JP6587473B2 - Vehicle seat and method for manufacturing vehicle seat - Google Patents

Description

  The present invention relates to a vehicle seat, and more particularly to a technique that is effective when applied to a design (design) on a trim cover.

  Vehicle seats such as automobile seats are required to have various functions such as safety, holdability, and getting on and off (ease of getting on and off), and at the same time, there are many demands for improving passenger comfort such as sitting comfort and vibration absorption performance. In addition, it is a large part that attracts attention among the interior parts of automobiles, and there are various demands on its appearance and design.

  When a design (design) is applied to a trim cover, which is a seat cover, as a design expression of an automobile seat, processing such as embroidery is performed in a state of a cut piece before sewing the trim cover, for example, by sewing.

  As a background art in this technical field, for example, there is a technique such as Patent Document 1. Patent Document 1 states that “a trim having a predetermined shape on the surface side by scraping a desired thickness according to a predetermined pattern from the back side of the leather used as the skin material, and bending and deforming the thin wall portion. "Cover" is disclosed.

  Patent Document 2 discloses “a vehicle seat in which a mesh string is formed by arranging pattern strings in a line shape in a substantially cross state”.

  Patent Document 3 states that “a leather material with a three-dimensional pattern is prepared in the preparation process, and in the shape-retaining treatment process, the leather material is exposed to a predetermined heating steam and has a core on the back side. A method of processing a three-dimensional pattern of a leather material in which a ground is pasted and the surface side of the leather material is placed on a flat support surface having elasticity and pressed from the upper surface of the interlining is disclosed.

Japanese Patent No. 2632163 Japanese Utility Model Publication No. 6-52700 Japanese Patent No. 5857964

  As described above, when embroidery is performed in the state of the cut piece before the trim cover is sewn, for example, by sewing the sewing machine, it is necessary to introduce a computer sewing machine for embroidery processing, and much time is required for embroidery processing. This leads to an increase in manufacturing cost and an increase in lead time.

  In addition, it is necessary to prepare cutting pieces that have been subjected to a design (design) according to a customer's request, and the types of cutting pieces increase, making inventory management complicated.

  In addition, since the trim cover is formed by sewing the cut piece after the design (design) is applied to the cut piece, each trim cover is subject to variations due to variations in the cut of the skin material and variations in the cut piece during sewing. There is also a risk that the design will shift.

  The manufacturing method of the trim cover of Patent Document 1 is to form a wrinkle pattern on the surface of the skin material. However, since it is necessary to scrape a part of the back surface side of the skin material, the degree of freedom in design (design) design. In addition, it is disadvantageous for suppressing the manufacturing cost and shortening the lead time.

  The skin pattern structure of Patent Document 2 described above can form a novel mesh weaving line, but is cumbersome, and is also disadvantageous for suppressing the manufacturing cost and shortening the lead time.

  Since the three-dimensional pattern processing method of Patent Document 3 processes a three-dimensional pattern in advance in the preparation process, there is a risk that the three-dimensional pattern formed in the preparation process may lose shape before the shape-retaining treatment is performed. It is unsuitable for manufacturing mass-produced products such as automobile seats that require a small and uniform quality. Further, it is necessary to prepare a flat support surface having elasticity, which is disadvantageous in terms of manufacturing cost and lead time.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a vehicle seat having a highly durable three-dimensional pattern on its surface that is not easily deformed.

  Another object of the present invention is to provide a method for manufacturing a vehicle seat having a three-dimensional pattern that has a high degree of freedom in design (design) and has little influence on sitting comfort while suppressing an increase in manufacturing cost and lead time. There is to do.

The present invention also includes (a) a step of preparing a laminated material by laminating a skin material made of a wadding, a hot-melt adhesive, and a leather-based material in order from the lower layer, and (b) a pressing with a desired pattern formed A step of pressing the laminate material by pressing a mold from the skin material side; (c) supplying heated steam from the back surface side of the skin material while pressing the laminate material; A vehicle seat manufacturing method including a heating step.

In addition, the present invention provides (a) a step of preparing a trim cover made of a laminated material of a skin material made of wadding and leather-based material , and (b) a hot melt adhesive on the wadding side surface of the trim cover, (C) a step of pressing the trim cover by pressing a pressing mold on which a desired pattern is formed from the skin material side, and (d) adding the trim cover. The vehicle seat manufacturing method includes a step of supplying heated steam from the back surface side of the skin material and heating the pressurizing portion in a pressed state.

  According to the present invention, it is possible to realize a vehicle seat having a highly durable three-dimensional pattern that is less likely to lose its shape.

  In addition, according to the present invention, there is provided a method for manufacturing a vehicle seat having a three-dimensional pattern having a high degree of freedom in design (design) and having little influence on sitting comfort while suppressing an increase in manufacturing cost and lead time. Can do.

