JP5924274B2 - Manufacturing method of products with skin - Google Patents

Description

  The present invention relates to a method of manufacturing a product with a skin having a stitch line on the surface of the skin.

  As one form of a product with a skin formed by arranging the skin on the base material, a stitch line that simulates the stitching of parts is formed on the skin to give it the appearance of using the skin. The one that produced a sense of luxury is known. In the above-mentioned product with skin, the substrate has a non-planar surface (three-dimensional surface) such as a curved surface, a bent surface, and an uneven surface. The epidermis is deformed and laminated according to the surface shape of the substrate.

Such a product with a skin is manufactured through the following steps, for example (see, for example, Patent Document 1).
The epidermis is heated by the heater. The skin softened by heating is vacuum-sucked and brought into close contact with a vacuum forming die, thereby shaping the outer shape of the product.

Subsequently, the shaped skin is sewed with an upper thread and a lower thread by a sewing machine, thereby forming a stitch line including a plurality of seams arranged in a linear shape on the surface of the skin.
Apart from the skin, the substrate is molded by an injection molding machine or the like. After the adhesive is applied to the surface of the substrate, it is dried. And the said skin in which the stitch line was formed is bonded together on the surface of a base material.

JP 2008-18612 A

  However, in the conventional manufacturing method described above, stitch lines are formed by sewing on the skin that is shaped into a three-dimensional shape, so that the normal part of the skin (scheduled line formation place) can be accurately defined with a thread. Difficult to sew.

In addition, since the shrinkage rate of the skin is likely to vary depending on the temperature, it is difficult to apply the skin to the base material in a state where the positions of the stitch lines are aligned.
In this way, there are two cases where the stitch line position varies: when the stitch line is formed by sewing the epidermis with a thread, and when the epidermis where the stitch line is formed is affixed to the substrate. The variation in the position of the stitch line that appears in the attached product may be large.

And if the position of the stitch line deviates beyond the allowable range, wrinkles will enter the skin, and the skin will float from the base material, impairing the appearance quality (look).
This invention is made | formed in view of such a situation, The objective is providing the method which can manufacture easily the product with an outer_skin | epidermis excellent in the external appearance quality in which the outer_skin | epidermis closely_contact | adhered to the base material. There is.

A method of manufacturing a product with a skin that solves the above problems includes a base material, a skin disposed on the base material, and a stitch comprising a plurality of seams arranged so as to form a line along the surface of the skin A molded body forming step of forming a molded body by integrating the skin in close contact with the substrate, and after the molded body forming step The stitch line is formed by embedding the yarn in a portion spaced apart from the surface of the molded body and fixing it to the deeper portion than the surface of the skin while keeping the yarn along the surface of the skin. The stitch line forming step is performed, and in the stitch line forming step, a portion of the yarn embedded in the molded body is joined to the base material by ultrasonic welding.

According to said manufacturing method, in the case of manufacture of a product with a skin, a molded object formation process and a stitch line formation process are performed.
In the molded body forming step, the skin is disposed on the substrate. A molded body is formed by integrating the epidermis in a state of being in close contact with the base material.

  In the stitch line forming step, the yarn is placed on the surface of the skin after the formed body forming step. The thread is buried in a portion deeper than the surface of the skin and fixed to the molded body at a location where the molded body is separated from each other. By this fixing, a stitch line composed of a plurality of seams arranged in a line along the surface of the epidermis is formed.

  In this way, the yarn is embedded in the molded body in which the skin is integrated with the base material to form a stitch line. For this reason, when forming a stitch line (embedding a thread), a phenomenon in which wrinkles enter the skin and the skin rises from the base material hardly occurs. A skin-attached product having an excellent appearance quality can be easily obtained because the skin adheres closely to the surface of the substrate.

  Moreover, the operation | work which sticks the skin in which the stitch line was formed to a base material becomes unnecessary. The operation of aligning the stitch lines is only performed when the yarn is embedded in the molded body. The number of scenes where the stitch line positions are adjusted is reduced, and the variation in the stitch line positions finally appearing on the skinned product is reduced.

  According to the above manufacturing method, in the stitch line forming step, a portion of the yarn arranged along the surface of the skin and embedded in the molded body is joined to the base material by ultrasonic welding. That is, the portion of the yarn embedded in the molded body is vibrated. By this vibration, frictional heat is generated at the interface between the base material and the yarn, and the base material is melted and bonded (joined) to the yarn. By this bonding (bonding), the yarn is fixed to the base material located at a location deeper than the surface of the skin.

In this case, it is not necessary to use a separate member such as a fastener in order to fix the embedded portion of the yarn to the molded body.
In the method for manufacturing a product with a skin, in the stitch line forming step, it is preferable that the yarn is embedded and ultrasonic welding is performed by an ultrasonic horn of an ultrasonic welding machine.

  According to the above manufacturing method, in the stitch line forming step, the yarns arranged along the surface of the skin are separated from each other by the ultrasonic horn of the ultrasonic welder at a location where the formed body is spaced apart from the surface of the skin. It is pushed into a deep part. By this pushing, the thread is embedded in the molded body. In this state, the ultrasonic horn is vibrated, and frictional heat is generated at the interface between the base material and the yarn, and the base material is melted and bonded to the yarn. Thus, since not only ultrasonic welding but also thread embedding is performed by the ultrasonic horn, it is not necessary to provide a separate device for embedding the thread.

  In the method for manufacturing a product with a skin, the embedding of the yarn by the ultrasonic horn in the stitch line forming step is preferably performed at least in a hole formed in the skin of the molded body prior to the embedding. .

Here, in the case of embedding a thread in a molded body in which no hole is formed, it is necessary to embed the thread while making a hole in the molded body with an ultrasonic horn.
In this regard, according to the manufacturing method described above, prior to the stitch line forming step, holes are made at locations where threads are to be embedded in at least the skin of the molded body.

