JP2003334895A - Skin material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent a sewing thread from being broken by absorbing and relaxing a tension acting the sewing thread during returning of the thread when a stitch is formed. <P>SOLUTION: A back lining member 40 with an appropriate elasticity and a specified thickness is placed along the back side of a prearranged line 26 for forming stitches on a skin material 20 made of a synthetic resin. While the back lining member 40 is sewn on the back side of the skin material 20 with sewing threads 32 and 34, the stitches 30 are successively formed. In this instance, the sewing thread 32 is prevented from being broken by absorbing and relaxing the tension during returning of the thread acting the sewing thread 32 passed through the back lining member 40 through thread through-holes formed on the skin material 20 by a sewing needle 56. The back lining member 40 is a sheet-like foam made of a resin such as a urethane resin. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a skin material,
More specifically, the present invention relates to a skin material in which a synthetic resin material is preformed into a desired shape and then stitches are sequentially formed by sewing with a sewing thread from the front side.

[0002]

2. Description of the Related Art Various vehicle interior members such as an instrument panel, a center console, a door panel and a seat are installed in a passenger compartment of a vehicle such as a passenger car.
Since these vehicle interior members are largely exposed in the passenger compartment, the atmosphere and texture of the passenger compartment are greatly affected, and the passengers often come into direct contact with each other. There are many. Therefore, in vehicle interior members to be implemented in many vehicle types, the outer surface of a synthetic resin base material molded into a required shape (such as injection molding or blow molding), for example, woven or knitted fabric such as fabric or tricot, A skin material made of synthetic resin or genuine leather is provided to improve texture and feel.

Of these, genuine leather is considered to be the highest grade as a material for the skin material for improving the texture and feel of the vehicle interior member, but since this genuine leather is inferior in elasticity, it is almost stretched and deformed. It is impossible. Therefore, when it is used as a skin material for a vehicle interior member having a complicated outer surface shape such as an uneven surface or a cubic curved surface, a plurality of genuine leather sheets precut into a required shape are mutually sewn with a sewing machine, A shape that matches the outer shape of the vehicle interior member is created. However, in addition to the fact that the material itself is expensive, the genuine leather has the problem that the number of molding work steps increases due to the addition of cutting work, sewing work, etc., and the manufacturing cost increases. The vehicle interior member using the skin material is actually applied only to some luxury cars.

Therefore, in recent years, synthetic resin skin materials, which are advantageous in terms of moldability, cost and durability, are becoming mainstream. This synthetic resin skin material, when distinguished from the molding mode, is formed from a resin sheet material into a required shape based on a vacuum forming technique, a resin powder formed into a required shape based on a powder slush forming technique, and a spray. Those molded from polyurethane or the like into a desired shape based on the molding technology have been put into practice. With such skin materials made of synthetic resin, the surface pattern of the above-mentioned genuine leather is accompanied by technological innovation of each molding technology mentioned above.
Of course, it is possible to reproduce the (texture pattern), and when sewn together a plurality of genuine leather sheets, a linear groove formed in each sheet boundary portion, or when sewn together each genuine leather sheet with a sewing thread. It is also possible to reproduce the stitches (seam pattern) that are formed.

However, in the stitch pattern integrally formed on the surface of the molded skin material, since the skin material and the stitch pattern have the same color, a texture equivalent to that of a stitch formed from an actual sewing thread is obtained. It's impossible to put out, and it's easy to see that it's not a real stitch. Also, it is possible to make the color of the stitch different from the color of the skin material by painting, but after the completion of molding of the skin material, a painting process that requires a large number of masking steps will be added, As a result, the manufacturing cost was increased.

[0006]

Therefore, in order to obtain a texture equivalent to that of a genuine leather skin material with a synthetic resin skin material, as shown in FIG. A method of actually forming stitches 30 with sewing threads (upper thread, lower thread) 32, 34 by a sewing machine 50 on a line 26 for forming stitches in a synthetic resin skin material 20 preformed into a shape has been proposed. There is. In FIG. 8, a grain pattern 22 and a linear groove 24 resembling genuine leather are simultaneously formed at the time of molding, and the stitches 30, 30 are formed along the groove 24.
A synthetic resin skin material 20 in which 30 are sequentially formed is used as a base material 1.
2 illustrates an instrument panel 10 as a vehicle interior member configured by being disposed at a required position on the outer surface of No. 2. In such an instrument panel 10, a synthetic resin skin material 20 actually formed as a single molded member is formed by mutually stitching a plurality of (six in the illustrated example) genuine leather sheets. Since it has a texture equivalent to that of the above-mentioned genuine leather skin material, the texture is suitably improved.