  Problems, configurations, and effects other than those described above will be clarified by the following description of embodiments.

It is a figure showing the whole vehicular seat outline concerning one embodiment of the present invention. It is a figure which shows the design (pattern) of the vehicle seat which concerns on one Embodiment of this invention. It is a figure which shows the A-A 'part cross section in FIG. It is a figure which shows notionally a part of manufacturing process of the vehicle seat which concerns on one Embodiment of this invention. It is a figure which shows notionally a part of manufacturing process of the vehicle seat which concerns on one Embodiment of this invention. It is a figure which shows notionally a part of manufacturing process of the vehicle seat which concerns on one Embodiment of this invention. It is a figure which shows notionally a part of manufacturing process of the vehicle seat which concerns on one Embodiment of this invention. It is a figure which shows notionally a part of manufacturing process of the vehicle seat which concerns on one Embodiment of this invention. It is a figure which shows notionally a part of manufacturing process of the vehicle seat which concerns on one Embodiment of this invention. It is a figure which shows the pattern (embroidery) given to the surface of the conventional vehicle seat.

  Embodiments of the present invention will be described below with reference to the drawings. In the drawings, the same components are denoted by the same reference numerals, and detailed description of the overlapping portions is omitted.

  First, with reference to FIG. 8, the pattern given to the surface of the conventional motor vehicle seat is demonstrated. FIG. 8 is a view in which a lattice-like sewing sewing (embroidery) 15 is applied to the surface of a cut piece of a skin material used for an automobile seat.

  In a conventional automobile seat, when a pattern is formed on the sheet surface, as shown in FIG. 8, it is common to perform sewing by sewing (embroidery) directly on the cut piece of the skin material 9. This method is suitable for forming a planar pattern on the surface of an automobile seat. For example, a plurality of patterns (patterns) are stored in advance in a computer sewing machine, and a desired pattern (pattern) is selected. A pattern is formed by sewing (embroidery) 15 on the surface of the skin material 9.

  Conventional pattern formation by sewing (embroidery) requires introduction of an expensive computer sewing machine as described above, leading to an increase in the manufacturing cost of automobile seats. Further, when forming a complicated pattern, it takes time for sewing (embroidery), and the lead time increases. In the case of an automobile seat, the occupant's clothes seated and the sewing machine (embroidery) may come into contact with each other, and the sewing machine (embroidery) may be worn due to friction. In addition, when a three-dimensional pattern is formed by sewing (embroidery), there is a limit to the pattern (shape) that can be processed, and the manufacturing cost and lead time are further increased.

  Next, the vehicle seat in the present embodiment will be described with reference to FIGS. 1 to 3. FIG. 1 is a perspective view showing an overall outline of a vehicle seat 1 of the present embodiment. FIG. 2 is an enlarged view of the seat back 3 where the pattern (groove) 6 in FIG. 1 is formed. FIG. 3 is an enlarged view of a cross section taken along the line A-A ′ of FIG. 2.

  As shown in FIG. 1, the vehicle seat 1 is provided with a seat cushion 2 serving as a seat surface portion of a seat on a seat frame (not shown). On the back side of the seat cushion 2, a seat back 3 serving as a seat back portion is provided via a reclining mechanism (not shown). A headrest 4 that protects the occupant's head and neck is provided on the upper portion of the seat back 3. Side supports 5 are provided on both sides of the seat cushion 2 to support the occupant's thigh from the lateral direction when sitting. A pattern 6 made of a concave groove is formed on the upper side of the seat back 3.

  In FIGS. 1 and 2, a lattice-like pattern is used as an example of the pattern 6, but the present invention is not limited to this. For example, a circular pattern or a fixed pattern is regularly arranged. It is also possible to replace with a geometric pattern or the like.

  The pattern 6 will be described in detail with reference to FIG. As shown in FIG. 3, the pattern 6 is formed as a concave groove (dent) in the wadding 8 and the skin material 9 that are the batting of the trim cover. The wadding 8 and the skin material 9 are bonded to each other with a hot-melt adhesive 10 such as hot melt.

  The skin material 9 is made of a leather-based material such as genuine leather or synthetic leather, or a cloth-based material such as knitted fabric or woven fabric.

  The hot-melt adhesive 10 is an adhesive mainly composed of a thermoplastic resin such as ethylene vinyl acetate (Ethylene-Vinyl-Acetate), for example. It is a material that is solid or semi-solid at normal temperature and becomes liquid at high temperature. Depending on the material and components, it is heated and melted at about 50 ° C. to 200 ° C., and then solidified by cooling and functions as an adhesive.