  In the stitch line forming step, thread embedding with an ultrasonic horn is performed in the hole. That is, the thread and the ultrasonic horn are pushed into the already formed hole. Accordingly, the thread can be smoothly pushed into the formed body as long as it is not necessary to make a hole with the ultrasonic horn.

A method of manufacturing a product with a skin that solves the above problems includes a base material, a skin disposed on the base material, and a stitch comprising a plurality of seams arranged so as to form a line along the surface of the skin A molded body forming step of forming a molded body by integrating the skin in close contact with the substrate, and after the molded body forming step The stitch line is formed by embedding the yarn in a portion spaced apart from the surface of the molded body and fixing it to the deeper portion than the surface of the skin while keeping the yarn along the surface of the skin. a stitch line forming step of is carried out, the stitch in the line forming step, relative to the formed body a fastener from the surface of the skin, the group by implanting the deep portion from the surface of the skin By engaging in, the yarn to affix embedded in the molded body.

  According to the above manufacturing method, in the stitch line forming step, the fastener is driven into the molded body from the surface side of the skin where the yarn is arranged to a position deeper than the surface of the skin. Part of the yarn (locations separated from each other in the length direction) is pressed by the fasteners and embedded in a location deeper than the surface of the skin in the molded body. In addition, when the fastener is locked to the base material, a part of the yarn (locations spaced apart from each other in the length direction) is fixed to the formed body (base material) at the location where it is embedded as described above.

  In the method for manufacturing a product with an outer skin, in the stitch line forming step, the fastener includes a pair of leg portions and a connecting portion that connects the base end portions of the both leg portions. In a state in which the yarn is sandwiched and the connecting portion is positioned on the rear side of the leg portions in the driving direction, the fastener is driven into the molded body and locked to the base material to thereby fix the yarn. It is preferable to embed and fix the molded body.

According to the above manufacturing method, in the stitch line forming step, a fastener including a pair of leg portions and a connecting portion is used for embedding and fixing the yarn.
The fastener is driven into the molded body in such a manner that both legs sandwich the thread and the connecting portion is positioned on the rear side of the legs in the driving direction of the fastener. The yarn is embedded up to a portion (base material) deeper than the surface of the skin in the molded body by the connecting portion that is displaced by the driving. As described above, when the driven fastener is locked to the base material and remains in the molded body, the yarn is in a state (fixed state) in which movement is restricted by both the leg portions and the connecting portion.

In the method for manufacturing a product with a skin, it is preferable to use, as the fastener, one formed by folding a wire into two immediately before being driven into the molded body.
According to said manufacturing method, a fastener provided with a pair of leg part and a connection part is formed by folding a wire in two. In the stitch line forming step, the fastener is formed immediately before the fastener is driven into the molded body and the yarn is embedded in the molded body. As described above, since the fastener necessary for embedding the thread is formed immediately before driving, it is not necessary to prepare the fastener in advance, and it is only necessary to prepare it in the state of the wire before being used as the fastener.

In the manufacturing method of the said product with a skin, it is preferable to use what the uneven | corrugated | grooved part was formed in the surface as said wire.
According to the above manufacturing method, the fastener formed by folding the wire into two has an uneven portion on the surface. When this fastener is driven into the molded body, it comes into contact with the molded body at the uneven portion of the surface. Due to the contact at the concavo-convex portion, the fastener is less likely to come out of the molded body than when the surface is formed smoothly. Therefore, the thread embedded by the fastener continues to be fixed at a location deeper than the surface of the epidermis.

In the method for manufacturing a product with skin, it is preferable to use a thin piece in which the both leg portions and the connecting portion are integrally formed as the fastener.
According to the above manufacturing method, in the stitch line forming step, the thin piece is used as a fastener for embedding and fixing the yarn. Since this thin piece is formed by integrally forming a pair of leg portions and a connecting portion, processing such as bending of a material such as a wire rod is not required immediately before the fastener is driven into the molded body.

  According to the above method for manufacturing a product with a skin, the stitches are formed by embedding yarns in the molded body in which the skin is integrated with the base material, so that the skin is in close contact with the base material and has excellent appearance quality. A product with a skin can be easily produced.

It is a figure which shows 1st Embodiment of the manufacturing method of the product with a skin, and is a partial perspective view of the product with a skin manufactured by the method. The fragmentary sectional view which expands and shows a part of product with a skin of FIG. (A)-(D) are process drawings explaining the molded object formation process in 1st Embodiment. It is a figure explaining the stitch line formation process in a 1st embodiment, and is a fragmentary sectional view showing signs that a hole is made in the skin. It is a figure explaining the stitch line formation process in 1st Embodiment, and is a fragmentary sectional view which shows a mode that a thread | yarn is arrange | positioned along a skin and a hole. It is a figure explaining the stitch line formation process in 1st Embodiment, and is a fragmentary sectional view which shows a mode that a thread | yarn is embedded and fixed to the hole of a molded object. It is a figure which shows 2nd Embodiment of the manufacturing method of the product with a skin, and is a partial perspective view which shows the outline | summary of the stitch line formation process of the method. The fragmentary sectional view which expands and shows a part of product with a skin manufactured in 2nd Embodiment. It is a figure explaining the stitch line formation process in 2nd Embodiment, and is a fragmentary sectional view which shows a mode that a fastener is formed using a wire. The fragmentary sectional view which shows the state in the middle of folding the wire of FIG. 9 in two. The fragmentary sectional view which shows the state which folded the wire of FIG. 10 into two and formed the fastener. The fragmentary sectional view which shows the state before driving the fastener of FIG. 11 in the hole of a molded object. FIG. 13 is a partial cross-sectional view showing a state in which the fastener of FIG. It is a figure which shows 3rd Embodiment of the manufacturing method of a product with a skin, and is a fragmentary sectional view which expands and shows a part of product with a skin manufactured by the same method. The fragmentary perspective view which shows the outline | summary of the stitch line formation process in 3rd Embodiment. It is a figure explaining the stitch line formation process in 3rd Embodiment, and is a fragmentary sectional view which shows the state before driving a fastener in a molded object. FIG. 17 is a partial cross-sectional view showing a state in which the fastener of FIG. 16 is driven into a molded body and a thread is embedded in the molded body.