However, the synthetic resin skin material 20 molded based on the above-mentioned molding technique has (a) a thickness of about 1 mm at the stitch forming line 26, which is considerably thin, and (b) weave. Due to various conditions such as being harder than cloth, knitted fabric, or genuine leather, the following problems and problems are inherent in sequentially forming the stitch 30 with the upper thread (sewing thread) 32 and the lower thread (sewing thread) 34. Was. That is, when the sewing needle 56 of the sewing machine 50 pierces the above-mentioned synthetic resin skin material 20, the thread passage hole 2 formed in the skin material 20.
No. 8 does not have a substantially circular opening reflecting the cross-sectional shape of the sewing needle 56, but has a cut shape formed by tearing the piercing portion. Moreover, the end edge portion of the thread passage hole 28 formed in a cut shape is likely to have a sharp burr shape like a blade edge of a knife. Therefore, at the time of sewing with the sewing machine 50, the thread passing hole 28
When the upper thread 32 and the lower thread 34 are in a state of tightening the skin material 20 due to the tension acting when the upper thread 32 inserted in the upper thread 3 is returned, the edge portion of the thread passage hole 28 causes the upper thread 3 to move.
The upper thread 32 and / or the lower thread 3
The inconvenience of inducing yarn breakage of No. 4 occurred. That is,
When proper tension acts on the upper thread 32 and the lower thread 34, thread breakage of these threads 32, 34 is induced, and if the tension is set to be small in order to avoid this, looseness is formed in the formed stitch 30. It was difficult to form the proper stitch 30 as it would occur.

On the other hand, when the tension acting on the upper thread 32 and the lower thread 34 is too strong, the tightening force on the skin material 20 becomes large, so that the thread passage hole 28 and the thread passage hole adjacent thereto In some cases, the yarn 28 and 28 are broken by the tightening force of the yarns 32 and 34.

[0009]

SUMMARY OF THE INVENTION The present invention has been proposed in order to preferably solve the above-mentioned problems, and absorbs and relaxes the tension at the time of thread return that acts on a thread when forming a stitch by a sewing machine. It is an object of the present invention to provide a synthetic resin skin material which is configured to suitably prevent the yarn breakage.

[0010]

SUMMARY OF THE INVENTION In order to solve the above problems and achieve the intended purpose, the present invention provides a stitch by sewing a synthetic resin material into a required shape and then sewing the thread from the front side thereof. In a skin material formed by sequentially forming a backing member of a required thickness having appropriate elasticity on the back side of the stitch formation planned line in the skin material, the backing member is formed by the sewing thread. The stitches are sequentially formed while being sewn on the back side of the thread, and at this time, the tension at the time of thread return that acts on the thread inserted into the backing member through the thread hole formed in the skin material by the sewing needle is applied. The backing member absorbs and relaxes the thread so that the thread breakage of the sewing thread can be prevented.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION Next, a skin material according to the present invention will be described below with reference to the accompanying drawings with reference to preferred embodiments. Note that the skin material of the present invention can be implemented as a skin material of the instrument panel 10 shown in FIG. 8, for example, but can also be implemented as a vehicle interior member other than this and further as a skin material of furniture and various other members. is there.

FIG. 1 is a partial perspective view schematically showing a skin material according to a preferred embodiment of the present invention, FIG. 2 is a sectional view taken along line II-II of FIG. 1, and FIG. 3 is a line III-III of FIG. FIG. The skin material 20 of the embodiment is made of synthetic resin preformed by the same method as the conventional one based on any one of the above-mentioned vacuum forming technology, powder slush forming technology, or spray forming technology. It has a shape that substantially matches the outer surface shape of the panel base material 12 that constitutes the panel 10. That is, the skin material 20 itself is basically the same as the conventional one shown in FIGS. The synthetic resin skin material 20 has a thickness of about 1 to 2 mm, although there is a slight dimensional difference between the parts, and has appropriate flexibility and elasticity.