  In FIG. 3, the wading 8 and the skin material 9 in which concave grooves (dents) are formed constitute a trim cover that serves as a seat cover for a vehicle seat. The trim cover at a location where at least a concave groove (dent) is formed is formed of a laminated material of a wadding, a hot-melt adhesive, and a skin material in order from the lower layer.

  In the vehicle seat of the present embodiment, as shown in FIG. 3, a back base fabric material 7 serving as a core material of the trim cover is further bonded to the lower layer of the wadding 8 via a hot-melt adhesive 10. Yes.

  The formation method of the pattern 6 demonstrated above is demonstrated using FIGS. 4-5B. FIG. 4 is a diagram conceptually showing a method for forming the pattern 6 in this embodiment. 5A and 5B are views showing FIG. 4 divided in the order of steps.

  As shown in FIG. 4, a pressing die 11 on which a desired pattern is formed is pressed against the laminated material consisting of three layers of a wadding 8, a hot-melt adhesive 10 and a skin material 9 from the skin material 9 side. The heated steam 13 is supplied from the steam nozzle 12 while the pressurized state is maintained, and the adhesive 10 is melted so that the wadding 8 and the skin material 9 are bonded to each other while the wadding 8 and the skin material 9 are recessed. A shaped groove (recess) is formed. This concave groove (dent) is a pressurization mark by the pressing die 11. As shown in FIG. 4, the skin material 9 is pressed by the pressing die 11 and heated by the heating steam 13 in the state of the cut piece.

  The above steps will be described in order with reference to FIGS. 5A and 5B. As shown in FIG. 5A, a laminated material is prepared by overlapping three layers of a wadding 8, a hot-melt adhesive 10, and a skin material 9, and the pressing die 11 is pressed from the skin material 9 side with a predetermined pressure.

  Next, as shown in FIG. 5B, the heated steam 13 is supplied from the steam nozzle 12 to the pressurized portion while maintaining the state of being pressed by the pressing die 11. The hot-melt adhesive 10 is melted by the heating steam 13, the adhesive 10 is cooled by stopping the supply of the heating steam 13, and the wadding 8 and the skin material 9 are bonded to each other. Thereby, a concave groove (dent) is formed in the wading 8 and the skin material 9 while the wadding 8 and the skin material 9 are bonded to each other.

  As described above, according to this embodiment, it is possible to form a highly durable three-dimensional pattern on the surface of the trim cover. In addition, since a three-dimensional pattern can be formed on the trim cover by a simple method without requiring expensive capital investment such as a computer sewing machine, the degree of freedom in design (design) design is suppressed while suppressing an increase in manufacturing cost and lead time. It is possible to manufacture a vehicle seat having a three-dimensional pattern that is high and has little effect on sitting comfort.

  As described with reference to FIGS. 5A and 5B, the pressing of the laminated material by the pressing die 11 is more preferably performed before the heating steam 13 is supplied to the pressurizing unit. This is because, when the heating steam 13 is supplied without being pressed by the pressing die 11, there is a possibility that the stacked three-layer material may be displaced.

  Moreover, it may replace with the heating with the heating vapor | steam 13, and may perform the heating of 50 to 200 degreeC which is the melting temperature of the adhesive material 10 with another heating means.

  Another method for forming the pattern 6 will be described with reference to FIGS. 6 to 7B. FIG. 6 is a diagram conceptually showing a method for forming the pattern 6 in this embodiment. 7A and 7B are diagrams showing FIG. 6 divided in the order of steps.

  As shown in FIG. 6, in this embodiment, a trim cover 14 composed of a wadding 8 and a skin material 9 is prepared in a separate process in advance, and a core is placed under the wadding 8 via a hot-melt adhesive 10. The backing base fabric material 7 as a material is overlapped, and a pressing die 11 on which a desired pattern is formed is pressed from the skin material 9 side and pressed. While maintaining the state of being pressurized by the pressing die 11, the heating steam 13 is supplied from the steam nozzle 12 to melt the adhesive 10, thereby bonding the wadding 8 and the back base fabric material 7, and the wadding 8 and the skin. A concave groove (dent) is formed in the material 9.

  As shown in FIG. 6, the trim cover 14 is formed by trimming a trim cover in accordance with a sheet shape by sewing a cut piece, and then superposing the hot-melt adhesive 10 and the back base fabric material 7 to form a press die 11. Pressing by heating and heating by the heating steam 13 are performed.

  The above steps will be described in order with reference to FIGS. 7A and 7B. As shown in FIG. 7A, the back base fabric material is provided on the back surface side of the trim cover 14 made of the wadding 8 and the skin material 9 prepared in a separate process in advance, that is, on the front surface side of the wadding 8 via a hot-melt adhesive 10. 7 are overlapped and pressed from the skin material 9 side by a pressing die 11 with a predetermined pressure.

