injected through raw material injection hole 11d is dispersed by colliding with tensioned portion 23d of tensioning tape 23. Therefore, the headrest according to this modification also suppresses the formation of hard spots in skin 11.

[0080] In addition, in the headrest according to this modification, the tensioning tape 23 is wound around the main portions 10c and 10d once, so that the tensioned position of the tensioning portions 23c and 23d is more reliably maintained between the main portions 10c and 10d. Furthermore, because the tensioning portions 23c and 23d of the tensioning tape 23 are attached to each other, it is possible to more reliably prevent the tensioning tape 23 from coming off or becoming misaligned from the main portions 10c and 10d when raw material is poured.

[0081] In this modified example, the tension tape 23 is wound around the frame 10 between the main portion 10c and the main portion 10d in one turn, but it is also possible to use a configuration in which the tension tape 23 is wound around two or more turns.

[0082] [Variation 2] A headrest according to Modification 2 will be described with reference to Fig. 9. Note that, in Fig. 9, the headrest has the same configuration as that of the above embodiment, except for the tension molding 33.

[0083] The headrest according to this modification does not use tension tapes (strip-shaped members) 13, 23 as tension members as in the above embodiment and modification 1, but employs a tension molded body 33 obtained by resin molding. The tension molded body 33 is made of a resin material (such as polystyrene or ABS resin) that does not repel the raw material used to form the pad.

[0084] As shown in Fig. 9, the tensile molding body 33 has locking portions 33a and 33b and a tension portion 33c that are integrally formed. The length of the tensile molding body 33 in the direction from the front to the back of the paper in Fig. 9 (X direction) is set to be approximately the same as or slightly shorter than the length of the main portions 10c and 10d of the frame 10. However, the length of the tensile molding body 33 is set to be a length that can cover at least an area that includes a position facing the raw material injection hole 11d (injection point) provided in the skin 11.

[0085] Each of the locking portions 33a and 33b has a C-shaped cross section with an opening at the upper portion in the Z direction. The cross section of each of the locking portions 33a and 33b is formed such that the opening at the upper portion is formed at an angle of less than 180° so that when the locking portions 33a and 33b are locked to the main portions 10c and 10d of the frame 10, they are unlikely to come off the lock from the main portions 10c and 10d.

[0086] The tension portion 33c has a substantially flat plate shape. However, the shape of the tension portion 33c may be a plate shape that protrudes upward or downward in the Z direction, a corrugated plate shape, or the like, in addition to a flat plate.

[0087] To attach the tension molding 33 having the shape shown in Fig. 9 to the frame 10, the locking portions 33a and 33b are locked to the main portions 10c and 10d, respectively. Note that it is preferable to lock the locking portions 33a and 33b to the main portions 10c and 10d from below in the Z direction as shown in Fig. 9, as this makes them less likely to come off when the raw material for forming the pad is poured in, but it is also possible to lock them from above in the Z direction depending on the strength of the locking.

[0088] In a headrest including the stretched molding 33 configured as described above, as in the headrest 1 according to the above embodiment and the headrest according to the first modification, during the manufacture of the headrest, the flow of raw material for forming the pad injected through the raw material injection hole 11d is dispersed by colliding with the stretched portion 33c of the stretched molding 33. Therefore, the headrest according to this modification also suppresses the formation of hard spots in the skin 11.

[0089] [Other variations] In the above embodiment and Modification 1, adhesive tapes (tensioning tapes 13, 23) having an adhesive surface on one main surface are used as an example of tensioning members. However, in the present invention, it is also possible to use a belt-shaped member (ribbon-shaped member) that does not have an adhesive surface. In this case, an adhesive can be used to fix the belt-shaped members to the main portions 10c, 10d of the frame 10 or to join the belt-shaped members together. Also, as shown in FIG. 8, a stapler, for example, can be used to join the edge portions of the belt-shaped members together.

[0090] In the above embodiment, as shown in Figure 4, etc., a configuration was adopted in which the tensioning portion 13c of the tensioning tape 13 was tensioned so as to circumscribe the upper part of each of the main portions 10c and 10d in the Z direction, but in the present invention, it is also possible to adopt a configuration in which the tensioning portion 13c is tensioned so as to circumscribe the lower part of the main portions 10c and 10d in the Z direction.

[0091] In the above embodiment and the first and second modifications, pipes are used as components of the frame 10, but in the present invention, it is also possible to use solid metal bars or the like.

[0092] In the above embodiment and the above variants 1 and 2, no particular mention is made of the material constituting the skin 11, but in the present invention, various materials can be used, such as vinyl chloride, fabric, synthetic leather, artificial leather, and genuine leather.