Although not specifically shown here, in the case of the vacuum forming technique, a resin sheet material made of vinyl chloride (PVC), olefin resin (TPO) or the like is vacuum-sucked to form a vacuum forming mold. By adsorbing to the molding surface, the skin material 20 having a desired shape is integrally molded. In the case of the powder slush molding technique, a resin powder made of PVC, TPO, TPU or the like is fused to the molding surface of the powder slush molding die to integrally mold the skin material 20 having a desired shape. On the other hand, in the case of the spray molding technique, polyurethane (PU) or the like is sprayed onto the molding surface of the spray mold to integrally mold the skin material 20 having a desired shape.

The skin material 20 of the embodiment formed by any one of the above-described molding techniques has the surface pattern of the genuine leather and the texture of the genuine leather.
The embossed pattern 22 is formed on the surface 21a side which is the design surface of the. The embossed pattern 22 is formed on the surface 21a by transferring and reproducing the embossed pattern (not shown) of each of the above-described molding dies at the time of molding by forming a convex pattern corresponding to the embossed pattern 22. However, in the case of the above-mentioned resin sheet material that is vacuum formed, there is a case where a grain pattern is already formed on the surface of the resin sheet material before forming.

Further, in the skin material 20 of the embodiment, the groove 24 which reproduces the boundary line formed in the boundary portion between the adjacent sheets when the leather sheets that have been precut separately are sewn together is provided with the surface 21a serving as the design surface. Is formed linearly at the required position. That is, as described above, in the case of the leather material made of genuine leather, a plurality of genuine leather sheets preliminarily cut into a required shape are sewn to each other with a sewing machine to create a shape that matches the outer surface shape of the instrument panel 10. Therefore, the groove 24 is for reproducing the groove formed at the sheet boundary portion between the genuine leather sheets. Thereby, the skin material 20 of the embodiment
Despite being integrally molded as one single molded member, for example, in FIG. 1, the separately formed upper left sheet material and lower right sheet material have their edges joined together. looks like. The skin material 20 applied to the instrument panel 10 illustrated in FIG. 8 includes reference numerals 20A, 20B, 2
It is shown that a total of six genuine leather sheets designated by 0C, 20D, 20E, and 20F are sewn together to create a shape that matches the outer surface shape of the instrument panel 10.

In the skin material 20 of the embodiment, the groove 2 is used.
4, a backing member 40 of a required thickness having appropriate elasticity is provided on the back side of the stitch formation scheduled line 26 provided along the line 4, and the backing member 40 is provided on the back surface 21b of the skin material 20. The stitches 30 are sequentially formed while sewing. As will be described later, the backing member 40 is formed by the sewing needle 56 of the sewing machine 50 when the stitches 30 are sequentially formed while the backing member 40 is sewn on the back side of the skin material 20 by the sewing machine 50. By absorbing and relaxing the tension at the time of thread return acting on the upper thread 32 inserted into the backing member 40 through the thread passage hole 28 formed in the skin material 20 by the compressive elastic deformation of itself. The upper thread 32 and / or the lower thread 34 are prevented from being broken.

As shown in FIGS. 4 (a) and 4 (b), the backing member 40 has a surface layer 44, 44 made of nylon woven cloth, which is attached to both surfaces of a urethane layer 42 having a required thickness. Sheet-like foam with a laminated structure with a width W of about 20 mm,
The thickness H is formed into a strip shape having a thickness of about 2 to 3 mm, and is cut for use in accordance with the length of the stitch formation scheduled line 26. The woven fabric forming the surface material 44 is, for example, 3
It is made of nylon denier of about 0 denier,
Even when the back surface 21b of the skin material 20 is contacted, the skin material 2 does not adhere to the back surface 21b as if it was attached to the skin material 20,
It has the property of being able to slide moderately with respect to zero. Therefore, when the stitches 30 are sequentially formed with the backing member 40 set on the back side of the line 26 for stitch formation in the skin material 20, slight movement of the backing member 40 with respect to the skin material 20 is allowed. It has become so. The urethane layer 42 is formed by subjecting a required urethane raw material to a foaming reaction and has a foaming density of about 20 kg / m ^3, so that the urethane layer 42 is rich in elasticity and flexibility.
The backing member 40 as described above allows easy penetration of the sewing needle 56 of the sewing machine 50, and enables elastic extensional deformation in the longitudinal direction and compressive elastic deformation in the thickness direction. There is.

