JP2015071280A - Method for manufacturing trim cover - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a trim cover, capable of manufacturing the trim cover with high designability with high working efficiency by ultrasonic welding a resin film simultaneously when forming a dent on the trim cover by ultrasonic welding.SOLUTION: A method for manufacturing a trim cover includes: a placing step of placing a trim cover C on a horn 4 in a direction where a backing material 10 contacts the horn 4, and placing a PVC film 3 on a skin material 2 side; a compression step of moving an anvil 5 so as to approach the horn 4, and compressing part of the PVC film 3 and part of the trim cover C between the anvil 5 and the horn 4; a welding step of ultrasonic vibrating the horn and welding part of the PVC film 3 and the skin material 2; a separation step of separating the anvil 5 from the PVC film 3 and part of the trim cover C; and a removing step of removing a part excluding the welded part of the PVC film 3 from the skin material 2.

Description

  The present invention relates to a trim cover manufacturing method, and more particularly, to a trim cover manufacturing method for manufacturing a trim cover decorated with a resin film.

  A trim cover used for a vehicle seat is generally composed of a wadding material such as urethane, a skin material that covers the surface of the wadding material, and a backing material that covers the back surface of the wadding material. In order to improve the tactile sensation, aesthetics, and heat dissipation and to improve the stability of the shape, a recess has been conventionally formed by sewing on a part of the trim cover. However, in recent years, in addition to sewing, a technique for forming a recess in a trim cover by ultrasonic welding has become widespread (for example, see Patent Document 1).

In addition, as a method for imparting ultrasonic vibration to a skin material using a horn, Patent Document 2 discloses that a transfer surface of a horn is transferred to a skin material to form a stitch, and this stitch is sewn when sewing a sewing thread. A technique used as a guide is disclosed.
In particular, in FIG. 8 of Patent Document 2, a resin film (transfer film foil) is pasted on the transfer surface of the horn, and the other portion is obtained by transferring the resin film to the skin material pressed against the transfer surface. It is described to improve the aesthetic appearance with a different appearance.

JP-A-4-341294 JP 2008-49835 A (FIG. 8)

  Depending on the technique for forming the recess in the trim cover by applying ultrasonic welding described in Patent Document 1, the recess only appears in the appearance, and a sufficient effect cannot be obtained in terms of improving the aesthetic appearance.

On the other hand, as described in Patent Document 2, when the resin film is transferred to the skin material, the appearance of the resin film can be improved as much as the resin film is added.
However, the resin film is directly affixed on the transfer surface of the horn, and all of the resin film on the transfer surface is welded to the skin material by the ultrasonic vibration of the horn. Therefore, only a part of the resin film on the transfer surface cannot be transferred to the skin material, and it is difficult to apply a fine pattern to the skin material.

  In addition, before transferring the resin film to the skin material, it is necessary to apply the resin film to the transfer surface of the horn in advance, so a new resin film is applied to the horn every time the resin film is transferred to the skin material. Therefore, workability was remarkably low.

  Therefore, the present invention has been made in view of the above problems, and its purpose is to provide a design film by ultrasonically welding a resin film at the same time when a recess is formed in the trim cover by ultrasonic welding. An object of the present invention is to provide a trim cover manufacturing method capable of manufacturing a high trim cover with high work efficiency.

  According to the trim cover manufacturing method of the present invention, the trim cover manufacturing method of the present invention uses a anvil and a horn that vibrates ultrasonically to decorate a trim cover for a sheet in which a skin material, a wadding material, and a backing material are laminated. A trim cover manufacturing method for manufacturing, wherein the backing material is placed on the horn in a direction in which the backing material is in contact with the horn, and a resin film is placed on the skin material side so as to be stacked. A pressing step of moving the anvil closer to the horn to press part of the resin film and part of the trim cover between the anvil and the horn, and ultrasonic vibration of the horn. A welding step of welding a part of the resin film and the skin material, a separating step of separating the anvil from a part of the resin film and the trim cover, and the skin material. It includes a removal step of removing the non-welded portion of al the resin film, and is solved by the production of the trim cover decorating.

