A method of forming a headrest assembly includes providing a first mold that encloses a first cavity in a closed condition. A support is positioned in the first cavity. A first material is blow molded into the first cavity and around a portion of the support to form a core part. The core part and support are removed from the first mold. A second mold encloses a second cavity in a closed condition. The core part and the support are placed into the second mold in an open condition. A fluid is injected into the core part through the support. The second mold is converted to the closed condition. A second material is injection molded into the second cavity and around the core part to form an outer shell around the core part. A fluid is withdrawn from the core part through the support.

A component of a vehicle seat and method for the production thereof includes a cover having a plurality of panels with each panel including a peripheral mating surface. The plurality of panels are mated together at the peripheral mating surfaces to form a cavity and foam is injected into the cavity of the cover.

A sleeve device for a headrest, the device including a sleeve body for insertion into a vehicle seat, the sleeve body including a tubular wall describing an inner axial passage and a rod-engaging portion which is deformable inwardly relative to the tubular wall, the rod-engaging portion including a flexible pad on its external side, wherein the pad is configured to be urged, in use, to force the engaging portion into the axial passage and/or against a rod received within the axial passage.

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 allowed to develop an integrally formed headrest.

A vehicle headrest includes an electro-acoustic transducer and an acoustic enclosure that supports the electro-acoustic transducer. A unitary foam member is coupled to the acoustic enclosure. The foam member has regions of contrasting firmness including a first region having a first firmness and a second region having a second firmness that is greater than the first firmness. The second region defines a speaker grille that is configured to overlie the electro-acoustic transducer.

A headrest includes a stay, a skin material, a cushion material and a dynamic damper. The cushion material is foam-molded integrally with the stay inside the skin material, and has a hollow portion therein. The dynamic damper is attached to the stay, and is disposed in the hollow portion in such a manner as not to abut on the cushion material.

Provided is a foam in place simulation method that simulates steps of forming a foam in place molded product by supplying a foaming raw material inside a surface skin that is disposed inside a mold through an inlet port thus filling a foamed body into the surface skin. The method is configured to simulate the steps of: setting a shape of the inside of the mold as a fixed boundary condition; setting a material characteristic value of the surface skin whose shape changes corresponding to a filling state of the foamed body into the surface skin; and forming the foam in place molded product from the surface skin by filling the foamed body into the surface skin based on the shape of the surface skin at the time of setting the surface skin inside the mold based on the fixed boundary condition and the material characteristic value.

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.

A headrest includes: (a) a headrest frame, (b) a speaker unit supported by the headrest frame and having a speaker box, a speaker attached to the speaker box, and a megaphone-shaped tube attached to the speaker box, (c) a cushion material, (d) a skin material having an opening, sewed into a pouch shape, and covering the headrest frame, the speaker unit, and the cushion material, and (e) a ring-shaped member securing the entire opening-side end portion of the skin material sandwiched between the ring-shaped member and the megaphone-shaped tube.

An integral skin foam molded article includes: a skin formed by sewing a plurality of skin pieces in a bag shape; and a resin foam which is molded inside the skin integrally with the skin, wherein: at least one skin piece among the plurality of skin pieces has a surface material made of a natural leather, and includes a wadding material stacked on a back side of the surface material in a non-surface joined state and a lining material stacked on the wadding material; and in a shrinkage rate with respect to an in-plane compression load, a shrinkage rate of the lining material is smaller than a shrinkage rate of the wadding material.