Patent ID: 7028973

Claim:
A foaming die that forms a headrest having an inverted L-shaped configuration with at least one headrest stay; wherein said headrest has a horizontal portion and a vertical head support portion extending from said horizontal portion; wherein said at least one stay has a first portion extending into said vertical head support portion, a second portion extending through said horizontal portion and a third portion extending out from said horizontal portion and parallel to said first portion; wherein said foaming die receives and encloses a headrest unit comprising said at least one headrest stay and a hollow trim cover assembly corresponding to the inverted L-shaped configuration of the headrest; said hollow trim cover assembly comprising: a horizontal cover portion corresponding to said horizontal portion of said headrest and a vertical head support cover portion corresponding to said vertical head support portion of said headrest; said vertical head support cover portion extending continuous with and vertically from said horizontal cover portion; wherein said horizontal cover portion includes a front horizontal cover surface region and a back horizontal cover surface region opposite to said front horizontal cover surface region; wherein said vertical head support cover portion includes a front vertical head support cover surface region and a back vertical head support cover surface region opposite to said front vertical head support cover surface region; and wherein said foaming die includes an access for a liquid foaming agent to be injected into an inside of said hollow trim cover assembly engaged in said foaming die when closed so that the liquid foaming agent can cure into a foam padding filled in said hollow trim cover assembly together with the third portion of said at least one headrest stay extending through said closed foaming die to form the headrest; wherein said foaming die has a plurality of die components, each having a die surface and hinged together to close and engage a whole of said hollow trim cover assembly when filled against said die surfaces; wherein a first die surface of a first die component engages said back vertical cover surface region while the third portion of said headrest stay extends over an outer surface of said first die component when the foaming die is closed and said hollow trim cover assembly is filled; wherein said first die component includes a movable die element slidably engaged therein having a die surface which is a portion of the die surface of the first die component and also engages said back vertical cover surface region when the foaming die is closed and said hollow trim cover assembly is filled; and wherein said movable die element is movable away from said back vertical cover surface region subsequent to injection of the liquid foaming agent so as to define a recessed space in said first die component and above said back vertical cover surface region which facilitates removal of a cured headrest.