HEADREST AND VEHICLE SEAT PROVIDED THEREWITH, AND METHOD OF MANUFACTURING HEADREST

• US 20150246628A1
• Filed: 08/21/2013
• Published: 09/03/2015
• Est. Priority Date: 09/25/2012
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Ishimoto, Manabu, Haga, Kouichiro
• Granted Patent: US 9,539,923 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 44/1238 and having flexible and solid areas
• CPC Class Codes: B29C 44/1271 the preformed parts being partially covered
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B29L 2031/3023 Head-rests
• CPC Class Codes: B60N 2/64 Back-rests or cushions B60N2/2222 takes precedence
• CPC Class Codes: B60N 2/682 Joining means
• 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
• CPC Class Codes: B60N 2/809 vertically slidable

Abstract

It is obtained a headrest and a vehicle seat provided therewith and a method of manufacturing a headrest, that can reduce load to a neck portion of a vehicle occupant at a time of a rear collision while ensuring NV performance. A first urethane and a second urethane are disposed at an inner side of a headrest skin of a vehicle seat, and structure a headrest pad. The first urethane is embedded in the second urethane, and is elastically deformable, and supports a mass body. An elastic coefficient of the second urethane is set to be higher than that of the first urethane.

Claims

1. A headrest comprising:

a headrest stay that has leg portions that are supported at a seat back and that extend in a seat height direction;

a first cushion material that is disposed at an inner side of a headrest skin, that supports a mass body and is formed of an elastically deformable urethane, and that is fixed to the headrest stay by adhesive force of the urethane itself; and

a second cushion material that is disposed at the inner side of the headrest skin, that structures a headrest pad together with the first cushion material, and that is formed of a urethane having a higher elastic coefficient than the first cushion material.

2. The headrest of claim 1, wherein

the first cushion material has a first overlap portion that is set at a position that overlaps the mass body as seen in a seat front view, and

the second cushion material has a second overlap portion that is set at a position that overlaps the mass body and the first overlap portion as seen in a seat front view.

3. The headrest of claim 1, wherein the first cushion material covers an entire periphery of a peripheral edge of the mass body.

4. The headrest of claim 1, wherein the first cushion material is embedded in the second cushion material.

5. The headrest of claim 1, wherein a volume of the second cushion material is set to be greater than a volume of the first cushion material.

6. The headrest of claim 1, wherein

the leg portions are provided as a left/right pair at the headrest stay, and

the mass body is disposed between the pair of left and right leg portions, and is set at a position that overlaps the pair of left and right leg portions as seen in a seat side view.

7. The headrest of claim 1, wherein a plurality of the mass bodies are disposed.

8. The headrest of claim 7, wherein respective resonance frequencies of the mass bodies that are supported by the first cushion material differ.

9. The headrest of claim 7, wherein the mass bodies are disposed so as to be lined-up apart at left and right both sides in a seat transverse direction with respect to a seat transverse direction central line at the headrest.

10. A vehicle seat comprising:

a seat cushion on which a vehicle occupant sits;

a seat back that is supported at a rear end portion of the seat cushion; and

the headrest of claim 1 that is disposed at an upper end portion of the seat back and supports a head portion of the vehicle occupant.

11. A method of manufacturing a headrest, comprising:

a first step of setting a mass body between a pair of leg portions of a headrest stay;

a second step of, after the first step, by supplying and foam-molding urethane, that is a raw material of a first cushion material, at an outer peripheral side of the mass body, connecting the mass body and regions at mass body sides of the leg portions, by the first cushion material;

a third step of, after the second step, inserting the headrest stay into an interior of a headrest skin that is bag-shaped, and placing the first cushion material and the mass body in the interior of the headrest skin; and

a fourth step of, after the third step, by injecting and foam-molding urethane, that is a raw material of a second cushion material whose elastic coefficient is set to be higher than that of the first cushion material, in the interior of the headrest skin, forming a headrest pad by the first cushion material and the second cushion material.