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.

In at least one embodiment, the present disclosure provides a vehicle seat assembly comprising a cushion having an “A” surface and a “B” surface, a central portion, and two bolster areas, with each bolster area being adjacent the central portion, with the cushion having a plurality of intrusions extending from the “A” surface towards the “B” surface to form a hardness gradient between at least one of the bolster areas and the central portion of between 5% to 25%, the plurality of intrusions comprising a plurality of pairs of patterns, each pair of patterns comprising a first pattern spaced apart and opposingly and inversely facing a second pattern.

Lower end portions of an edge and another edge are fixed to a wire through pull-in cloths and a fixing member such that the pull-in cloths pull the lower end portions in toward the rear and into an opening (slit). This enables the edge and the another edge to be closed together in a state in which tension is applied to a front covering and a side covering. This enables the external appearance of a seatback to be preserved. Further, the edge and the another edge can be separated from each other, enabling a connector to be inserted into the opening from between the edge and the another edge, and the connector to be connected to an ISOFIX member. An inferior external appearance of the seatback can accordingly be suppressed while securing insertability of the connector.

A trim panel is provided with a first leather portion laminated with a stabilization material, wherein the first portion has a thickness. The trim panel is provided with a second leather portion adjacent to the first leather portion without a laminated stabilization material. The second portion has thickness that is equal to the thickness of the first portion.

A method for forming polyurethane foams for vehicle seat components in a molding apparatus is provided. The method includes a step of directing one or more polyol compositions into a mold. Each of the one or more polyol compositions includes a polyol, water, and a catalyst. The method also includes a step of directing an isocyanate composition into the mold, the isocyanate composition including one or more isocyanates. The one or more polyol compositions and the one or more isocyanates are combined into a reaction composition that forms a foamed vehicle seat component. Characteristically, the mold has a shape that defines a foamed vehicle seat component. Characteristically, either the one or more polyol compositions and/or the isocyanate composition includes a liquid antimicrobial agent that is a liquid at temperatures above 10° C.

The present invention relates to an integrated foam type headrest and a manufacturing method thereof. The headrest includes: a headrest cover; a cushion member which is attached to the inside of the cover before forming foam of a foam material, and is made of material having high elongation and low resistant resilience; a partition member, attached to the inside of the cushion member, for preventing the foam material from penetrating the cushion member; a stay frame for fixing the headrest to a sheet; and a foam material which surrounds the stay frame and is filled in the inside of the cover of the headrest by means of foam-forming. Accordingly, even though a cushion member having a thickness of 10 mm or more is installed to satisfy the softness properties of the headrest, the cushion member can be stably adhered to the cover, and can be reliably installed even at a curved part. Furthermore, sewing convenience is achieved, and thus mass production is possible.

A vehicle seating system and a method for producing a vehicle seating system may include a cushion made at least in part from a stranded-mesh material and configured to support a seated occupant. Also included may be a support structure configured to support the cushion and a trim-cover material configured to be disposed over at least a portion of the stranded-mesh material. The stranded-mesh material may include an integrated attachment arrangement configured to receive a fastening arrangement for securing the trim-cover material to the stranded-mesh material.

An in-mold foam molded article has a foam body made from olefin-based resin pre-expanded beads and an insert member having an elongated connecting portion and movement resisting portions provided apart from one another in the elongated connecting portion. The insert member is subjected to insert molding upon in-mold foam molding using the olefin-based resin pre-expanded beads. The foam body has a movement facilitating structure that facilitates relative movement between the insert member and the foam body during shrinkage of the in-mold foam molded article after release from a mold.

A seat pad (10) is formed from a foamed molded body. A passenger contact surface (11) which, in a plan view of the seat pad (10), is formed in the shape of a rectangle that is long in the lengthwise direction (X) and short in the widthwise direction (Y), is provided. The passenger contact surface (10) comprises a main pressure-receiving area (11a) with which the buttocks or the waist of a passenger come into contact, and a subsidiary pressure-receiving area (11b) that is adjacent to the main pressure-receiving area (11a) in the lengthwise direction (X). The passenger contact surface (11) is provided with partitioning grooves (15) that extend in the lengthwise direction (X) and that are arranged across the main pressure-receiving area (11a) and the subsidiary pressure-receiving area (11b). The partitioning grooves (15) are arranged so as to lie parallel to each other in the widthwise direction (Y). Additional grooves (16) are formed on the bottom surfaces of the partitioning grooves (15). In the partitioning grooves (15), the average volume, which is the ratio of the volume of the additional grooves (16) per unit area of the bottom surfaces of the partitioning grooves (15), is smaller in a first section (15a) located in the main pressure-receiving area (11a) than in a second section (15b) located in the subsidiary pressure-receiving area (11b).

A vehicle seat core material includes a molded article that includes thermoplastic resin expanded beads. The molded article has a substantially rectangular shape in a top view, and has a front side and a rear side opposite the front side. The molded article has an average density (Z) of 20 kg/m.sup.3 to 50 kg/m.sup.3. The molded article includes, on the rear side of the molded article, a rear thin portion having a thickness of 10 mm to 40 mm, the thickness of the rear thin portion being smaller than an average thickness of the molded article. A ratio (Y/Z) of a density (Y) of the rear thin portion to the average density (Z) of the molded article is 1.05 to 3. The rear thin portion of the molded article has a fusion rate of 70% or more.