  In this way, the trim cover is placed on the horn so that the backing material is in contact with the horn, the resin film is placed on the skin material side, and the anvil is brought closer to the horn, so that By applying ultrasonic vibration from the horn to the trim cover and the resin film so as to pressurize the part and a part of the trim cover, a recess is formed in the trim cover and the skin material and the resin film are welded. This makes it possible to manufacture trim covers with high design properties with high work efficiency.

In the pressurizing step, a protrusion is formed on the anvil, and only the protrusion may be pressed against the resin film and a part of the trim cover.
In this way, by using the anvil in which the protrusion is formed and applying pressure so that only the protrusion is pressed against a part of the resin film and the trim cover, heat generated by the ultrasonic vibration is applied to the protrusion. It will be transmitted locally to the part of the resin film that approaches the horn. For this reason, only the resin film pressed by the protrusions can be locally welded to the skin material, so that the portion of the skin material to which the resin film is transferred can be made into a fine design and trim with high design properties The cover can be manufactured.

Moreover, in the said pressurization process, the part of the said resin film which touches the part in which the said protrusion is not formed, and the said trim cover do not apply the pressure from the said anvil, and are good only to contact.
As described above, in the portion where the protrusion on the anvil is not formed, only the resin film pressed by the protrusion is selectively welded to the trim cover by not applying pressure to the resin film and the trim cover. be able to. For this reason, only the resin film pressed by the protrusions can be locally welded to the skin material, so that the portion of the skin material to which the resin film is transferred can be made into a fine design and trim with high design properties The cover can be manufactured.

The resin film placed in the placing step may be a plurality of different types of resin films.
Thus, by using a plurality of different types of resin films, the transfer portion of the resin film on the skin material can be designed in various ways, and a trim cover with high design can be manufactured.

The resin film may be formed from a thermoplastic resin.
Thus, since the resin film is formed of a thermoplastic resin, the resin film can be suitably welded to the skin material by ultrasonic welding in which heat is applied by ultrasonic vibration.

It is preferable that the pressing surface which is the pressing portion of the anvil is circular.
Thus, when a pressurization surface is circular, when separating a resin film from a welding part, the bias of the stress near a welding part can be controlled and it can control that a resin film tears.

Further, in the placing step, it is preferable that the plurality of resin films are placed on the skin material side while being separated from each other.
In this way, by placing a plurality of the resin films spaced apart from each other and placing them on the skin material side, the resin film can be welded to the skin material at a plurality of locations, and work efficiency is increased. A mutual resin film does not adhere by ultrasonic welding.

Also, a cover delivery roller and a film delivery roller around which each of the trim cover and the resin film is wound, and a cover take-up roller and a film that winds up each of the trim cover and the resin film drawn out from the delivery roller. A winding roller is prepared, and in the placing step, the trim cover and the resin film are pulled out from the cover sending roller and the film sending roller, transported and placed on the horn, and in the removing step. The trim cover and the resin film are wound in different directions by the cover take-up roller and the film take-up roller, and other than the welded portion of the resin film is peeled off and removed from the skin material. Also good.
Thus, by using a roller, it becomes possible to send out a resin film and a trim cover continuously on a horn, and furthermore, a trim cover and a resin film are attached by a cover winding roller and a film winding roller. By winding in different directions, a separate removal operation by the operator is not required, and the portion other than the welded portion of the resin film can be peeled off and removed from the skin material, so that the work efficiency can be improved.

  According to the method for manufacturing a trim cover according to claim 1 of the present invention, it is possible to weld a skin material and a resin film at the same time as forming a recess in the trim cover, and to manufacture a trim cover with high design efficiency with high work efficiency. It becomes possible.

  According to the trim cover manufacturing method of the second and third aspects of the present invention, only the resin film pressed by the protrusions can be locally welded to the skin material, so that the skin material to which the resin film is transferred can be obtained. The portion can be made into a fine design, and a trim cover with high design can be manufactured.

