JP2020065841A - Skin and molded product - Google Patents

Abstract

To provide a skin that makes it difficult for a foaming liquid to leak from a needle hole during foam molding of a foam body.SOLUTION: The skin in which the foam body is integrally foamed and which covers the foam body includes a skin material and a first thread for sewing the skin materials through at least a part of a needle hole penetrating the skin material. The first thread comprises a bulky thread having fibers having crimps in addition to the fluffing of the fiber ends. As a result, the bulging of the bulky thread of the first thread passing through the needle hole makes it difficult for the foaming liquid to leak from the needle hole during foam molding of the foam body.SELECTED DRAWING: Figure 1

Description

  TECHNICAL FIELD The present invention relates to a skin and a molded product, and more particularly to a skin and a molded product that make it difficult for a foaming liquid to leak from a needle hole.

  BACKGROUND ART There is known a technique for manufacturing a molded product by skin-integral foam molding in which a skin is formed by stitching skin materials, and a foaming liquid of a raw material is injected into the back surface side of the skin to foam-mold a foam. In this foaming with integral skin formation, the foaming liquid injected to the back surface side of the skin may leak out from the gap between the needle hole and the thread through which the needle passes when the skin materials are sewn together and harden outside the skin. Conventionally, in order to suppress this leakage, when a skin material is sewn together, a band-shaped sealing material that is raised and fluffed is sewn together on the back surface side of the skin material (Patent Document 1).

JP, 2005-34212, A

  However, the above-mentioned conventional technique has a problem that it is not possible to sufficiently suppress the leakage of the foaming liquid from the needle hole.

  The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a skin and a molded article that make it difficult for the foaming liquid to leak from the needle hole.

  In order to achieve this object, the epidermis of the present invention is one in which a foam is integrally foamed to cover the foam, and the epidermis material and at least a part of a needle hole penetrating the epidermis material, A first yarn for sewing the skin materials together, and the first yarn comprises a bulked yarn having fibers having crimps other than the fluffing of the fiber ends.

  According to the epidermis of claim 1, since the first yarn passing through at least a part of the needle hole penetrating the epidermis material has the bulky yarn having the fiber having the crimp other than the fluff at the fiber end, the crimp The gap between the needle hole and the first yarn can be reduced by the high property (bulging of the bulky yarn). Further, since the space is formed between the fibers by the crimp, even if the foaming liquid forming the foam enters the gap between the needle hole and the first yarn, the foaming liquid can be absorbed in the space between the fibers. Furthermore, the bulging yarn is inflated by absorbing the foaming liquid, and the absorbed foaming liquid is cured, so that the gap between the needle hole and the first yarn can be made smaller. As a result, it is possible to make it difficult for the foaming liquid to leak from the needle hole during foam molding of the foam.

  According to the outer skin of claim 2, the high-bulk yarn is a filament-processed yarn obtained by crimping the filament. As a result, the bulge of the bulky yarn can be increased by weakening the twist of the bulky yarn or eliminating the twist of the bulky yarn, as compared with the case where the bulky yarn is a spun yarn. As a result, in addition to the effect of claim 1, it is possible to make it more difficult for the foaming liquid to leak from the needle hole during foam molding of the foam.

  According to the outer skin of the third aspect, the second yarn loops or loops the other yarn with the first yarn and laces the other yarn, and the outer skin materials are sewn together by the first yarn and the second yarn. Since the first thread passes through both the needle holes that penetrate through the skin material to be sewn together, the first thread leaks the foaming liquid through both the needle holes even if the second thread does not have the bulky thread. It can be difficult. As a result, in addition to the effect of claim 1 or 2, it is possible to make it difficult for the foaming liquid to leak out from the needle hole, and to reduce the amount of the first yarn (bulk height yarn) used.

  According to the outer skin of the fourth aspect, the second yarn loops or loops the other yarn with the first yarn and laces the other yarn, and the outer skin materials are sewn together by the first yarn and the second yarn. Since the second yarn includes the bulk yarn, the first yarn or the second yarn having the bulk yarn can be reliably passed through both of the needle holes that respectively penetrate the skin materials to be sewn together. As a result, in addition to the effect of claim 1 or 2, it is possible to make it more difficult for the foaming liquid to leak out from the needle hole.