(First embodiment)
Hereinafter, 1st Embodiment of the manufacturing method of a product with a skin is described with reference to FIGS.

  First, a product with a skin manufactured by applying the manufacturing method will be described. In the first embodiment, various vehicle interior products such as an instrument panel, a console, a door trim, a glove box, and a pillar garnish are targeted for products with a skin.

  As shown in FIGS. 1 and 2, the product with skin 10 includes a base material 11, a skin 15, and a stitch line 25 as main constituent members. Next, each component of the product with skin 10 will be described.

<Substrate 11>
The base material 11 is a member that forms a skeleton part of the skinned product 10 and has a non-planar surface (three-dimensional surface) such as a curved surface, a bent surface, and an uneven surface. The base material 11 is formed by performing resin molding such as injection molding using a resin material. In the present embodiment, a thermoplastic resin is used as the resin material. As the thermoplastic resin, for example, PP (polypropylene), PC (polycarbonate), ABS (acrylonitrile / butadiene / styrene copolymer) and the like are used, but other resins may be used.

Although not shown, a plurality of holes on the base 11 are provided with vacuum suction holes that penetrate the base 11 in the thickness direction.
<Skin 15>
The skin 15 is a member that forms the outer shell portion of the product 10 with skin, and is disposed on the substrate 11. The skin 15 is deformed along the surface of the base material 11 and is brought into close contact with the surface of the base material 11 via an adhesive layer (not shown) made of an adhesive.

  In the first embodiment, the skin 15 is composed of a skin layer 16 and a soft layer 17 laminated on the back side of the skin layer 16. The soft layer 17 is attached to the skin layer 16 and is integrated with the skin layer 16. The skin layer 16 is formed of synthetic leather, a resin sheet, or the like, and the soft layer 17 is formed of polyethylene foam, foam, or the like. The skin 15 has a wrinkle pattern 18 on its surface 15A as found in leather products.

A molded body 20 is constituted by the base material 11 and the skin 15 integrated with the base material 11 in a state of being in close contact with the base material 11.
<Stitch line 25>
The stitch line 25 is for reproducing the stitching of the parts of the skin 15 in the skin 15 so as to give the product 10 with the skin the appearance of using the skin and to create a high-class feeling. It is provided for the purpose of decoration (decoration).

  The stitch line 25 includes a plurality of seams 26 arranged so as to form a line along the surface 15 </ b> A of the skin 15. In other words, the thread 27 appears intermittently on the surface 15 </ b> A of the skin 15, and this appearing portion constitutes the seam 26.

  As the thread 27, a thread having a strength that does not break when it is pushed into the molded body 20 is used. The thread 27 is embedded up to the base material 11 located at a location deeper than the surface 15A of the skin 15 at locations spaced from each other in the direction along the surface of the molded body 20. And the thread | yarn 27 is being fixed to the base material 11 by welding the base material 11 to the thread | yarn 27 embedded as mentioned above. In FIG. 2, the welded portion 11A is shown by a thick line.

Next, as an operation of the first embodiment, a method for manufacturing the skinned product 10 configured as described above will be described with reference to FIGS.
In this manufacturing method, a molded body forming step and a stitch line forming step are performed. Next, each forming process will be described.

<Molded body forming step>
The molded body forming step is a step of forming the molded body 20 by integrating the skin 15 in close contact with the base material 11.

  In this molded body forming step, in order to bring the skin 15 into close contact with the substrate 11, the skin 15 in which the soft layer 17 is laminated on the skin layer 16 is heated by the heater 31, as shown in FIG. Softened.

  In addition to the heating of the skin 15, the base material 11 is formed into a predetermined three-dimensional shape by resin molding such as injection molding. During this molding, a vacuum suction hole is also formed. As shown in FIG. 3B, an adhesive application gun 32 is used to apply the adhesive 33 to the surface of the substrate 11. By drying the adhesive 33, an adhesive layer (not shown) is formed on the surface of the substrate 11.

Subsequently, the skin 15 is integrated with the substrate 11 in close contact with the base material 11, and an operation for forming the texture 18 on the skin 15 is performed.
For this operation, a vacuum forming die shown in FIG. 3C is used. Here, the vacuum forming die includes a lower die 34 that is immovable and an upper die 35 that moves up and down to approach and separate from the lower die 34. The lower die 34 is provided with a molding protrusion 34A, and the upper die 35 is provided with a molding recess 35A. A reverse shape of the embossing 18 is formed in the molding recess 35A. In FIG. 3C, the inverted shape of the texture 18 is indicated by a bold line. Although not shown, a plurality of holes for vacuum suction are formed in a plurality of locations of the lower mold 34 and a plurality of locations of the upper mold 35.

  As shown in FIG. 3C, the base material 11 is mounted on the molding protrusion 34 </ b> A of the lower die 34 in a state where the upper die 35 is spaced upward from the lower die 34. The softened skin 15 is disposed on the substrate 11. The skin 15 is vacuum-sucked downward through the vacuum suction holes of the lower mold 34 and the substrate 11. By this vacuum suction, the skin 15 comes into close contact with the base material 11, and the skin 15 is shaped to the surface shape of the base material 11.

  The upper die 35 is lowered in a state where the vacuum suction is stopped. When the upper die 35 approaches the lower die 34, the skin 15 is vacuumed upward through the vacuum suction hole of the upper die 35, and the skin 15 is brought into close contact with the molding recess 35A. Due to this close contact, the texture 18 is transferred to the surface 15 </ b> A of the epidermis 15.