  According to the trim cover manufacturing method of the present invention, it is possible to manufacture a trim cover with high design properties.

  According to the trim cover manufacturing method of the fifth aspect of the present invention, the resin film can be suitably welded to the skin material.

  According to the trim cover manufacturing method of the sixth aspect of the present invention, the resin film can be prevented from tearing.

  According to the trim cover manufacturing method of the seventh aspect of the present invention, the working efficiency is increased, and the mutual resin films are not attached by ultrasonic welding.

  According to the trim cover manufacturing method of the eighth aspect of the present invention, the working efficiency can be improved.

It is a perspective view which shows the state which mounted the PVC film on the trim cover. It is a schematic diagram which shows an ultrasonic welding tool. It is a flowchart which shows the process of a trim cover manufacturing method. It is a front view which shows a trim cover and a PVC film. It is a front view which shows the state which mounted the trim cover and the PVC film on the horn. It is a front view which shows the state which pressed the anvil against the trim cover and the PVC film. It is a front view which shows the state which removed the trim cover with a PVC film from the horn. It is a front view which shows the state which removes the removal part of a PVC film from the trim cover with a PVC film, and forms the trim cover with a PVC film. It is a typical perspective view which shows the form which ultrasonically welds a trim cover and a some PVC film with a horn and an anvil. It is a schematic diagram which shows the structure which conveys a trim cover and a PVC film using a roller.

  Hereinafter, a trim cover manufacturing method according to an embodiment of the present invention (hereinafter, this embodiment) will be described with reference to the drawings.

The trim cover C2 with a PVC film manufactured according to the present embodiment by the trim cover manufacturing method is used for a sheet, and a part of the PVC film 3 is welded to a part of the trim cover C.
Specifically, as shown in FIG. 1, the trim cover C includes a wadding material 1, a skin material 2 bonded to the surface of the wadding material 1, and a backing material 10 bonded to the back surface of the wadding material 1. It is configured to be layered.
The wadding material 1 is made of slab urethane or the like and has a cushioning property.
The skin material 2 is formed from a chemical fiber such as polyester.
The backing material 10 is made of polypropylene, polyethylene, nonwoven fabric, or the like. The skin material 2 and the backing material 10 and the wadding material 1 are bonded to each other on the front and back surfaces of the wadding material 1 after applying heat to the wadding material 1 to form an adhesive state. ing.

  The PVC film 3 is a film made of PVC (PolyVinyl Chloride), which is a thermoplastic material, and is colored or glossy in order to add decoration to the trim cover C2 with PVC film. It is made of a material different from the skin material 2, such as having a pattern.

  Then, in order to weld a part of the PVC film 3 to a part of the trim cover C, and to improve the tactile sensation, aesthetics, and heat dissipation and to improve the shape stability, the recess 6 is formed in the trim cover C. Therefore, the horn 4 and the anvil 5 which are the ultrasonic welding tools T shown in FIG. 2 are used.

The horn 4 receives the vibration from the ultrasonic transducer 4b connected to the high frequency power source 4a and reciprocates in the horizontal direction, and the vibration energy generated by the movement is transferred to the trim cover C and the PVC mounted on the mounting surface 4c. It is given to the film 3.
The anvil 5 has a columnar protrusion 5a that protrudes downward on the horn 4 side at a position facing the mounting surface 4c of the horn 4, and is vertically moved by a pneumatic cylinder or a hydraulic cylinder (not shown). It is possible to operate. The anvil 5 configured as described above can press the trim cover C placed on the placement surface 4c of the horn 4 with a predetermined pressure so as to press the protrusion 5a.

Next, the flow of the trim cover manufacturing method will be described with reference to FIGS.
Here, FIG. 3 is a flowchart showing the steps of the trim cover manufacturing method according to the embodiment of the present invention. FIG. 4 is a front view showing the trim cover C and the PVC film 3, FIG. 5 is a front view showing a state where the trim cover C and the PVC film 3 are placed on the horn 4, and FIG. FIG. 7 is a front view showing a state in which the trim cover C1 with a PVC film is removed from the horn 4, and FIG. 8 is a plan view of the PVC film from the trim cover C1 with a PVC film. It is a front view which shows the state which removes the removal part 3b of the film 3, and forms the trim cover C2 with a PVC film.

