DUAL FIRMNESS HEAD RESTRAINT

• US 20130134760A1
• Filed: 11/28/2011
• Published: 05/30/2013
• Est. Priority Date: 11/28/2011
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Sutton, Jeremy
• Granted Patent: US 10,011,058 B2
• Time in Patent Office: Days
• US Class Current: 297/391
• CPC Class Codes: B29C 44/0461 by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
• CPC Class Codes: B29C 44/0492 Devices for feeding the different materials
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: B29C 45/1676 using a soft material and a rigid material, e.g. making articles with a sealing part
• CPC Class Codes: B29L 2031/3023 Head-rests
• CPC Class Codes: B60N 2/7017 characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
• CPC Class Codes: B60N 2/80 Head-rests

Abstract

A method of making a vehicle headrest restraint and connecting first and second molds to form a mold cavity. A first material is injected with a first density into the mold cavity. A second material is injected with a second density into the mold cavity. The first and second materials are cooled to develop an integrally formed headrest.

Claims

1. A method of making a vehicle headrest restraint comprising:

connecting first and second molds to form a mold cavity;

injecting a first material with a first density into the mold cavity;

injecting a second material with a second density into the mold cavity; and

cooling the first and second materials to develop an integrally formed headrest.

2. The method of claim 1, wherein the step of injecting a first material and injecting a second material, further comprises:

extending an injection blade having first and second pour channels into the mold cavity and simultaneously injecting the first material and the second material.

3. The method of claim 1, further comprising:

inserting a first blade into the mold cavity to inject the first material; and

subsequently injecting a second blade into the mold cavity to inject the second material.

4. The method of claim 1, further comprising:

inserting first and second headrest supports into the first and second support sleeves, respectively.

5. The method of claim 4, further comprising:

positioning the first and second headrest supports in the mold cavity for integral connection with the headrest restraint.

6. The method of claim 1, further comprising:

operably connecting the integrally formed headrest with a vehicle seat.

7. The method of claim 1, wherein the step of cooling the first and second materials further comprises:

causing at least one of the first material and the second material to cure as a foam-like substrate upon cooling.

8. A headrest restraint comprising:

an integrally molded headrest comprising;

a forward flexible portion adapted to support the head of a passenger and absorb impact forces during a collision event; and

a rearward stiff portion adapted to support the forward flexible portion and provide sufficient strength to withstand impact forces from the head of a passenger during a collision event, the forward flexible portion and the rearward stiff portion being simultaneously injection molded into a single mold cavity; and

first and second headrest supports extending downwardly from the rearward stiff portion and adapted to interface with a vehicle seat assembly.

9. The headrest restraint of claim 8, wherein the first and second headrest supports are fixedly connected directly to the rearward stiff portion.

10. The headrest restraint of claim 8, wherein the first and second headrest supports are removably connected with sleeves secured in the rearward stiff portion.

11. The headrest restraint of claim 8, comprising:

a trim layer disposed over the headrest restraint.

12. The headrest restraint of claim 8, wherein at least one of the forward flexible portion and the rearward stiff portion form a foam-like substrate.

13. A vehicle headrest restraint comprising:

a dual-density molded headrest comprising;

a forward flexible portion adapted to support the head of a passenger; and

a rearward stiff portion integrally formed with the forward flexible portion and adapted to support the forward flexible portion; and

first and second headrest supports extending downwardly from the rearward stiff portion and adapted to interface with a vehicle seat back.

14. The headrest restraint of claim 13, wherein the first and second headrest supports are fixedly connected directly to the rearward stiff portion.

15. The headrest restraint of claim 13, wherein the first and second headrest supports are removably connected with sleeves secured in the rearward stiff portion.

16. The headrest restraint of claim 13, further comprising:

a trim layer disposed over the headrest restraint.

17. The headrest restraint of claim 13, wherein at least one of the forward flexible portion and the rearward stiff portion form a foam-like substrate.