  A molded article according to a fifth aspect comprises the skin according to any one of the first to fourth aspects, and a foam integrally foamed with the skin and covered with the skin. Therefore, the same effect as that of any one of claims 1 to 4 is achieved.

It is a sectional view of a molded product in one embodiment. It is sectional drawing of the epidermis in the II-II line of FIG. It is a schematic diagram of a 1st thread.

  Hereinafter, preferred embodiments will be described with reference to the accompanying drawings. First, a molded product 1 according to one embodiment will be described with reference to FIGS. 1 and 2. FIG. 1 is a sectional view of a molded product 1. FIG. 2 is a sectional view of the epidermis 10 taken along the line II-II in FIG.

  As shown in FIG. 1, the molded article 1 includes a foam 2 made of a foamed synthetic resin such as flexible polyurethane foam, and a skin 10 covering the foam 2. In the molded product 1, the foaming liquid is foamed and hardened by injecting the foaming liquid into the back surface 10b side (inside) of the skin 10 arranged in the cavity of the mold for foam molding (not shown) to integrally foam. A foam-integrated foam-molded product in which the foam 2 is integrated with the skin 10. Examples of such a molded article 1 include headrests, armrests for vehicles, console boxes, seat cushions, seatbacks, and the like.

  As shown in FIGS. 1 and 2, the skin 10 is a member that covers the foam 2, and the surface 10 a of the skin 10 is the outer surface of the molded product 1. The skin 10 includes a plurality of skin materials 11 and 12, and a first thread 15 and a second thread 16 that sew the edge portions 13 and 14 of the skin materials 11 and 12 together. Although the skin 10 of the present embodiment is formed in a substantially bag shape and covers the entire foam 2, the skin 10 may be formed in a shape other than the bag so as to cover a part of the foam 2. .

  The skin materials 11 and 12 are composed of two or more layers in which cloth-like foamed synthetic resin is integrated on the back side of fabric, synthetic leather, leather or the like, from the viewpoint of sitting comfort, touch feeling, elasticity, and the like. However, the cloth-like foamed synthetic resin may be omitted. Also, in order to prevent the foaming liquid from impregnating the fabric or cloth-like foamed synthetic resin, attach a film to the inside of the fabric or cloth-like foamed synthetic resin or heat and melt the inside of the cloth-like foamed synthetic resin. The skin materials 11 and 12 may be formed by forming a film.

  The skin 10 is formed by stacking the edges 13 and 14 of the two skins 11 and 12 so that the surfaces 10a contact each other, and stitching the edges 13 and 14 over the entire length by lock stitching. Therefore, the first thread 15 and the second thread 16 pass through the needle holes 17 and 18 formed through the skin materials 11 and 12 by the needle at the time of sewing, and the other threads are laced with each other to form the two skin materials 11. , 12 are sewn together.

  In the present embodiment, the other yarn lacing portion of the first yarn 15 and the second yarn 16 is located closer to the skin material 12 side (lower side in FIG. 2) than the boundary between the two skin materials 11 and 12. . Therefore, the first yarn 15 passes through the needle hole 17 of the skin material 11 and passes through a part of the needle hole 18 of the skin material 12. On the other hand, the second yarn 16 passes through a part of the needle hole 18 of the skin material 12 and does not pass through the needle hole 17 of the skin material 11.

  Next, the first yarn 15 will be described with reference to FIG. FIG. 3 is a schematic diagram of the first yarn 15. As shown in FIG. 3, the first yarn 15 is a twisted yarn in which a high-bulk yarn 15a and a heat-resistant yarn 15b having higher heat resistance than the high-bulk yarn 15a are twisted together. In the present embodiment, the first yarn 15 is composed of three twisted yarns obtained by twisting a total of three bulked yarns 15a and two heat resistant yarns 15b.