  First, as shown in FIG. 4, a trim cover C and a PVC film 3 are prepared. As shown in FIG. 5, the trim cover C is placed on the horn 4 so that the backing material 10 side is in contact with the placement surface 4 c of the horn 4. It mounts on the mounting surface 4c, and the PVC film 3 is stacked and mounted on the upper surface of the skin material 2 (mounting step S1).

  Next, as shown in FIG. 6, the anvil 5 is moved so as to approach the horn 4 by a pneumatic cylinder or a hydraulic cylinder (not shown), and the trim cover C is sandwiched between the horn 4 and the anvil 5 so that the protrusion 5a. Is pressed against a part of the PVC film 3 and a part of the trim cover C to apply pressure (pressurizing step S2). By this pressurization, a recess 6 is formed along the shape of the protrusion 5a.

Here, the position where the PVC film 3 is pressed by the anvil 5 is a substantially central position avoiding the edge of the PVC film 3 so that the portion pressed by the protrusion 5a has a circular shape with no chipping. By doing in this way, the details will be described later, but when separating the removed portion 3b of the PVC film 3 from the welded portion 3a, the stress bias in the vicinity of the welded portion 3a can be suppressed, and an unintended crack is generated. Can be suppressed.
Further, the PVC film 3 and the trim cover C are applied with pressure only from the lower surface, which is the contact surface of the projection 5a of the anvil 5, and the other portions are simply touched. Thus, by setting the pressure to the PVC film 3 and the trim cover C only from the lower surface of the protrusion 5a, the PVC film 3 can be welded only to the bottom surface of the recess 6 described below, and otherwise. The removal portion 3b can be suitably removed.

Next, the horn 4 is ultrasonically vibrated. The wadding material 1 is thermally cured by the heat energy generated by the application of vibration energy, and the recess 6 formed in a pressurized state is held in the trim cover C.
Further, the recess 6 of the trim cover C is formed, and the skin material 2 and the PVC film 3 are in a solid-phase joined state, that is, a welded state by the vibration energy of the horn 4 (welding step S3). In this way, the trim cover C1 with a PVC film formed by welding the trim cover C and the PVC film 3 is formed.

Then, as shown in FIG. 7, the anvil 5 is separated from the horn 4 (separation step S4), and the trim cover C1 with PVC film is removed from the ultrasonic welding tool T.
After the placing step S1, the plurality of pressurizing steps S2, the welding step S3, and the separating step S4 are repeated multiple times at different locations on the trim cover C, and then the plurality of locations are welded together, and then the PVC film The trim cover C1 may be removed from the ultrasonic welding tool T.

Finally, as shown in FIG. 8, the removal part 3b other than the welding part 3a of the PVC film 3 is removed from the skin material 2 (removal process S5), and the trim cover C2 with a PVC film is formed.
In this way, the recess 6 is formed in the trim cover C, and at the same time, the skin material 2 and the PVC film 3 can be welded, and the decorative property is enhanced by the color or pattern of the PVC film 3 and the like. The trim cover C2 will be manufactured.

In the placement step S1, the PVC film 3 is placed on the skin material 2 side of the trim cover C. In the welding step S3, the PVC film 3 abuts on the surface of the projection 5a of the anvil 5 on the horn 4 side. Thus, the welded portion 3a is formed.
Thus, by placing the PVC film 3 on the skin material 2 side of the trim cover C, it is difficult for the vibration energy of the horn 4 to propagate to the PVC film 3 as a whole and is pressed against the protrusion 5a. Only the welding part 3a can be brought close to the horn 4 and the vibration energy of the horn 4 can be easily propagated. That is, it is possible to propagate the vibration energy only in the vicinity of the bottom surface of the recess 6 near the horn 4 without reducing the vibration energy, and the PVC film 3 can be locally welded.