  The vacuum suction upward is stopped, and the compressed air is ejected downward through the vacuum suction hole of the upper die 35. The skin 15 is pressed against the molding protrusion 34A of the lower mold 34 by this compressed air. Further, the skin 15 is vacuum-sucked downward through the vacuum suction hole of the lower die 34. The shaped skin 15 is brought into close contact with the base material 11 by pressing with the compressed air and vacuum suction. A molded body 20 is formed in which the skin 15 is integrated with the base material 11 through an adhesive layer (not shown).

The upper mold 35 is raised to open the vacuum mold, and the molded body 20 is taken out from the vacuum mold as shown in FIG.
Although not shown, the surplus portion of the skin 15 is trimmed (removed).

<Stitch line formation process>
The stitch line forming step is a step of forming the stitch line 25 on the surface 15A of the skin 15.

  In the stitch line forming step, first, as shown in FIG. 4, more precisely, with respect to the locations spaced from each other in the direction along the surface of the molded body 20, more precisely, the locations where the thread 27 is to be embedded are A hole 37 is drilled. The object in which the hole 37 is drilled is the epidermis 15 here.

Next, as shown in FIG. 5, the thread 27 is placed along the surface 15 </ b> A and the hole 37 of the skin 15. At this time, the thread 27 is tensioned via the pulley 38.
The thread 27 is embedded and fixed to a portion deeper than the surface 15 </ b> A of the skin 15 at the above-described portion of the molded body 20 (location separated from each other in the direction along the surface).

  More specifically, as shown in FIG. 6, the ultrasonic horn 39 of the ultrasonic welder is moved above the predetermined hole 37 and the thread 27. The ultrasonic horn 39 is moved down and inserted into the hole 37. Part of the thread 27 (locations separated from each other in the length direction) is pushed into a location deeper than the surface 15A of the skin 15 by the ultrasonic horn 39 that moves downward as described above. By this pushing, the part of the thread 27 is embedded in the molded body 20.

  Here, if the thread 27 is embedded in the molded body 20 in which the hole 37 is not formed, it is necessary to embed the thread 27 while opening the hole 37 in the molded body 20 (at least the skin 15) by the ultrasonic horn 39.

  In this regard, in the first embodiment, as described above, prior to the stitch line forming step, a hole 37 is formed in a place where the thread 27 is to be embedded in the molded body 20 (skin 15) (see FIG. 4).

  In the stitch line forming step, the thread 27 is embedded by the ultrasonic horn 39 in the hole 37. That is, a part of the thread 27 and the ultrasonic horn 39 are pushed into the already formed hole 37.

  In a state where the part of the thread 27 is embedded in the molded body 20, the ultrasonic horn 39 is vibrated in the vertical direction. This vibration is transmitted to the part embedded in the molded body 20 in the yarn 27, and the same part vibrates. Due to this vibration, frictional heat is generated at the interface between the base material 11 and the thread 27, and the base material 11 is melted and bonded (joined) to the thread 27. Due to this bonding (bonding), the part of the thread 27 is fixed to the base material 11 located at a location deeper than the surface 15 </ b> A of the skin 15. Thus, not only ultrasonic welding but also the thread 27 is embedded by the ultrasonic horn 39.

  After the ultrasonic welding is finished, the ultrasonic horn 39 is raised with the vibration stopped, and is extracted from the hole 37. The ultrasonic horn 39 is moved along the surface 15 </ b> A of the skin 15 to above the hole 37 to be pushed next. Such pushing and vibration of the thread 27 by the ultrasonic horn 39 are repeated for each hole 37, whereby a stitch line including a plurality of seams 26 arranged in a line along the surface 15 </ b> A of the skin 15. 25 is formed.

  In the first embodiment, another member such as a fastener is not used to fix the embedded portion of the thread 27 to the molded body 20. Therefore, another member such as a fastener does not remain in the molded body 20.

  Further, in order to fix the thread 27 to the molded body 20, the thread 27 is merely embedded in the molded body 20 and is not sewn. Therefore, unlike the case of sewing using two types of threads (upper thread and lower thread), only one type of thread 27 is used.

  When the molded body 20 is sewn with a sewing machine, the molded body 20 is restricted in shape, such as a flat portion to be sewn. However, in the first embodiment in which the thread 27 is embedded in the molded body 20, the molded body 20 is less likely to be restricted in shape as described above. Therefore, the freedom degree about the shape of the molded object 20 increases.

  Moreover, in 1st Embodiment, unlike patent document 1, the operation | work which affixes the skin in which the stitch line was formed on a base material is unnecessary. The operation of aligning the position of the stitch line 25 is only performed when the thread 27 is embedded in the molded body 20. The scene where the position of the stitch line 25 is aligned is reduced, and the variation in the position of the stitch line 25 that finally appears on the skinned product 10 is reduced.

  When the stitch line 25 is formed, since the part of the thread 27 is embedded in the molded body 20 in which the skin 15 is integrated with the base material 11, wrinkles enter the skin 15, and the skin 15 becomes the base material 11. Phenomenon that floats up hardly occurs. The skin 15 is in close contact with the base material 11, and the skin 15 does not have wrinkles or floats or is small.

  In the product 10 with the skin obtained as described above, many portions of the yarn 27 constituting the stitch line 25 are located on the surface 15A of the skin 15. On the other hand, the portion of the thread 27 that is fixed to the molded body 20 is located at a location deeper than the surface 15A of the skin 15 at a location where the molded body 20 is spaced from each other. Therefore, the fixed portion of the thread 27 with the molded body 20 is difficult to see from the outside.

According to the first embodiment described in detail above, the following effects can be obtained.
(1) In the molded body forming step, a molded body 20 in which the skin 15 is integrated with the base material 11 is formed (FIGS. 3A to 3D). In the stitch line forming step, the yarn 27 is placed along the surface 15A of the skin 15 and the yarn 27 is embedded to a deeper location than the surface 15A of the skin 15 at locations spaced from each other in the direction along the surface of the molded body 20. The stitch line 25 is formed by fixing to the body 20 (FIGS. 5 and 6).