  The high-bulk yarn 15a has a fiber having a crimp (crimp) in addition to the fluff at the fiber end. The crimped fibers include animal hair including wool, cotton, and bulky yarn in which crimps are formed on synthetic fibers. The high-bulk yarn 15a may be composed only of fibers having crimps, or fibers having crimps may be mixed-spun with fibers having crimps. Fibers in which crimps are formed by fluffing of fiber ends in spun yarns obtained by spinning various staples (short fibers) are not included in the fibers having crimps in the bulked yarns 15a.

  Bulky yarns include high bulk spun yarns and filament processed yarns. The high-bulk spun yarn is produced by mixing and spinning a first fiber that shrinks by heating and a second fiber that is a staple that is less likely to shrink by heating than the first fiber, and then heat-treating the second fiber to swell. A crimp is formed. The types of the first fiber and the second fiber can be appropriately set as long as the first fiber contracts at the desired heating temperature and the second fiber does not contract. The first fiber may be staple or filament (long fiber). The bulky spun yarn has almost no elasticity.

  Further, when spinning a synthetic fiber, a low-shrinking spinning solution and a high-shrinking spinning solution are spun from one hole with a partition plate as a boundary to obtain a composite fiber, and then a high-shrinking spinning solution. By heating to a temperature at which only the liquid portion shrinks, a composite fiber in which a crimp is formed in one fiber like wool may be produced. This composite fiber is a kind of filament processed yarn.

  The filament processed yarn is a filament of thermoplastic resin such as nylon, polyester, acryl, polyethylene and polypropylene, which is crimped by utilizing its thermoplasticity. One type of filament may be bundled into a filament processed yarn, or a plurality of types of filament may be bundled into a filament processed yarn. For crimping, known processing methods such as twisting-heat setting-untwisting method, false twisting method, indentation method, rubbing method, shaping method, and air injection method are used.

  A plurality of filaments are heat-sealed in a filament-processed yarn formed by a method such as an indentation method or an air injection method. Therefore, in such a filament processed yarn, the stretchability (elongation rate specified in JIS L1013: 2010 based on ISO 2060: 1994) hardly changes with respect to the filament before processing.

  On the other hand, a filament-processed yarn formed by a method such as twisting-heat-setting-untwisting method, false-twisting method, and rubbing method has a plurality of filaments that are not heat-sealed, so that the elasticity of the filament before processing is increased. Stretchability is better than that, and the bulge (bulk height) changes according to the amount of stretching. Such filament processed yarn is referred to as stretchable bulky yarn (wooley yarn). In this embodiment, a filament processed yarn (stretchable bulky processed yarn) obtained by crimping a nylon filament by false twisting is used as the bulky yarn 15a.

  The heat resistant yarn 15b is a spun yarn made of polyester, and has no crimped fiber other than fluffing at the fiber end. Although not shown, the second yarn 16 is a twisted yarn obtained by twisting three spun yarns (heat resistant yarns 15b) made of polyester, and does not have the bulky yarn 15a.

  The heat resistant yarn 15b is superior in heat resistance to the bulky yarn 15a. This heat resistance is the degree of difficulty in deterioration of the strength of the bulky yarn 15a and the heat resistant yarn 15b at a predetermined temperature such as near the maximum temperature at which the molded article 1 is expected to be used. For example, when the nylon high-bulk yarn 15a is used for the molded article 1 of the automobile seat, the high-bulk yarn 15a gradually deteriorates when the temperature inside the vehicle becomes high, but the polyester heat-resistant yarn 15b is used. This makes it difficult for the first yarn 15 to break.

  The high-bulk yarn 15a may be made of a heat-resistant material such as polyester which is suitable for use in the molded article 1 of the automobile seat. In this case, even if the first yarn 15 is formed only from the bulked yarn 15a without using the heat resistant yarn 15b, the first yarn 15 used in the molded article 1 of the automobile seat can be hard to be cut sufficiently. If the heat resistance of the heat resistant thread 15b is better than that of the bulked thread 15a, the heat resistant thread 15b may be made of a material other than polyester, or the heat resistant thread 15b may be made of a filament.