[0093] In the above embodiment and modified example 1, no specific dimensions were mentioned regarding the width of the tension tapes 13, 23, but this may be set appropriately depending on factors such as the distance between the main portions 10c, 10d of the frame 10 in the headrest 1 and the raw material injection hole 11d of the skin 11, and may be, for example, approximately 30 mm to 50 mm. The thickness of the tension tapes 13, 23 may also be set appropriately in relation to the injection pressure of the raw material used to form the pad, and for example, 0.1 mm or more is sufficient, and it may be approximately 1 mm or less.

[0094] The tension tape may be a narrow tape or string wound in a spiral shape between main portion 10c and main portion 10d multiple times to cover the area including the position facing raw material injection hole 11d.

[0095] In the above embodiment and the first modified example, a nonwoven fabric substrate adhesive tape is used as the tensioning tape 13, 23. However, in the present invention, it is also possible to use an adhesive tape having a substrate made of Japanese paper, cloth, pulp, or the like. However, even in this case, it is important to use a tape that does not have a release layer (a layer containing silicone resin) formed on the surface side of the substrate (specifically, a tape whose adhesive surface is covered with release paper before being attached to the frame 10) to prevent the raw material for forming the pad from being repelled by the tensioning tape when the raw material is injected. This is because if the raw material is repelled by the tape's release layer, cavities may occur around the tape in the finished product.

[0096] In the above embodiment and the above modifications 1 and 2, a configuration was adopted as an example in which the circular raw material injection hole 11d remains in the underside 11a of the skin 11 even after the headrest 1 is completed, but in the present invention, the raw material injection hole may be blocked after the pad is formed. Note that when the raw material injection hole is blocked in this way after the pad is formed, the hole mark after the blocking is estimated to be the "injection point."

[0097] In the above embodiment, as shown in FIG. 2, the raw material injection hole 11d is provided in the front part of the frame insertion holes 11b and 11c in the X direction. 11c The raw material injection hole 11d may be provided on the straight line connecting the main part 11a and the main part 11b. 10c and the main part 10d By providing the tensioned portion of the tension member between them, the same effects as those of the above embodiment and the above first and second modifications can be obtained.

[0098] In the above embodiment and modified example 1, tension tapes 13, 23 are attached to main portion 10c and main portion 10d, and in modified example 2, tension molding 33 is fastened to main portion 10c and main portion 10d, but in the present invention, metal plates or the like may be joined (welded or brazed) to main portion 10c and main portion 10d. In this case, the same effects as those of the above embodiment and modified examples 1 and 2 can be obtained. [Explanation of symbols]

[0099] 1 headrest 1a rear 1b front 10 frames 10c, 10d Main section (main frame section) 11 Epidermis 11d Raw material injection hole 12 pads 13,23 Tension tape (tension member) 13a, 13b, 23a, 23b Attachment part (fixing part) 13c,23c,23d,33c Tensioning part 33 Stretched molded body (stretched member) 33a, 33b Stop (fixed part)

Claims

1. A method for manufacturing a headrest attached to a vehicle seat, comprising: a step of fixing a tension member having a tension portion stretched between the pair of main frame portions to at least one of the pair of main frame portions for a frame having a pair of main frame portions that are spaced apart from each other in a first direction and each extending in a second direction that intersects the first direction; a step of setting a bag body formed by processing a skin into a bag shape, and the pair of main frame portions and the tension member housed inside the bag body, in a forming die; a step of injecting a flowable material into the bag body from a specific location on the skin that faces the tension member at a distance in a third direction that intersects both the first direction and the second direction, thereby forming a pad in which the pair of main frame portions and the tension member are embedded; Equipped with A method for manufacturing a headrest.

2. In the method for manufacturing a headrest according to claim 1, the tension member is a strip-shaped member having one main surface formed as an adhesive surface, In the fixing step, the adhesive surfaces are attached to the pair of main frame portions, respectively, to fix the tension member to the pair of main frame portions. A method for manufacturing a headrest.

3. In the method for manufacturing a headrest according to claim 2, In the fixing step, the tension member is wound at least once between the pair of main frame portions with the adhesive surface facing inward, one end edge portion of the tension member in the winding direction is arranged in a state where it overlaps another portion different from the one end edge portion, and the tension member is attached at the overlapping portion by the adhesive surface. A method for manufacturing a headrest.

4. In the method for manufacturing a headrest according to claim 1, the tension member is a molded body formed using a resin material, and the tension portion has a plate shape; and a pair of locking portions are provided at each end of the tension portion in the first direction and can be locked to each of the pair of main frame portions, and the molded body is formed integrally with the tension portion, In the fixing step, the pair of locking portions of the formed body are respectively locked to the pair of main frame portions, thereby fixing the tension member to the pair of main frame portions. A method for manufacturing a headrest.

Images