Foaming die device adapted to effect foaming in trim cover assembly integrally to form headrest, and foaming process for forming headrest by effecting foaming in trim cover assembly integrally, using the foaming die device

Patent metadata

Field	Value
Publication number	US-9840175-B2
Application number	US-201414298325-A
Country	US
Kind code	B2
Filing date	Jun 6, 2014
Priority date	Jun 19, 2013
Publication date	Dec 12, 2017
Grant date	Dec 12, 2017

Abstract

A foaming die device for forming a headrest is provided, which comprises a lower die having a first protrusion and an upper die having a second protrusion. The lower and upper dies are used for accommodating a trim cover assembly with a headrest stay portion extending outwardly through a stay passage hole formed in the trim cover assembly. The first and second protrusions are adapted to press and turn over a projected area created about the stay hole into the inside of that trim cover assembly. Also, a foaming process for forming the headrest, using this foaming die device, is provided, in which the projected area is turned over by the first and second protrusions into the trim cover assembly when placing the trim cover assembly in the dies. Hence, conventional preliminary steps using cylindrical stick to turn over the projected area into the trim cover assembly are eliminated.

First claim

What is claimed is:

1. A foaming die device, which is so constructed as to allow accommodation therein of a trim cover assembly in which a headrest stay is installed therein such that at least one stay portion of said headrest stay passes through at least one stay passage hole of said trim cover assembly and is exposed exteriorly of the trim cover assembly, wherein a projected area is created in a peripheral end of said at least one stay passage hole and laid on and about said at least one stay portion so as to be exposed exteriorly of the trim cover assembly, and further allow a liquid foaming agent to be injected into an inside of said trim cover assembly and cured therein, to thereby form a headrest having said at least one stay portion exposed exteriorly thereof,
said foaming die device comprising:
an upper die having a cavity region and a second mating surface;
a lower die having a cavity region and a first mating surface adapted to be mated with said second mating surface of said upper die;
said upper and lower dies being able to be mated with and separated from each other;
wherein, when said upper and lower dies are mated with each other, a cavity is defined between said cavity region of said upper die and said cavity region of said lower die, said cavity being of such a dimension as to accommodate a whole of said trim cover assembly therein,
a first stay receiving recession formed in said first mating surface of said lower die, said first stay receiving recession being so configured to receive said at least one stay portion;
a second stay receiving recession formed in said second mating surface of said upper die, said second stay receiving recession being so configured to receive said at least one stay portion;
a first protrusion provided in said lower die, said first protrusion protruding in a direction from an inner wall of said lower die towards said cavity region of said lower die;
a second protrusion provided in said upper die, said second protrusion protruding in a direction from an inner wall of said upper die towards said cavity region of said upper die; and
said first and second protrusions being adapted to press and turn over the trim cover assembly around said at least one stay passage hole to form said projected area relative to said at least one stay passage hole into the inside of said trim cover assembly when said upper and lower dies are mated, and to maintain said projected area while said liquid foaming agent is injected into said inside of said trim cover assembly.

2. The foaming die device as claimed in claim 1 , wherein said first protrusion is so formed to become small in thickness as it proceeds to a distal end thereof and have an extension surface forming one part of a wall surface of a first wall which defines said first stay receiving recession, whereas said second protrusion is so formed to become small in thickness as it proceeds to a distal end thereof and have an extension surface forming one part of a wall surface of a second wall which defines said second stay receiving recession.

3. The foaming die device as claimed in claim 1 , wherein a first stay receiving element is securely provided to said lower die, said first stay receiving element being adapted to receive said at least one stay portion of said headrest stay, wherein a second stay receiving element is securely provided to said upper die, said second stay receiving element being adapted to receive said at least one stay portion of said headrest stay, wherein said first stay receiving element comprises a first body portion secured to said lower die and including said first protrusion, wherein the first protrusion extends into said cavity region of said lower die, wherein said second stay receiving element comprises a second body portion secured to said upper die and including said second protrusion, and wherein the second protrusion extends into said cavity region of said upper die.

4. The foaming die device as claimed in claim 1 , wherein a first stay receiving element is securely provided to said lower die, said first stay receiving element being adapted to receive said at least one stay portion of said headrest stay, wherein a second stay receiving element is securely provided to said upper die, said second stay receiving element being adapted to receive said at least one stay portion of said headrest stay, wherein said first stay receiving element comprises a first body portion secured to said lower die and including said first protrusion, wherein said first protrusion extends into said cavity region of said lower die, wherein said second stay receiving element comprises a second body portion secured to said upper die and including said second protrusion, wherein the second protrusion protrudes into said cavity region of said upper die, wherein said first protrusion is so formed to become small in thickness as it proceeds to a distal end thereof and have an extension surface forming one part of a wall surface of a first wall which defines said first stay receiving recession, whereas said second protrusion is so formed to become small in thickness as it proceeds to a distal end thereof and have an extension surface forming one part of a wall surface of a second wall which defines said second stay receiving recession.

5. The foaming die device as claimed in claim 3 , wherein said first body portion and said first protrusion, associated with said first stay receiving element, are both formed in a substantially semi-cylindrical shape, wherein said first body portion of said first stay receiving element is securely connected to said lower die by at least one securing screw, wherein said second body portion and said second protrusion, associated with said second stay receiving element, are both formed in a substantially semi-cylindrical shape, and wherein said second body portion of said second stay receiving element is securely connected to said upper die by at least one securing screw.

Assignees

• Tachi S Co

Inventors

• Tabata Tsuyoshi
• Kojima Takafumi

Classifications

• B29L2031/3023

  Head-rests · CPC title

• B29C44/1257

  Joining a preformed part and a lining, e.g. around the edges · CPC title

• B29C44/351

  Means for preventing foam to leak out from the foaming device during foaming · CPC title

• B60N2/7017 Primary

  characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for · CPC title

• B29C44/1233

  the preformed parts being supported during expanding · CPC title