Tachi-s Co., Ltd.

Tsuyoshi Tabata

Shinichi Mizuno

Hiromi Yamamoto

Hideki Kamata

Kazuo Katsuta

Takafumi Kojima

Takumi Hirano

Kenzo Hibino

In a skin integral molded article which is formed by filling the inside of a skin which is formed into a bag shape with a foamed body and molding the foamed body integrally with the skin, an opening through which a foaming raw material is supplied into the skin is formed in the skin, in one side skin and other side skin which are formed with the opening being interposed, the one-side skin is bent into inside the opening, the other-side skin is provided with a part disposed ahead of a part which is bent into inside the opening and is formed to be pliable, and the part which is disposed ahead of the other-side skin part and is formed to be pliable is formed in contact with a leading end part of the one-side skin part which is bent into the opening.

Skin integral molded article and manufacturing method thereof

A vehicle seat includes a headrest, a seat back to which the headrest is attached, and a seat cushion connected to the seat back. The headrest includes pillar frames attached to the seat back, a core member that includes a pouring passage penetrating from one end to the other end, a cover that covers the core member and a part of the pillar frames, and a cushion member that is formed in a gap between the outer surface of the core member and the inner surface of the cover and inside the pouring passage. The pouring passage extends in a first direction from the one end of the core member to reach a predetermined position, extends in a second direction from the predetermined position to reach the other end, and includes a bent part at the predetermined position.

Vehicle seat and method of manufacturing headrest

A seat for vehicles including a seat cushion, a seat back, and a head rest has the following arrangement to ensure that a surface member can be relatively easily but positively removed from a urethane pad if a foam molding defect is found in the urethane pad in integral molding of the urethane pad and the surface member. In the seat for vehicles, any one of the seat cushion, seat back, and head rest has a configuration where a surface of the urethane pad is covered with the surface member. The urethane pad and the surface member are partially bonded together by integral molding.

Seat for vehicles

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.

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

A process is provided for forming a foam product integral with a cover surface, which restricts emission of the carbon oxide during the step of preparing a carbon-oxide-mixed liquid by mixing carbon oxide into a first material containing polyol as a primary ingredient; under a pressure applied thereto. The process includes a first step wherein a carbon-oxide-mixed liquid material is prepared by mixing carbon oxide C into a first material containing polyol as a primary ingredient, under a pressure applied thereto, without effecting a forced stirring during said first step; a second step wherein said carbon-oxide-mixed liquid material and a second material containing isocyanate as a primary ingredient are impinged on and mixed with each other in a high-pressure foaming agent preparation device, thereby providing a resultant urethane material as a liquid urethane foaming agent; and a third step wherein said liquid urethane foaming agent produced at said second step is introduced toward an inside of a surface cover element under a pressure applied thereto.

Process for forming a foam product integral with surface cover element

A seat cushion of a seat, which can avoid creation of wrinkle or crease in an area of a trim cover element corresponding to a lateral side of the seat cushion, irrespective of a downward load applied to the seat cushion, thereby making it possible to maintain an outer appearance of the seat cushion in a good quality condition. In a surface of a recessed region of a padding forming a part of the seat cushion, defined flexible portions are formed to be flexed in an inward direction by a downward load applied thereto. Non-bonding areas are defined between the trim cover element and the flexible portions.

Seat cushion

A patch elementof a doughnut-like disc shape is fixedly provided, by sewing or adhesive, to a reverse surface of a seat-back-side areadefined in a trim cover assembly section covering a top regionof a headrest HR, in such a fashion that the patch elementcircumscribes an entire edge of a headrest stay passage hole. Additionally, the patch elementis formed from a material capable of being impregnated with a liquid foaming agent injected in the trim cover assembly. Such patch elementhas been impregnated with the liquid foaming agent S injected in the trim cover assemblyduring a foaming process to form the headrest HR. Consequently, a density of the patch elementitself becomes extremely high, and therefore a strength of the patch elementcan be increased to a great degree.

Headrest with headrest stay

A trim cover assembly of extremely soft property comprises a surface cover element, a wadding cover, and a thick foam wadding sandwiched therebetween, wherein the thick foam wadding has a compressed thin end surface region sewn with the surface cover element and wadding cover. Sewing method for forming such trim cover assembly involves: pressing and collapsing an end surface of the thick foam wadding in downwardly slantwise direction to provide a compressed thin area, thereby allowing direct access thereto of a conventional sewing machine; operating the sewing machine to sew the compressed thin area with the surface cover element, thereby producing a sewn trim cover having a compressed thin end region therein; and thereafter sewing the wadding cover with such sewn trim cover in correspondence with the compressed thin end region. As such, a trim cover assembly having the thick foam wadding is easily formed by the conventional sewing machine.

