Headrest and method of manufacturing the headrest

Patent metadata

Field	Value
Publication number	US-11027464-B2
Application number	US-201816056633-A
Country	US
Kind code	B2
Filing date	Aug 7, 2018
Priority date	Apr 21, 2015
Publication date	Jun 8, 2021
Grant date	Jun 8, 2021

Abstract

A method of manufacturing a headrest including a stay, a skin material, a cushion material, and a dynamic damper is provided. The method includes arranging the skin material in a molding die, arranging the stay, to which an air bag is attached in such a manner as to cover the dynamic damper, inside the skin material, and injecting a foamable synthetic resin raw material into the skin material to foam-mold the injected foamable synthetic resin raw material integrally with the stay.

First claim

What is claimed is:

1. A method of manufacturing a headrest, the headrest including a stay, a skin material, a cushion material that is foam-molded integrally with the stay inside the skin material and that has a hollow portion therein, and a dynamic damper that is attached to the stay and that is disposed in the hollow portion in such a manner as not to abut on the cushion material, the method comprising:
arranging the skin material in a molding die;
arranging the stay, to which an air bag is attached in such a manner as to cover the dynamic damper, inside the skin material;
injecting a foamable synthetic resin raw material into the skin material to foam-mold the injected foamable synthetic resin raw material integrally with the stay; and
taking out the air bag from the headrest after foam formation and solidification of the foamable synthetic resin raw material, or perforating a hole in the air bag and removing air therefrom after foam formation and solidification of the foamable synthetic resin raw material.

2. A method of manufacturing a headrest, the headrest including a stay, a skin material, a cushion material that is foam-molded integrally with the stay inside the skin material and that has a hollow portion therein, and a dynamic damper that is attached to the stay and that is disposed in the hollow portion in such a manner as not to abut on the cushion material, the method comprising:
arranging the skin material in a molding die;
arranging the stay, to which an air bag is attached in such a manner as to cover the dynamic damper, inside the skin material; and
injecting a foamable synthetic resin raw material into the skin material to foam-mold the injected foamable synthetic resin raw material integrally with the stay, such that the air bag breaks and air is removed therefrom in a course of foam formation and solidification by heat generated at a time of foam formation and solidification of the foamable synthetic resin raw material.

3. A method of manufacturing a headrest, the headrest including a stay, a skin material, a cushion material that is foam-molded integrally with the stay inside the skin material and that has a hollow portion therein, and a dynamic damper that is attached to the stay and that is disposed in the hollow portion in such a manner as not to abut on the cushion material, the method comprising:
arranging the skin material in a molding die;
arranging the stay so that the attached dynamic damper is surrounded by the skin material, wherein the dynamic damper is covered by a low-melting-point material having a melting point lower than a foam formation-solidification reaction temperature of a foamable synthetic resin raw material, wherein the low-melting point material is formed having an outer shape corresponding to an inner shape of the hollow portion; and
injecting the foamable synthetic resin raw material into the skin material to foam-mold the injected foamable synthetic resin raw material integrally with the stay and the low-melting-point material, and cause the low-melting-point material to fuse by heat generated at a time of foam formation and solidification of the foamable synthetic resin raw material.

4. The method according to claim 3 , wherein:
the low-melting-point material includes wax.

5. The method according to claim 3 , wherein:
the low-melting-point material incudes ice.

6. The method according to claim 3 , wherein:
the low-melting-point material includes resin.

7. The method according to claim 6 , wherein:
the low-melting-point resin is not a foamable synthetic resin raw material.

8. The method according to claim 3 , further comprising:
removing the fused low-melting-point material from the headrest.

Assignees

• Toyota Boshoku Kk

Inventors

• Mizobata Hiroshi
• Miyake Shuuhei

Classifications

• B29L2031/3023

  Head-rests · CPC title

• B29C44/1252

  Removing portions of the preformed parts after the moulding step · CPC title

• B60N2002/899

  characterised by structural or mechanical details not otherwise provided for · CPC title

• B29C44/14

  the preformed part being a lining {(B29C44/1209 takes precedence)} · CPC title

• B60N2/80

  Head-rests · CPC title