  According to the molded article 1 and the skin 10 as described above, the first yarn 15 passing through both the needle holes 17 and 18 of the skin materials 11 and 12 has a plurality of fibers having crimps other than the fluffing of the fiber ends. The high thread 15a is provided. This makes it possible to reduce the gap between the needle holes 17 and 18 and the first yarn 15 due to the bulkiness (the bulge of the bulky yarn 15a) due to the crimp during foam molding of the foam 2.

  In addition, during foaming of the foam 2, a space is formed between the fibers of the bulky yarn 15a by crimping, so that the foaming liquid that has penetrated into the gap between the needle holes 17 and 18 and the first yarn 15 can be separated between the fibers. Can be absorbed in space. Further, the bulging yarn 15a is inflated by absorbing the foaming liquid, and the absorbed foaming liquid is cured, so that the gap between the needle holes 17 and 18 and the first yarn 15 can be made smaller. As a result, it is possible to make it difficult for the foaming liquid to leak out from the needle holes 17 and 18 during foam molding of the foam 2.

  Since the first yarn 15 passes through both the needle holes 17 and 18, even if the second yarn 16 does not have the bulky yarn 15a, the first yarn 15 allows the foaming liquid to be discharged from both the needle holes 17 and 18. It can be hard to leak. As a result, the amount of the first yarn 15 (bulk yarn 15a) used can be reduced by using the second yarn 16.

  Since the high-bulk yarn 15a is a filament-processed yarn, the high-bulk yarn 15a is made to have a weaker twist than the high-bulk yarn 15a is a spun yarn, or the high-bulk yarn 15a is untwisted to increase the bulkiness. The bulge of the thread 15a can be further increased. This makes it more difficult for the foaming liquid to leak from the needle holes 17 and 18.

  Further, the bulky yarn 15a is made of a stretchable bulky processed yarn which is excellent in stretchability and whose bulge changes according to the amount of stretching. Therefore, by adjusting the tension of the first yarn 15 (bulk height yarn 15a) when the skin materials 11 and 12 are sewn together, the bulge of the bulk yarn 15a can be easily adjusted. This makes it easier to increase the bulge of the high-bulk yarn 15a, and makes it more difficult for the foaming liquid to leak out from the needle holes 17 and 18.

  Further, the elasticity of the first yarn 15 is superior to that of the second yarn 16. As a result, when the first yarn 15 and the second yarn 16 lacing the other yarns in the needle holes 17 and 18, the first yarn 15 extends and the other yarn lacing portion is a boundary between the two skin materials 11 and 12. It can be more easily located on the skin material 12 side. As a result, the first yarn 15 can be easily passed through both the needle holes 17 and 18, so that the foam liquid can be more unlikely to leak from the needle holes 17 and 18 during foam molding of the foam body 2.

  Although the present invention has been described above based on the embodiment, the present invention is not limited to the above embodiment, and various improvements and modifications can be easily made without departing from the spirit of the present invention. It can be inferred. For example, the outer shape of the molded product 1 may be changed appropriately. Further, the molded product 1 may be used as a cushion other than the vehicle seat. Instead of sewing the plurality of skin materials 11 and 12, the edges of one skin material may be sewn together.

  In the above embodiment, the case where the first yarn 15 is the twisted yarn of the bulked yarn 15a and the heat resistant yarn 15b has been described, but the first yarn 15 is not necessarily limited to this. The first yarn 15 is not limited to the twisted yarn as long as it includes the high-bulk yarn 15a and the heat-resistant yarn 15b, and for example, the high-heat yarn 15a may be spirally wound around the heat-resistant yarn 15b. Further, the first yarn 15 has a yarn other than the bulky yarn 15a and the heat resistant yarn 15b, for example, spun yarn of natural fiber or chemical fiber having no crimps other than the fiber ends, filaments not subjected to crimping, and the like. May be. The heat resistant yarn 15b may be omitted, and the first yarn 15 may be composed of only the bulky yarn 15a.

