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 cooled to develop an integrally formed headrest.

A method of making a headrest includes folding a first sheet of foam into a foam sleeve. The foam sleeve is slid over an internal core part of the headrest. The foam sleeve and the core part in turn are covered with an outermost cover. The cover is formed from (i) a first layer of material corresponding to a front face of the cover, (ii) a second sheet of foam having a periphery substantially the same shape as the first layer of material, affixed to a backside of the first layer, (iii) a second layer of the material corresponding to a rear face of the cover, and (iv) a third sheet of foam having a periphery substantially the same shape as the second layer of material, affixed to a backside of the second layer. The front and rear faces are joined together to form the cover.

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 passage 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.

A headrest has a pad that is formed integrally with an outer cover by foam molding, and is also provided with: a low-resilience layer that is set in a front part of the pad and has lower resilience than the pad; a support member that is harder than the pad and supports the low-resilience layer from a backside of the low-resilience layer; and a blocking member that is located at a position to cover a contact area of the low-resilience layer and the support member from an outer circumference side while being in contact with at least one of the low-resilience layer and the support member and blocks infiltration of a foamed resin material of the pad into the contact area.

A headrest that facilitates the assembly of a structural member for absorbing impact, and a method for producing the same. The method for manufacturing the headrest having surface material, headrest stay, seal sealing an opening at the bottom of headrest, plate-like impact-absorbing member, one end of which is connected to seal, and foamed body in headrest includes a step of inserting headrest stay in insertion holes and of seal and assembling it, a step of inserting headrest stay and impact-absorbing member through the opening, a step of inserting a circumferential portion of the opening of surface material into seal, a step of injecting a foaming material through injection hole of seal and foaming it, and a step of forming a foamed body by curing the injected foaming material. The opening is sealed when the foaming material impregnates and cures at the circumferential portion of the opening.

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.

A headrest for a motor vehicle has a head box which has a front side turned towards a passenger and a rear side turned away from the passenger. A cushion surrounds the head box at least on its front side and its rear side. A cover surrounds the cushion. The cushion is constructed in two parts and forms a front cushion half and a rear cushion half. Both cushion halves are joined to each other by an integral hinge. The rear cushion half has an inner surface corresponding to the contour of the rear side of the head box and the front cushion half has an inner surface corresponding to the contour of the front side of the head box.