  Conversely, in the PVC film 3, the portion facing the side surface of the protrusion 5 a away from the horn 4 and the removal portion 3 b which is a portion above the side surface have weak vibration energy transmitted from the horn 4 and are not completely welded. . For this reason, only the welding part 3a is left on the skin material 2, and the removal part 3b can be easily removed from the skin material 2.

  Moreover, the protrusion 5a is cylindrical as mentioned above, and the pressurization surface which pressurizes the PVC film 3 in pressurization process S2 is circular. For this reason, the boundary between the welded portion 3a and the removed portion 3b of the PVC film 3 has a circular shape because ultrasonic welding is performed in a state where the circular pressure surface of the protrusion 5a is pressed. Thereby, when the removal part 3b of the PVC film 3 is cut off from the welded part 3a, the stress bias in the vicinity of the welded part 3a can be suppressed, and the PVC film 3 can be prevented from being torn. If it does in this way, it will become easy to reuse the PVC film 3 which removed except the welding part 3a.

<< Other Embodiments >>
In the above embodiment, the vehicle seat of the present invention has been mainly described. However, the above embodiment is for facilitating the understanding of the present invention, and does not limit the present invention. The present invention can be changed and improved without departing from the gist thereof, and the present invention naturally includes combinations of features of the embodiments and equivalents thereof.

For example, in the placing step S1, as shown in FIG. 9, a plurality of PVC films 3 may be placed on the trim cover C at intervals so as not to overlap, and the horn 4 and the plurality of protrusions 5a. You may make it press the trim cover C and the PVC film 3 in multiple places by the anvil 5 provided with.
If it does in this way, while the hollow 6 can be formed in multiple places by one pressurization process S2 and welding process S3, the trim cover C and the PVC film 3 can be welded in multiple places, and work efficiency is improved. be able to. In particular, the plurality of PVC films 3 are arranged at intervals so as not to overlap each other, so that welding between them can be prevented.

  Further, as an apparatus for performing ultrasonic welding, as shown in FIG. 10, a cover delivery roller Ra and a cover take-up roller Rb that convey the trim cover C, and a film delivery roller Rc and a film take-up roller that convey the PVC film 3. You may make it use the apparatus provided with the conveyance components comprised from Rd.

Specifically, the cover delivery roller Ra winds the trim cover C and is rotatably provided, and the cover take-up roller Rb is rotatably provided and is supported by a motor (not shown). The PVC film trim cover C2 after the ultrasonic welding is wound up.
Similarly, the film delivery roller Rc winds the PVC film 3 and is rotatably provided. The film take-up roller Rd is rotatably provided and is supported by a motor (not shown). The removed portion 3b of the PVC film 3 after ultrasonic welding is wound up.

The cover delivery roller Ra and the film delivery roller Rc rotate when the trim cover C and the PVC film 3 are taken up by the cover take-up roller Rb and the film take-up roller Rd that are rotated by a motor (not shown).
The cover take-up roller Rb is arranged so as to take up the trim cover C obliquely upward, and the film take-up roller Rd is arranged to take up the PVC film 3 obliquely downward.

  The ultrasonic welding method using the apparatus configured as described above will be described. In the placing step S1, the cover take-up roller Rb and the film take-up roller Rd are wound by a motor (not shown), and the cover is sent out. From the roller Ra and the film delivery roller Rc, the part to which the trim cover C and the PVC film 3 are subjected to ultrasonic welding is pulled out and placed on the horn 4.

And after pressurization process S2, welding process S3, and separation process S4 which were explained in the above-mentioned embodiment, in the removal process S5, when the cover winding roller Rb and the film winding roller Rd are further rotated, PVC after ultrasonic welding Of the trim cover C1 with film, the trim cover C and the PVC film 3 are wound in different directions. In this way, the trim cover C and the PVC film 3 are wound up, and a force to peel them off is generated, so that the removal portion 3b other than the welding portion 3a is removed from the trim cover C1 with the PVC film. That is, at the site where ultrasonic welding has been performed, the trim cover C2 with the PVC film is wound around the cover winding roller Rb, and the removing portion 3b is wound around the film winding roller.
Thus, by using an apparatus provided with a roller, the trim cover C2 with a PVC film can be manufactured continuously, and production efficiency can be improved.