The stitch 3 formed on both sides of the groove 24 along the stitch formation line 26.
As shown in FIGS. 2 and 3, 0 and 30 are the skin material 2
2 sewing needles 5
The sewing machine 50 having 6, 56 is formed at the same time, and its pitch P is about 3 to 5 mm. Here, the upper thread 32 and the lower thread 34 forming the stitch 30 are made of, for example, polyester having a diameter of about 1 mm, and in particular, the upper thread 32 exposed on the front side of the skin material 20 is a skin material. Colors that are coordinated with the 20 colors are used. That is, if the upper thread 32 of a color different from the color of the skin material 20 is used, the stitch 30 can be made more prominent, and if the upper thread 32 of the same color as the skin material 20 is used, It is possible to make the stitch 30 inconspicuous.

As shown in FIG. 5, the stitches 30 and 30 are moved by aligning the guide pieces 54 provided on the skin presser 52 of the sewing machine 50 with the guide pieces 54 in the grooves 24 to move the skin material 20. The grooves 24 are sequentially formed along the groove 24 with a required gap. That is, the groove 24
The design is a reproduction of the sheet boundary portion formed when the edges of the genuine leather sheet are sewn together, but it functions as a guide groove when the stitch 30 is formed by the sewing machine 50. become.

[0020]

Operation of the embodiment Next, the backing material is applied to the back side of the line 26 where the stitch is to be formed, on the skin material 20 made of a synthetic resin which is pre-formed from a synthetic resin material into a required shape that matches the instrument panel 10. A case where the stitches 30, 30 are sequentially formed by sewing the upper thread 32 and the lower thread 34 from the front side of the set member 40 will be described with reference to FIG.

The synthetic resin skin material 20 of the embodiment, which is molded by any of the above-mentioned molding techniques, is formed in a shape that substantially matches the outer shape of the instrument panel 10, and is formed on the surface 21a side thereof. The surface pattern of the genuine leather and the embossed pattern 22 for giving the texture of the genuine leather are formed, and the groove 24 is integrally formed at a required position, and the stitch formation lines are formed on both sides along the groove 24. 26. Then, the strip-shaped backing member 40 is provided along the back surface 21b (back side) of the skin material 20 along the stitch formation planned line 26 while partially fixing the band-shaped backing member 40 using, for example, an adhesive or a double-sided tape. (FIG. 6 (a)).

The backing member 40 for the skin material 20
When the setting is completed, the sewing machine 50 is used to sew with the upper thread 32 and the lower thread 34 to sequentially form the stitches 30 on the scheduled stitch formation line 26 (FIG. 6 (b), FIG. 6 (c)). At this time, each sewing needle 56 of the sewing sewing machine 50 is moved downward by a predetermined sewing operation of the sewing sewing machine 50, penetrates the skin material 20 from the front side of the skin material 20, and penetrates the skin material 20, The backing member 4
It is pierced by 0 and penetrates the backing member 40.
As a result, the upper thread 32 hooked on each sewing needle 56 is
Is inserted into the backing member 40 through the thread passage hole 28 formed in the skin material 20 by piercing the sewing needles 56, 56.
(FIG. 6 (b)).

When the bobbin thread 34 is completely inserted into the ring of the upper thread 32 inserted in the backing member 40 by a predetermined sewing operation of the sewing machine 50, the sewing needle 56 is controlled to be raised and the backing member 40 is moved. And, it escapes from the skin material 20.
Along with this, the upper thread 32 returns to the surface 21a side of the skin material 20 and is locked to the lower thread 34, and the formation of one stitch 30 is completed. Here, when the upper thread 32 moves inside the thread passage hole 28 toward the surface 21a, the backing member 40 slightly moves with respect to the skin material 20, and the backing member 40 also moves.
Since a part of the upper thread 32 and the lower thread 34 come into direct contact with the edge portion of the thread through hole 28, a part of the upper thread 32 is pulled into the thread through hole 28. And / or thread breakage of the lower thread 34 is preferably prevented.