  Therefore, when forming the stitch line 25, it is possible to suppress the occurrence of wrinkles and floats on the skin 15, and to easily manufacture the product with skin 10 having excellent appearance quality in which the skin 15 is in close contact with the base material 11.

(2) In the stitch line forming step, a portion of the yarn 27 embedded in the molded body 20 is joined to the base material 11 by ultrasonic welding (FIG. 6).
Therefore, it is not necessary to use a separate member such as a fastener to fix the thread 27 to the molded body 20. Accordingly, another member such as a fastener does not remain in the molded body 20.

(3) In the stitch line forming step, the thread 27 is embedded and ultrasonic welded by an ultrasonic horn 39 of an ultrasonic welder (FIG. 6).
Therefore, the number of devices to be used can be reduced as compared with the case where the embedding of the yarn 27 into the molded body 20 and the ultrasonic welding are performed using separate devices.

  (4) The embedding of the thread 27 by the ultrasonic horn 39 in the stitch line forming step is performed in the hole 37 formed in the skin 15 of the molded body 20 prior to the embedding (FIGS. 4 and 6). .

Therefore, it is not necessary to make the hole 37 by the ultrasonic horn 39, and the thread 27 can be pushed into the formed body 20 smoothly.
(5) As a method of forming a stitch line, it is also conceivable to insert ridges that artificially represent seams into the molded body so as to form a row. However, in this case, it is difficult to realize a thread-like appearance and feel (hand) with a heel.

  In this regard, in the first embodiment, the thread 27 is used even though the sewing machine is not sewn. In addition, since a part of the thread 27 is embedded in a part of the molded body 20 that is spaced apart from each other, the seam 26 appears intermittently on the surface 15A of the skin 15. Therefore, it is possible to express the seam 26 having the same appearance and feel (hand) as those sewn with the sewing machine.

  (6) In the molded body forming step, a heated and softened sheet-shaped skin 15 is arranged on the surface of the base material 11 mounted on the lower mold 34 of the vacuum forming die, and the skin 15 is vacuum-sucked to form the base material. The compact 20 is formed by being in close contact with the resin 11 (FIGS. 3C and 3D).

  Therefore, the skin 15 can be brought into close contact with the base material 11 by vacuum suction through the lower mold 34 and shaped into the surface shape of the base material 11. A molded body 20 in which the skin 15 and the base material 11 are integrated can be formed.

(7) As the skin 15, a soft layer 17 laminated on the back side of the skin layer 16 is used (FIG. 2).
Therefore, it is possible to make the product 10 with a skin richer in cushioning and superior in touch (hand) than when the soft layer 17 is not provided.

(Modification of the first embodiment)
1st Embodiment can also be implemented as a modification which changed this as follows.
<Stitch line formation process>
-When pushing the thread | yarn 27 into the molded object 20, the ultrasonic horn 39 may be vibrated up and down along a coaxial line, rotating the axis line. In this way, the thread 27 can be screwed into the molded body 20.

The hole 37 may be provided in a part (at least the upper part) of the base material 11 in addition to the skin 15.
The thread 27 may be pushed into the hole 37 by a device different from the ultrasonic horn 39.

  Depending on the thickness, material, etc. of the skin 15, there may be a case where the hole 37 can be opened by the ultrasonic horn 39. In this case, the hole 37 may be omitted, and the operation of opening the hole 37 with the needle 36 may be omitted.

(Second Embodiment)
Next, 2nd Embodiment of the manufacturing method of a product with an outer skin is described with reference to FIGS.

  The second embodiment is different from the first embodiment in the manner of fixing the thread 27 to the molded body 20. Accordingly, when the stitch line forming step is performed, the operation of embedding and fixing the thread 27 in the molded body 20 is different from the first embodiment.

<Fixing aspect of the thread 27>
FIG. 8 shows a cross section orthogonal to the extending direction of the seam 26 of the thread 27 for a part of the product 10 with the skin of the second embodiment. As shown in FIG. 8, a hole 41 penetrating in the thickness direction of the molded body 20 is formed in the molded body 20 instead of the hole 37 in the first embodiment. In order to distinguish between the first embodiment not penetrating the molded body 20 and the second embodiment penetrating, the first embodiment is expressed as “hole 37”, and in the second embodiment “hole 41”. ".

In the second embodiment, a fastener 42 is used in place of the ultrasonic horn 39 and the thread 27 is embedded and fixed in the molded body 20.
As the fastener 42, what has a pair of leg part 43 and the connection part 44 which connects the base end part (upper end part of FIG. 8) of both the leg parts 43 is used. The fastener 42 is formed by folding a hard wire (metal wire) 45 (see FIG. 9) in two.

  The fastener 42 is driven and locked to the molded body 20 to a position deeper than the surface 15A of the skin 15. A fine uneven portion 45A is formed on the surface of the fastener 42, and the locking strength of the fastener 42 to the molded body 20 is enhanced.

  Part of the thread 27 (locations spaced apart from each other in the length direction) is embedded by the connecting portion 44 of the fastener 42 and is located immediately above the base material 11, which is a location deeper than the surface 15 </ b> A of the skin 15. . The part of the thread 27 is sandwiched between the leg portions 43 of the fastener 42 by the boundary portion (base end portion) with the connecting portion 44. The thread 27 is fixed to the molded body 20 in part by the connecting portion 44 and both leg portions 43.

<Stitch line formation process>
FIG. 7 shows an outline of the stitch line forming process. In the stitch line forming step, first, as shown in FIG. 7, the needles 27 are more accurately applied to the locations where the thread 27 is to be embedded in the locations separated from each other on the surface of the molded body 20 (skin 15). The hole 41 is opened by (not shown). Next, the thread 27 is stretched along the surface 15A and the hole 41 of the skin 15 in a tensioned state.

  Subsequently, the thread 27 is embedded and fixed up to a position deeper than the surface 15 </ b> A of the skin 15 by the fasteners 42 at positions separated from each other in the direction along the surface of the molded body 20.