In the above description, the PVC film 3 is used as the resin film welded to the trim cover C. However, the material is not limited to this, and any material having thermoplasticity to such a degree that it can be welded by ultrasonic vibration may be used. For example, it may be made of polypropylene, polycarbonate, or the like.
In addition, a plurality of different types of resin films may be used, and various designs may be used to improve the design.

In addition, in the said embodiment, the protrusion 5a of the anvil 5 is cylindrical shape, and a pressurization surface is circular shape. Since the pressing surface is circular in this way, the welded portion 3a welded in a pressurized state is also circular, and avoids stress bias when removing the removed portion 3b around the welded portion 3a. Can do. For this reason, it can avoid that a crack arises in a part of removal part 3b, and it becomes possible to reuse the removal part 3b as a raw material for forming the welding part 3a.
In addition, when the crack does not arise in the removal part 3b, when not assuming reuse, the shape is arbitrary, and the welding part 3a of the PVC film 3 welded to the skin material 2 according to the shape of a pressurization surface. The shape can be changed and the appearance can be changed.

1 Wadding material 2 Skin material 3 PVC film (resin film)
3a welding part 3b removal part 4 horn 4a high frequency power supply 4b ultrasonic transducer 4c placement surface 5 anvil 5a protrusion 6 dimple 10 backing material C trim cover C1, C2 trim cover with PVC film Ra cover sending roller Rb cover winding roller Rc Film delivery roller Rd Film winding roller T Ultrasonic welding tool

Claims (8)

A trim cover manufacturing method for decorating and manufacturing a trim cover for a sheet in which a skin material, a wadding material and a backing material are laminated using an anvil and an ultrasonically vibrating horn,
In the direction in which the backing material is in contact with the horn, the trim cover is placed on the horn, and a placing step of placing a resin film on the skin material side is placed,
A pressing step of moving the anvil closer to the horn and pressurizing a part of the resin film and a part of the trim cover between the anvil and the horn;
A welding step of ultrasonically vibrating the horn to weld a part of the resin film and the skin material;
A separation step of separating the anvil from a part of the resin film and the trim cover;
A removal step of removing other than the welded portion of the resin film from the skin material,
A trim cover manufacturing method comprising manufacturing the decorated trim cover.   2. The trim cover according to claim 1, wherein in the pressurizing step, a protrusion is formed on the anvil, and only the protrusion is pressed against the resin film and a part of the trim cover. Production method.   In the pressurizing step, the portion of the resin film that touches the portion where the protrusion is not formed and the trim cover are not in contact with the pressure from the anvil and are only in contact with each other. The method for manufacturing a trim cover according to claim 2.   The method for manufacturing a trim cover according to any one of claims 1 to 3, wherein the resin film placed in the placing step is a plurality of different types of resin films.   The method for manufacturing a trim cover according to any one of claims 1 to 4, wherein the resin film is formed of a thermoplastic resin.   The method of manufacturing a trim cover according to any one of claims 1 to 5, wherein a pressure surface which is a pressure portion of the anvil is circular.   The trim cover manufacturing method according to any one of claims 1 to 6, wherein, in the placing step, a plurality of the resin films are placed on the skin material side while being separated from each other. A cover delivery roller and a film delivery roller around which each of the trim cover and the resin film is wound, a cover take-up roller and a film take-up that wind up each of the trim cover and the resin film drawn out from the delivery roller. Prepare the roller and
In the placing step described above, the trim cover and the resin film are pulled out from the cover delivery roller and the film delivery roller, conveyed onto the horn, and placed.
In the removing step, the trim cover and the resin film are wound in different directions by the cover winding roller and the film winding roller, and the portions other than the welded portion of the resin film are peeled off from the skin material. The trim cover manufacturing method according to claim 1, wherein the trim cover manufacturing method is removed.

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