Further, when the thread is returned, a required tension is applied to the upper thread 32 by the upward movement of the sewing needle 56, so that the upper thread 32 and the lower thread 34, which are engaged with each other, become the skin material 20 and the upper thread 32. Since the backing member 40 is tightened from both sides (upper and lower sides in the drawing), the backing member 40 is rich in elasticity and flexibility so that the portion pushed by the lower thread 34 is elastically deformed in the thickness direction. (FIG. 6 (c)).

Here, the tension acting on the upper thread 32 is
For example, it is desirable to set the backing member 40 to such an extent that the stitches 30 are formed in a state where the backing member 40 is appropriately compressed and deformed (a state in which it is not deformed until it is completely crushed). Under such settings, the stitches 30 are sequentially formed while the backing member 40 is sewn on the back side of the skin material 20, so that the thread passage hole formed in the skin material 20 by the sewing needle 56. The upper thread 3 inserted through the backing member 40 via 28
It is possible to absorb and relieve the tension acting on the yarn 2 when the yarn is returned by the compressive elastic deformation of the backing member 40 in the thickness direction.
Therefore, it is possible to prevent excessive tension from being applied to the upper thread 32 and the lower thread 34, so that the thread breakage of the upper thread 32 and / or the lower thread 34 can be preferably prevented.

Further, the return elastic force of the backing member 40 that is elastically deformed compressively causes the upper thread 32 and the lower thread 3 to be moved.
Since the 4 is appropriately stretched, the formed stitch 30 is prevented from being loosened. Further, it is possible to avoid the inconvenience that the space between the thread passage hole 28 formed in the skin material 20 and the thread passage hole 28 adjacent thereto is broken by the tightening force of both the threads 32 and 34.

As described above, in the skin material 20 of the embodiment, the backing member 40 of a required thickness having an appropriate elasticity is set on the back side of the line 26 for stitch formation in the skin material 20 and is provided alongside. Since the backing member 40 is sewn on the back side of the skin material 20 so that the stitches 30 are sequentially formed, the elastic deformation of the backing member 40 absorbs and relaxes the tension acting on the upper thread 32. The thread breakage of the thread 32 and / or the bobbin thread 34 can be preferably prevented. Especially, the upper thread 32
Since a part of the backing member 40 is drawn into the thread passing hole 28 when the thread moves inside the thread passing hole 28,
The upper thread 32 and the lower thread 34 are prevented from directly contacting the edge portion of the thread passage hole 28, and thread breakage of the upper thread 32 and / or the lower thread 34 during sewing is suitably prevented. .

Further, in the skin material 20 of the embodiment, as shown in FIG. 7, the base material 12 preliminarily formed into the required shape, the skin material 20 and the required thickness to be foamed / interposed between the both materials 12, 20 are provided. The instrument panel 10 having a three-layer structure including the cushion material 14 can also be suitably implemented. That is, the base material 12 is set in the first molding die 62 of the foam molding die 60 and the skin material 20 is set in the second molding die 64.
(FIG. 7 (a)), when the cushion material 14 is foam-molded after the foam-molding mold 60 is closed (FIG. 7 (b)), the backing member 40 is formed by the stitches 30. Since the through hole 28 is covered from the back side of the skin material 20, it is possible to prevent the expanding cushion material 14 from leaking to the surface 21a side of the skin material 20 through the thread through hole 28.
That is, the backing member 40 functions as a sealing material when the cushion material 14 is foam-molded.

In the above-described embodiment, the backing member 40 is made of a sheet-like foam laminated with the urethane layer 42 and the surface materials 44, 44. However, the backing member 40 is not limited to this. Things are feasible. For example, as long as the backing member 40 has an appropriate elasticity and has a characteristic that it can slide appropriately without sticking to the back surface 21b of the skin material 20 at the time of sewing, various materials such as rubber and plastic can be used. It may be a sheet-like foam made of resin. Further, it may be a woven or non-woven fabric made of a thread made of an appropriate material.

The vehicle interior member to which the skin material 20 of the present application is applied is the instrument panel 10 of the above-mentioned embodiment.
Not limited to, center consoles, door panels, seats and the like. Further, in addition to the vehicle interior member, it can be implemented as a skin material for furniture and various other members.

