Ikeda Bussan Co. Ltd.

Tohru Satoh

Eiichi Yamano

Syuzaburo Kimura

Yoshiharu Ishikawa

Masatoshi Yasuno

A method of molding a headrest of automotive seat comprises the following steps. First, a bag shaped flexible outer skin member is prepared, has an elongate slit formed therethrough. A part of a stay member is inserted into the outer skin member through the slit and set relative to the outer skin member. A given biasing force is applied to longitudinal ends of the slit so that the slit is stretched in longitudinally opposed directions and thus caused to take a closed position. Then, an injection nozzle of a foamable material feeder is put into the slit by expanding the slit against the biasing force. A foamable material is poured into the outer skin member, and the material feeding is stopped when a given amount of material is fed to the outer skin member. The application of the biasing force to the slit is continued until the material is sufficiently cured.

Method for molding the headrest of an automotive seat

A headrest to be installed to a seat back of an automotive seat. The headrest comprises a generally bag-shaped outer skin including a surface section which has first and second end edge portions. The first end edge portion includes a first part integral with the surface section, and a second part integral with the first part and generally parallel with the surface section. A slit is defined between the first part of the first end edge portion and the second end edge portion. The headrest is produced by a process including the following steps: (a) bending the first end edge portion inward of the surface section so that the second part of the first end edge portion is generally parallel with the surface section; (b) forming first insertion holes in the second part of the first end edge portion and second insertion holes in the surface section; (b) inserting headrest stays of a frame inside the bag-shaped outer skin through the slit formed; (d) inserting each headrest stay into each first insertion hole and each second insertion hole so that the head rest stay is projected out of the surface section; (e) disposing the bag-shaped outer skin inside a foaming-fabrication mold; and (f) pouring a raw material of a foam material through the slit into the bag-shaped outer skin so that the second end edge portion is brought into contact with the first part of the first end edge portion so as to tightly close the slit.

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Yamato, Japan

Tohru Satoh