In the second embodiment, the fastener 42 is formed by folding the hard wire 45 into two immediately before driving into the molded body 20.
Specifically, a hard linear body 46, for example, a metal wire, is conveyed by a feed mechanism (not shown) in a direction intersecting (orthogonal to) the stitch line 25 (an obliquely lower left direction in FIG. 7). In the middle of the conveyance, the linear body 46 is passed between the pair of rollers 47, so that the unevenness 47 </ b> A formed on the surface of the roller 47 is transferred to the surface of the linear body 46. By this transfer, an uneven portion 45 </ b> A is formed on the surface of the linear body 46.

  When the filament 46 is conveyed for a predetermined length, the conveyance is stopped, and the ends of the filament 46 are gripped by the pair of gripping members 48 from both the upper and lower sides. A portion of the linear body 46 gripped by the gripping members 48 is later used as a connecting portion 44 of the fastener 42. The linear body 46 is cut into a predetermined length by a cutting device 51 disposed between both the gripping members 48 and both the rollers 47. The wire body 46 cut and shortened to a predetermined length (refer to a two-dot chain line in FIG. 7) is referred to as a wire 45 here. The cutting device 51 includes a fixed blade 52 and a movable blade 53 that cuts the filament 46 in cooperation with the fixed blade 52 by moving up and down with respect to the fixed blade 52.

As shown by the two-dot chain line in FIG. 7, both the gripping members 48 are moved to above the hole 41 where the thread 27 is to be driven next while gripping the wire 45.
As shown in FIGS. 7 and 9, a pair of bending pieces 56 are disposed above the hole 41 in a state of being separated from each other in a direction along the wire 45 (a direction orthogonal to the stitch line 25). . These bent pieces 56 are lowered as shown by arrows in FIG. In each bent piece 56, a groove 56A extending in the vertical direction is formed on the surface of the opposite bent piece 56 side.

  As shown in FIG. 10, both bending pieces 56 hit the wire 45 gripped by both gripping members 48 in the descending process. The both bending pieces 56 are brought into contact with the wire 45 in the groove portion 56A. When both bending pieces 56 are further lowered, both bending pieces 56 do not move. Therefore, in the wire 45, a portion gripped by both gripping members 48 (a portion to be the connecting portion 44) is a starting point of bending. Both side portions in the length direction of the wire 45 are bent downward.

  In the middle of the bending of the wire 45, the gap between the gripping members 48 is widened and the gripping of the wire 45 by the gripping members 48 is released. Further, both gripping members 48 are retracted from between both bending pieces 56.

  In the middle of the bending of the wire 45, in addition to the lowering, the two bent pieces 56 are moved toward each other as indicated by arrows in FIG. As a result of this movement, the gap between the two groove portions 56A is narrowed, and the wire 45 is bent larger than when both the bent pieces 56 are simply lowered. As the distance between the two groove portions 56A becomes narrower, the angle formed by both leg portions 43 becomes smaller. As shown in FIG. 11, when the wire 45 is folded in two until the both leg portions 43 become substantially parallel, the connecting portion 44 that connects the pair of leg portions 43 and the base end portions (upper end portions) of the both leg portions 43. It becomes the form of the fastener 42 provided with these. In this fastener 42, the distal end portions (lower end portions in FIG. 11) of both leg portions 43 are in a state in which the thread 27 is sandwiched immediately above the skin 15.

  The fastener 42 is formed immediately before the fastener 27 is driven into the molded body 20 and the thread 27 is embedded in the base material 11 in the stitch line forming step. In this way, the fasteners 42 necessary for embedding the thread 27 are formed immediately before driving, so that it is not necessary to prepare many fasteners 42.

  Next, as shown in FIG. 12, a bar-like driving punch 57 (see FIG. 7) disposed in a vertically extending posture is lowered above the fastener 42. The driving punch 57 descends between both the groove portions 56A and drives the fastener 42. In the middle of this driving, the connecting portion 44 comes into contact with the thread 27. Further, by lowering the driving punch 57, the connecting portion 44 is pressed downward as shown in FIG. Then, the fastener 42 is driven into the molded body 20 in a posture in which the thread 27 is sandwiched between the both leg portions 43 and the connecting portion 44 is positioned behind the both leg portions 43 in the driving direction.

  The thread 27 is pressed downward by the connecting portion 44 that is displaced along with the driving, and is embedded in a deeper portion of the molded body 20 than the surface 15A of the skin 15. Further, since the fastener 42 is locked to the base material 11 and remains in the molded body 20, the thread 27 is placed at the both leg portions 43 and the connecting portion at the place embedded as described above (directly above the base material 11). The movement is restricted by 44 (fixed state).

  In particular, the fastener 42 is driven into the molded body 20 so as to come into contact with the molded body 20 at the uneven portion 45A on the surface. Due to the contact at the concavo-convex portion 45A, the fastener 42 is less likely to come out of the molded body 20 than when the surface is formed to be smooth.

According to the second embodiment described in detail above, the following effects can be obtained in addition to the above (1) and (5) to (7).
(8) In the stitch line forming step, the fastener 42 is driven into the molded body 20 from the surface 15A side of the skin 15 to a position deeper than the surface 15A of the skin 15 to be locked to the base material 11, thereby 27 is embedded and fixed in the molded body 20 (FIGS. 9 to 13).

Therefore, unlike the first embodiment using the ultrasonic horn 39, the thread 27 can be embedded and fixed in the molded body 20 without melting the base material 11.
(9) As the fastener 42, one having a pair of leg portions 43 and a connecting portion 44 connecting the base end portions of both leg portions 43 is used (FIG. 8). The fastener 42 is driven into the molded body 20 and locked to the base material 11 in a state in which the thread 27 is sandwiched between both the leg portions 43 and the connecting portion 44 is positioned behind the both leg portions 43 in the driving direction. The thread 27 is embedded and fixed in the molded body 20 (FIGS. 11 to 13).

