Blow-molded headrest armature assembly

An armature assembly for use in a motor vehicle headrest comprising:

• two substantially straight support posts, wherein a formed upper end of each support post has a substantially flattened surface adjacent the armature;
• and,
• a blow molded hollow elongated plastic armature, preformed with attachment ports comprising paired angular indentations formed therein each said attachment port being adapted to receive one end of one of said support posts to permit retention of the support posts in a fixed position relative to each other and,
• a fastener extending through each of said support posts and said attachment ports and firmly securing said support posts to said attachment ports.

An armature assembly for a headrest comprising two steel support posts joined to a plastic armature having one or more attachment ports, wherein:

• each of said support posts has a formed upper end;
• said armature, comprising essentially a hollow elongated box, forms a shroud about the formed upper end of each said support post;
• said armature further includes at least one angular indentation formed therein at each attachment port with a surface formed to mate with a corresponding surface of the formed upper end of a corresponding one of said support posts;
• each attachment port is shaped to receive the formed upper end of the corresponding one of said support posts such that the support posts are retained in a fixed and essentially parallel position relative to each other;
• and,
• each of said support posts, being essentially straight along most of its length, has a curved portion near said formed upper end adjacent the armature.

A method for manufacturing an armature assembly for use in a motor vehicle headrest, comprising the steps of:

• forming by blow molding a hollow elongated plastic armature, comprising essentially a box having a front surface which is slightly concave, the box forming a plastic armature having angular attachment ports;
• fabricating a support post for each attachment port of said armature, each support post having a formed upper end with a surface for flush contact with at least a portion of the attachment port of said armature;
• and,
• attaching the formed end of one such support post to each attachment port of the armature by rivet or other suitable means.