Trim cover assembly and sewing method for forming same

A device for forming headrest in a foaming die, which includes a lid engagement mechanism operable to keep a lid member engaged in an injection nozzle placed in the foaming die, thereby preventing leakage of liquid foaming agent from the injection nozzle. Further, the device includes a lid disengagement mechanism operable to disengage the lid member from the injection nozzle and an injection gun movable vertically. The lid disengagement mechanism includes a pressure element provided at the injection gun. Upon downward movement of the injection gun, the pressure element acts on the lid member, so that the lid member is disengaged from the injection nozzle and the injection gun is then engaged with the injection nozzle, thereby allowing liquid foaming agent to be injected into a trim cover assembly placed in the foaming die.

Device for forming headrest

A foaming die device is provided, in which can be directly placed a basic armrest unit having a shaft element and a connecting bracket rotatably secured to the shaft element. The foaming die device comprises a lower die, an upper die, and an auxiliary die element of split type to be incorporated in a working die area defined by the lower and upper dies. The auxiliary die element comprises two die pieces that can be mated together so as to be in a slidable engagement about one end portion of the shaft element. Hence, the mated two die pieces or auxiliary die element is slidable along the shaft element for its partial engagement in a through-hole of the basic armrest unit, whereupon all the basic armrest unit and auxiliary die element may be directly placed in the working die area of lower and upper dies and subjected to foaming process.

Foaming die device for forming armrest

An armrest with cup holder of the type where the cup holder is integral with a foam padding in a trim cover assembly through a foaming process, wherein the cup holder is inserted in a hole formed in the trim cover assembly. A uniform stretcher protrusion is defined in a given local peripheral region of the cup holder about which the afore-said hole is engaged, so that a substantially circular edge of that hole is uniformly stretched by and along the uniform stretcher protrusion, thereby causing a close contact of such substantially circular edge of the hole on and about the uniform stretcher protrusion, so as to insure preventing leakage of a liquid foaming agent from between that particular hole and the cup holder during the foaming process.

Armrest with cup-holder

A foaming die device is provided, which has a closure element rotatably provided therein. The foaming die device allows a three-dimensional trim cover assembly with an opening defined therein to be placed therein and also allows a liquid foaming agent to be injected into an inside of so placed trim cover assembly for foaming operation. In operation, when the trim cover assembly is placed in foaming die device prior to the foaming operation, the closure element is able to be rotated toward and easily inserted in the opening to prevent leakage of the liquid foaming agent therethrough, whereas, when the trim cover assembly is taken out from the foaming die device subsequent to the foaming operation, the closure element is able to be rotated and easily removed from that opening.

Device for forming foamed product integral with trim cover assembly

A foamed product integral with trim cover assembly, of the type having a frame element provide therein, with two local portions of the frame element projecting outwardly therefrom. The trim cover assembly used has two extensions, with an opening defined therebetween. Both two extensions are bent to and juxtaposed on one cover material portion thereof, thereby forming a three-layer portion therein. The three-layer portion is sewn so as to define an unsewed region therein. The unsewed region has two spaced-part through-holes formed therethrough, hence providing two spaced-apart continuous through-hoes. The two local portions of frame element are inserted through the respective two spaced-apart continuous through-holes, so that the unsewed region is stretched horizontally to keep the corresponding portions of the juxtaposed two extensions and cover material portion in close contact with one another.

Foamed product integral with trim cover assembly and frame element

A structure of foaming die for forming a generally inverted-L-shaped headrest, which is designed to receive and enclose an incomplete headrest unit comprising a hollow trim cover assembly of a generally 'inverted L' shape having a horizontal upper portion and a vertical head support portion, and at least one headrest stay extending vertically from the horizontal upper portion. This die structure includes die surface portions workable for receiving and enclosing a whole of the hollow trim cover assembly. A movable die element is movably provided so as to be movable toward and away from an operative position where the movable die element is normally set to receive a back cover surface region of such head support portion, thereby allowing the movable die element to be moved away from the operative position and thus allowing a resulting headrest to be removed from the die subsequent to a foaming process.

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Tokyo, Japan

Tsuyoshi Tabata