  Therefore, the threaded fasteners 42 are locked to the base material 11 and are left in the molded body 20, so that the movement of the thread 27 is restricted (fixed) by both the leg portions 43 and the connecting portions 44. be able to.

(10) The fastener 42 is formed by folding the wire 45 in two immediately before driving into the molded body 20 (FIGS. 9 to 11).
Thus, since the fastener 42 necessary for embedding the thread 27 is formed immediately before driving, the fastener 42 does not have to be prepared in advance, and is prepared in the state of the wire 45 before being used as the fastener 42. Just do it.

(11) As the wire 45, a wire having an uneven portion 45A formed on the surface is used (FIGS. 7 and 9).
Therefore, by bringing the fastener 42 into contact with the molded body 20 at the concavo-convex portion 45 </ b> A on the surface thereof, it is difficult for the fastener 42 to come out of the molded body 20, and the thread 27 driven by the fastener 42 is attached to the skin 15. It can be maintained in a state where it is buried to a deeper position than the surface 15A.

(Modification of the second embodiment)
The second embodiment can also be implemented as a modified example in which this is changed as follows.
<Stitch line formation process>
-The hole 41 may not penetrate the molded body 20. For example, the hole 41 may be provided in the skin 15 and a part (at least the upper part) of the base material 11.

  -Depending on each thickness, each material, etc. of the skin 15 and the base material 11, it may be possible to drive the fastener 42 to a location deeper than the surface 15A of the skin 15 in the molded body 20. In this case, the hole 41 may be omitted.

  -The operation | work which cuts the filament 46 may be omitted. In this case, a plurality of wire rods 45 having a necessary length are prepared in advance, and these wire rods 45 are sequentially folded in two and driven into the molded body 20.

  -The operation | work which folds the wire 45 into two may be omitted. In this case, a plurality of fasteners 42 folded in advance in advance are prepared, and these fasteners 42 are sequentially driven into the molded body 20.

(Third embodiment)
Next, 3rd Embodiment of the manufacturing method of a product with an outer skin is described with reference to FIGS.

  The third embodiment is different from the second embodiment in the form of the fastener. Accordingly, when the stitch line forming step is performed, the operation of embedding and fixing the thread 27 in the molded body 20 is different from that of the second embodiment.

<Fixing aspect of the thread 27>
FIG. 14: has shown the cross section along the direction where the seam 26 is extended about some products 10 with a skin of 3rd Embodiment. This is different from FIG. 8 which shows a cross section orthogonal to the direction in which the seam 26 extends.

As shown in FIG. 14, a hole 37 is previously formed in the molded body 20 with a needle or the like in the skin 15 as in the first embodiment.
As in the second embodiment, the fastener 60 includes a pair of leg portions 61 and a connecting portion 62 that connects the base end portions (upper end portions in FIG. 14) of both leg portions 61 (see FIG. 15). However, in 3rd Embodiment, the connection part 62 and both the leg parts 61 are integrally formed by the hard thin piece (metal thin piece). The fastener 60 is driven into the molded body 20 to a location deeper than the surface 15A of the skin 15. The tip portions of both leg portions 61 are locked to the upper portion of the base material 11 by press-fitting.

  Part of the thread 27 (locations spaced apart from each other in the length direction) is embedded in the molded body 20 by the connecting portion 62 of the fastener 60 and is directly above the base material 11 which is a location deeper than the surface 15A of the skin 15. positioned. The part of the thread 27 is sandwiched between the leg portions 61 of the fastener 60 by the boundary portion (base end portion) with the connecting portion 62. The thread 27 is fixed to the molded body 20 in part by the connecting portion 62 and the both leg portions 61.

<Stitch line formation process>
FIG. 15 shows an outline of the stitch line forming process. As shown in FIGS. 15 and 16, in the stitch line forming step, first, more accurately, in a place where the thread 27 is to be embedded in a place where the molded body 20 (skin 15) is separated from each other on the surface. On the other hand, a hole 37 is opened by a needle (not shown). Next, the thread 27 is stretched along the surface 15 </ b> A and the hole 37 of the skin 15 in a tensioned state. Up to this point, the process is the same as in the first embodiment.

Subsequently, the thread 27 is embedded and fixed to a portion deeper than the surface 15 </ b> A of the skin 15 by the fastener 60 at a location where the molded body 20 is separated from each other.
In the third embodiment, the guide piece 63 is disposed immediately above the hole 37 to be embedded with the thread 27. The guide piece 63 is formed with a guide groove 63A that guides the vertical movement of the fastener 60. Then, the fastener 60 formed in advance is sequentially conveyed into the guide groove 63A.

  As shown in FIGS. 16 and 17, the thin plate-like driving punch 64 disposed above the guide piece 63 is lowered. The driving punch 64 comes into contact with the fastener 60 in the descending process. Even after the contact, the driving punch 64 is lowered so that the fastener 60 is pressed downward at the connecting portion 62. Then, the fastener 60 is driven and locked into the molded body 20 with the posture in which the thread 27 is sandwiched between the both leg portions 61 and the connecting portion 62 is positioned rearward of the both leg portions 61 in the driving direction. The driving punch 64 is guided to descend by passing through the guide groove 63 </ b> A together with the fastener 60.

  Part of the yarn 27 (locations separated from each other in the length direction) is pressed downward by the connecting portion 62 that is displaced along with the driving, and is embedded in the molded body 20 at a location deeper than the surface 15A of the skin 15. Further, since the fastener 60 is locked to the base material 11 and remains in the molded body 20, the thread 27 is placed by the both leg portions 61 and the connecting portion 62 in the portion (base material 11) embedded as described above. The movement is restricted (fixed state).

According to 3rd Embodiment explained in full detail above, the following effect is acquired in addition to said (1), (5)-(9).
(12) As the fastener 60, a thin piece in which both the leg portions 61 and the connecting portion 62 are integrally formed is used (FIG. 15).