  Next, as shown in FIG. 7B, the heated steam 13 is supplied from the steam nozzle 12 to the pressurized portion while maintaining the state of being pressed by the pressing die 11. The hot-melt type adhesive material 10 is melted by the heating steam 13, the adhesive material 10 is cooled by stopping the supply of the heating steam 13, and the wadding 8 and the backing cloth material 7 are bonded to each other. Thereby, concave grooves (dents) are formed in the wadding 8 and the skin material 9 while the trim cover 14 and the back base fabric material 7 are bonded to each other.

  As described above, according to the present embodiment, as in the first embodiment, it is possible to form a highly durable three-dimensional pattern on the surface of the trim cover, which is not easily deformed. In addition, since a three-dimensional pattern can be formed on the trim cover by a simple method without requiring expensive capital investment such as a computer sewing machine, the degree of freedom in design (design) design is suppressed while suppressing an increase in manufacturing cost and lead time. It is possible to manufacture a vehicle seat having a three-dimensional pattern that is high and has little effect on sitting comfort.

  Further, in this embodiment, as shown in FIG. 6, after the trim cover is formed by sewing the cut pieces to match the sheet shape, the wadding 8 and the skin material 9 are pressed by the pressing die 11 and heated by the heating steam 13. Since the concave groove (depression) is formed in the pattern, it is possible to prevent the displacement of the pattern due to the deviation generated when the cutting piece is sewn, that is, the depression of the concave groove (depression).

  As in Example 1, it is more preferable to press the laminated material with the pressing die 11 before supplying the heating steam 13 to the pressurizing unit. Moreover, it may replace with the heating by the heating steam 13, and may perform the heating of 50 to 200 degreeC which is the melting temperature of the adhesive material 10 with another heating means.

  Further, as shown in FIGS. 6 to 7B, the heating steam 13 may be supplied from either the front side or the back side of the skin material 9. However, when the skin material 9 is a leather-based material such as genuine leather or synthetic leather, it is more preferable to supply from the back side of the skin material 9 because the heating steam 13 is difficult to permeate the skin material 9. On the other hand, when the skin material 9 is a cloth-type material such as a knitted fabric or a woven fabric, the heating steam 13 is likely to pass through the skin material 9, and may be supplied from either the front surface side or the back surface side of the skin material 9.

  Further, when the trim cover 14 made of the wadding 8 and the skin material 9 is prepared in a separate process in advance, the bonding between the wadding 8 and the skin material 9 may be performed using a hot-melt adhesive 10. Other adhesive materials may be used.

  In each of the above-described embodiments, the design (pattern) is described using an example in which the design is formed on the seat back. However, it goes without saying that the design can be applied to parts other than the seat back such as a seat cushion, a headrest, and an armrest.

  In addition, this invention is not limited to an above-described Example, Various modifications are included. For example, the above-described embodiments have been described in detail for easy understanding of the present invention, and are not necessarily limited to those having all the configurations described. Further, a part of the configuration of one embodiment can be replaced with the configuration of another embodiment, and the configuration of another embodiment can be added to the configuration of one embodiment. Further, it is possible to add, delete, and replace other configurations for a part of the configuration of each embodiment.

  DESCRIPTION OF SYMBOLS 1 ... Vehicle seat, 2 ... Seat cushion, 3 ... Seat back, 4 ... Headrest, 5 ... Side support, 6 ... Pattern (groove), 7 ... Back base material, 8 ... Wadding (batting), 9 ... Skin material, DESCRIPTION OF SYMBOLS 10 ... Adhesive material, 11 ... Push type, 12 ... Steam nozzle, 13 ... Heated steam, 14 ... Trim cover, 15 ... Sewing machine sewing (embroidery).

Claims (2)

A vehicle seat manufacturing method including the following steps;
(A) A step of preparing a laminated material by superimposing a skin material made of a wadding, a heat-melt adhesive, and a leather material in order from the lower layer,
(B) a step of pressing the laminated material by pressing a pressing die on which a desired pattern is formed from the skin material side;
(C) The process of supplying heating steam from the back surface side of the skin material and heating the pressurizing part while the laminated material is being pressurized. A vehicle seat manufacturing method including the following steps;
(A) a step of preparing a trim cover made of a laminated material of a skin material made of wadding and a leather-based material ;
(B) a step of superimposing a backing fabric material on the wadding side surface of the trim cover via a hot-melt adhesive;
(C) a step of pressing the trim cover by pressing a pressing die on which a desired pattern is formed from the skin material side of the trim cover;
(D) A step of heating the pressurizing part by supplying heated steam from the back side of the skin material while the trim cover is pressurized.

Images