[0031]

As described above, the skin material according to the present invention is provided on the back side of the line for stitch formation in the skin material.
Since a backing member having an appropriate elasticity and a required thickness is set and installed alongside, the backing member is sewn to the back side of the skin material so that stitches are sequentially formed. The elastic deformation of the needle absorbs and relaxes the tension acting on the sewing thread, and has a beneficial effect of suitably preventing the thread from breaking. As the backing member, a sheet-like foam made of resin, a woven cloth, a non-woven cloth, or the like having an appropriate elasticity and a required thickness can be used.

[Brief description of drawings]

FIG. 1 is a partial perspective view schematically showing a skin material according to a preferred embodiment of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

3 is a sectional view taken along line III-III in FIG.

FIG. 4 (a) is a schematic perspective view showing a backing member along a back side of a line for stitch formation in a skin material with a part thereof broken away, and FIG. 4 (b) is a sectional view taken along line IV-IV in FIG. It is a figure.

FIG. 5 is a schematic perspective view showing a state in which stitches are sequentially formed along a stitch formation scheduled line with stitches while a backing member is provided on the back side of a skin material.

FIG. 6 is an explanatory cross-sectional view showing a state in which stitches are sequentially formed along a stitch formation line along a scheduled line for forming stitches with a backing member provided along the back side of the skin material with time. )
Shows a state before forming a stitch in which a backing member is set on the back side of the skin material, and (b) shows a sewing needle pierced from the skin material to the backing member, and the stitch is formed on the ring of the needle thread formed by this. A state in which a thread is inserted is shown, and (c) shows a state in which the lower thread and the upper thread are locked as the sewing needle rises, thereby forming a stitch.

FIG. 7 is an explanatory sectional view exemplifying a case where the skin material according to the embodiment is applied to a three-layer type instrument panel, (a) shows a base material set in a first molding die of a foam molding die. In addition, the state in which the skin material is set in the second molding die is shown, and (b) shows the state in which the cushion material is foam-molded between the base material and the skin material.

FIG. 8 is a schematic perspective view of an instrument panel in which a skin material of an example is arranged on the outer surface.

FIG. 9 is a schematic perspective view showing a state in which stitches are sequentially formed with sewing threads along a stitch formation planned line of the preformed skin material.

10 is a cross-sectional view taken along line XX of FIG.

[Explanation of symbols]

10 Instrument panel (vehicle interior material) 20 skin material 26 Stitch formation line 28 Thread hole 30 stitches 32 Upper thread (sewing thread) 34 bobbin thread (sewing thread) 40 Backing member

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 3D023 BA01 BB01 BD12 BE06 BE31                 4F100 AK01A AK01B AK51B AN00B                       AT00B BA02 BA07 BA32                       DG12B DG13B DG15B GB31

Claims (5)

[Claims] 1. A skin material (20) in which stitches (30) are sequentially formed by preforming a synthetic resin material into a required shape and then sewing with sewing threads (32, 34) from the front side of the skin material (20). On the back side of the stitch formation planned line (26) in the skin material (20), a backing member (40) of a required thickness having appropriate elasticity is provided alongside, and the backing member (32, 34) is used for the backing member ( 40) the skin material (20)
Sequentially forming the stitch (30) while sewing on the back side of the
At this time, a threading hole formed in the skin material (20) by a sewing needle
The sewing thread (3) inserted through the backing member (40) through the (28).
A skin material characterized in that the backing member (40) absorbs and relaxes the tension acting on 2) at the time of thread return to prevent thread breakage of the sewing thread (32). 2. The skin material according to claim 1, wherein the backing member (40) is a sheet-like foam made of a resin such as rubber, plastic or urethane. 3. The skin material according to claim 1, wherein the backing member (40) is a knitted fabric, a woven fabric or a non-woven fabric. 4. The backing member (40) is adapted to cover the thread passage hole (28) formed in the skin material (20) from the back side of the skin material (20). Item 4. The skin material according to any one of Items 1 to 3. 5. The skin material (20) is disposed on an outer surface of a vehicle interior member (10) installed in a vehicle passenger compartment.
The skin material according to any one of 4 above.