  Therefore, unlike the second embodiment, it is not necessary to perform a process such as bending a material such as a wire immediately before driving the fastener 60 into the molded body 20. In connection with this, a processing apparatus is also unnecessary.

(Modification of the third embodiment)
3rd Embodiment can also be implemented as a modification which changed this as follows.
<Stitch line formation process>
The hole 37 may be provided in a part of the base material 11 in addition to the skin 15.

  Depending on the thickness, material, etc. of the skin 15, it may be possible to drive the fastener 60 to a location deeper than the surface 15 </ b> A of the skin 15. In this case, the hole 37 may be omitted.

  -As the fastener 60, the thing by which the uneven | corrugated | grooved part was formed on the surface may be used similarly to 2nd Embodiment. Due to the uneven portion, the locking strength of the fastener 60 with respect to the molded body 20 can be increased.

(Modification common to the first to third embodiments)
In addition, the 1st-3rd embodiment mentioned above can also be implemented as a modification which changed this as follows.

<About thread 27>
A thread 27 having a color different from that of the skin 15 may be used. By doing in this way, the stitch line 25 can be emphasized and the external appearance quality of the product 10 with a skin can be improved further.

<About molded body formation process>
The molded body 20 in which the skin 15 is integrated with the base material 11 may be formed by a method different from the first to third embodiments.

The operation of transferring the texture 18 to the surface 15A of the skin 15 may be omitted.
<Stitch line formation process>
A plurality of needles 36 may be used, and holes 37 or holes 41 may be formed at a plurality of locations of the molded body 20 at a time.

<Applicable target>
-The above manufacturing method is not limited to vehicle interior parts, and can be widely applied to products with a skin having a stitch line on the surface of the skin.

In addition, the technical ideas that can be grasped from the respective embodiments will be described together with their effects.
(A) In the method for manufacturing a product with a skin according to any one of claims 1 to 8 , in the molded body forming step, the surface of the base material mounted on a vacuum mold is heated and softened. A sheet-like skin is disposed, and the molded body is formed by vacuum-sucking the skin to bring it into close contact with the substrate.

  According to said manufacturing method, a base material is mounted | worn with a vacuum forming die in a molded object formation process. On the other hand, the sheet-like skin is heated and softened. This softened skin is disposed on the surface of the substrate. The skin is vacuum-sucked through a vacuum forming die, and is brought into close contact with the base material, thereby forming the surface shape of the base material. A molded body in which the skin and the base material are integrated is formed.

(B) In the method for producing a product with a skin according to any one of claims 1 to 8 and (A), a product in which a soft layer is laminated on the back side of the skin layer is used as the skin.
As described above, when the soft layer is provided in addition to the skin layer, the product with the skin is richer in cushioning than the case where the soft layer is not provided, and the touch (hand) is excellent.

  DESCRIPTION OF SYMBOLS 10 ... Product with skin, 11 ... Base material, 15 ... Skin, 15A ... Surface, 20 ... Molded body, 25 ... Stitch line, 26 ... Stitch, 27 ... Thread, 37 ... Hole, 39 ... Ultrasonic horn, 42, 60 ... Fasteners, 43, 61 ... Legs, 44, 62 ... Connecting parts, 45 ... Wire rods, 45A ... Uneven parts.

Claims (8)

A method of manufacturing a product with an epidermis comprising a base material, an epidermis disposed on the base material, and stitch lines composed of a plurality of seams arranged linearly along the surface of the epidermis. And
A molded body forming step of forming a molded body by integrating the epidermis in a state of being in close contact with the substrate; and
After the forming body forming step, the thread is embedded along the surface of the skin, and the thread is embedded in a portion deeper than the surface of the skin at a position spaced apart from the surface of the forming body, and fixed to the forming body. The stitch line forming step for forming the stitch line is performed ,
In the stitch line forming step, a portion embedded in the molded body of the yarn is joined to the base material by ultrasonic welding, and the method for manufacturing a product with skin is characterized. The method for manufacturing a product with a skin according to claim 1 , wherein in the stitch line forming step, the embedding of the yarn and ultrasonic welding are performed by an ultrasonic horn of an ultrasonic welding machine. The method for producing a product with a skin according to claim 2 , wherein the embedding of the yarn by the ultrasonic horn in the stitch line forming step is performed at least in a hole formed in the skin of the molded body prior to the embedding. . A method of manufacturing a product with an epidermis comprising a base material, an epidermis disposed on the base material, and stitch lines composed of a plurality of seams arranged linearly along the surface of the epidermis. And
A molded body forming step of forming a molded body by integrating the epidermis in a state of being in close contact with the substrate; and
After the forming body forming step, the thread is embedded along the surface of the skin, and the thread is embedded in a portion deeper than the surface of the skin at a position spaced apart from the surface of the forming body, and fixed to the forming body. A stitch line forming step for forming the stitch line; and
Is done,
In the stitch line forming step, the fastener is driven into the molded body from the surface side of the skin to a location deeper than the surface of the skin and is locked to the base material, whereby the yarn is molded into the molded body. A method for producing a product with an epidermis , characterized by embedding and fixing. In the stitch line forming step, the fastener includes a pair of leg portions and a connecting portion that connects the base ends of the both leg portions, the yarn is sandwiched between the both leg portions, and the connecting portion is The thread is embedded and fixed in the molded body by driving the fastener into the molded body and locking it to the base material in a state of being positioned behind the both leg portions in the driving direction. 4. A method for producing a product with an epidermis according to 4 . The manufacturing method of the product with a skin according to claim 5 , wherein the fastener is formed by folding a wire rod in half immediately before being driven into the molded body. The manufacturing method of the product with a skin of Claim 6 using what the uneven | corrugated | grooved part was formed in the surface as said wire. The manufacturing method of the product with an outer skin of Claim 5 using the thin piece in which the said both leg part and the said connection part were formed integrally as the said fastener.