Integrated foam type headrest having different hardnesses, and manufacturing method thereof
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional headrest manufacturing methods either result in uniform hardness, compromising comfort and stability, or require complex and costly assembly processes to achieve varying hardness levels, leading to issues like loosening, creasing, and difficulty in attaching thick cushion members, which affect user comfort and mass production.
Innovation Solution
An integrated foam type headrest manufacturing method where a cushion member with high elongation and low rebound resilience, such as memory foam or sponge, is attached to the headrest cover before foaming, using a partition member to prevent foam penetration and ensuring stable bonding through thermal bonding, allowing for different hardness levels without additional finishing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional integrated foam type headrest is manufactured with uniform foam density, then the manufacturing process is simple and cost-effective, but the comfort and stability at the cushion portion are reduced due to uniform hardness
Solution Approach 1:
The patent applies local quality by dividing the foam material into two distinct density regions: a first density region (0.040-0.065 g/cm³) for the main body and a second density region (0.020-0.040 g/cm³) for the cushion portion. This creates different hardness levels in different areas of the same integrated foam structure, providing both manufacturing simplicity and enhanced user comfort at the cushion area.
2Ease of operation
If an assembly-type headrest with a separate cushion member is used to improve comfort, then user comfort is enhanced, but the manufacturing process becomes complex and time-consuming with multiple finishing and assembly steps
Solution Approach 1:
The patent merges the cushion member and headrest body into a single integrated foam structure with varying density regions. The cushion portion and main body are formed as one piece through controlled foaming processes, eliminating the need for separate cushion members, tape attachment, and multiple assembly steps required in conventional assembly-type headrests.
Solution Approach 2:
The patent incorporates the cushion portion directly into the foam structure during the initial foaming process, rather than adding it as a separate component afterward. The skin material is prepared with the cushion portion integrated before foaming, and the foam is injected to create the density gradient, completing the cushion integration in advance of final assembly.
3Ease of operation
If a thick cushion member (≥10 mm) is attached to the headrest cover to provide sufficient softness, then user comfort is improved, but the material elongation difference causes loosening, creasing, and attachment difficulties
Solution Approach 1:
The patent creates a composite foam structure with two different density regions within the same material system. The first density region (0.040-0.065 g/cm³) provides structural support while the second density region (0.020-0.040 g/cm³) provides softness. This composite approach eliminates the need to attach separate thick cushion members that would cause elongation mismatches with the headrest cover.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of headrests with varying hardness levels, enhancing user comfort and stability while simplifying manufacturing, reducing costs, and allowing for reliable attachment of thick cushion members, thus improving mass production and reducing defects like creasing and loosening.
Implementation Method 1
injecting a foam material into the headrest cover and foaming, thereby filling the interior of the headrest cover
Implementation Method 2
ensuring stable bonding through thermal bonding
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present invention relates to an integrated foam type headrest and a manufacturing method thereof. The headrest includes: a headrest cover; a cushion member which is attached to the inside of the cover before forming foam of a foam material, and is made of material having high elongation and low resistant resilience; a partition member, attached to the inside of the cushion member, for preventing the foam material from penetrating the cushion member; a stay frame for fixing the headrest to a sheet; and a foam material which surrounds the stay frame and is filled in the inside of the cover of the headrest by means of foam-forming. Accordingly, even though a cushion member having a thickness of 10 mm or more is installed to satisfy the softness properties of the headrest, the cushion member can be stably adhered to the cover, and can be reliably installed even at a curved part. Furthermore, sewing convenience is achieved, and thus mass production is possible.