  By constructing the first yarn 15 only from the bulked yarn 15a which is a filament processed yarn, the twist of the first yarn 15 can be weakened or the twist of the first yarn 15 can be eliminated, and The bulge of the one thread 15 can be further increased. As a result, it is possible to make it more difficult for the foaming liquid to leak from the needle holes 17 and 18.

  In the above embodiment, the case where the second yarn 16 is a twisted yarn formed by twisting three spun yarns (heat resistant yarns 15b) made of polyester has been described, but the present invention is not necessarily limited to this. The second yarn 16 may be composed of a spun yarn of a chemical fiber or a natural fiber other than polyester, a filament of silk or a chemical fiber, or a composite yarn of these. Further, the second yarn 16 may have the bulky yarn 15a. This makes it difficult for the second thread 16 to leak the foaming liquid from the needle holes 17 and 18.

  In the above embodiment, the case where the skin materials 11 and 12 are sewn together by the lock stitch with the one first thread 15 and the one second thread 16 has been described, but the invention is not limited to this. The skin materials 11 and 12 may be sewn together with only one first thread 15. In this case, the first thread 15 always passes through the needle holes 17 and 18 of the skin materials 11 and 12 to be sewn together, so that it is possible to prevent the foaming liquid from leaking out from both the needle holes 17 and 18.

  Further, the first thread 15 and the second thread 16 may be looped or laced with another thread by a stitch other than the lock stitch, and the skin materials 11 and 12 may be sewn together. Further, the skin materials 11 and 12 may be sewn together by a stitch using a plurality of first threads 15 or a plurality of second threads 16.

  In any stitch, by setting the first thread 15 to pass through both the needle holes 17 and 18 of the skin materials 11 and 12 to be sewn together, the first thread 15 causes foaming from both the needle holes 17 and 18. It is possible to make it difficult for liquid to leak out. Even if the second yarn 16 does not include the high-bulk yarn 15a, it is possible to prevent the foaming liquid from leaking out from both the needle holes 17 and 18, and by using the second yarn 16, the first yarn 15 (bulk-high yarn 15a). Can reduce the amount of use.

  Further, in both stitches, both the first yarn 15 and the second yarn 16 are provided with the bulky yarn 15a, so that the bulky yarn is provided in both the needle holes 17 and 18 of the skin materials 11 and 12 to be sewn together. The first yarn 15 or the second yarn 16 having 15a can be reliably passed. As a result, it is possible to make it more difficult for the foaming liquid to leak from the needle holes 17 and 18.

  When the skin materials 11 and 12 are sewn together by the first thread 15 and the second thread 16, a sealing material such as Woolly spin tape laminated on the skin materials 11 and 12 may be sewn together. This makes it more difficult for the foam liquid to leak from the needle holes 17 and 18 during foam molding of the foam 2. In the above embodiment, since the sealing material is not sewn together, it is possible to save the trouble of sewing the sealing material to the correct position and ensure the sewing workability.

DESCRIPTION OF SYMBOLS 1 Molded product 2 Foam 10 Skin 11 and 12 Skin material 15 1st thread 15a Bulk thread 16 2nd thread 17 and 18 Needle hole

Claims (5)

A skin in which a foam is integrally foamed to cover the foam,
Skin material,
A first thread for sewing the skin materials together through at least a part of a needle hole penetrating the skin material,
The first skin comprises a bulky yarn having fibers having crimps in addition to the fluffing of the fiber ends, and the first yarn is a skin.   The skin according to claim 1, wherein the bulky yarn is a filament-processed yarn obtained by crimping a filament. A second yarn for looping or lacing the other yarn with the first yarn and sewing the skin materials together with the first yarn,
The skin according to claim 1 or 2, wherein the first thread passes through both of the needle holes that pass through each of the skin materials to be sewn together. A second yarn for looping or lacing the other yarn with the first yarn and sewing the skin materials together with the first yarn,
The skin according to claim 1 or 2, wherein the second yarn comprises the bulky yarn.   A molded article comprising: the skin according to any one of claims 1 to 4; and a foam integrally foamed with the skin and covered with the skin.

Images