JP6846904B2 - Manufacturing method of skin material with decorative stitching - Google Patents

Description

The present invention relates to a method for producing a skin material with a decorative stitch that forms a decorative stitch on the skin material.

Patent Document 1 discloses a method of forming decorative stitches on a skin material formed into a three-dimensional shape by a sewing machine (see, for example, Patent Document 1). Further, depending on the shape of the skin material, a method of using a post-type sewing machine in which a pot stand is provided on a post erected from the sewing machine bed is also known as a sewing machine.

Japanese Unexamined Patent Publication No. 2011-46311 (paragraph [0028], FIG. 3)

However, in the conventional method for manufacturing a skin material with decorative stitches described above, for example, when a decorative stitch is formed in the vicinity of the corner portion of the skin material having a corner portion, the corner portion is pressed against the pot stand and deformed to form the skin. Wrinkles and stitch shrinkage may occur on the material. That is, in the conventional method for manufacturing a skin material with a decorative stitch, there is a problem that a defective product is generated depending on the shape of the skin material and the portion where the decorative stitch is formed.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for producing a skin material with decorative stitches, which can reduce the occurrence of defective products.

The invention of claim 1 was made in view of the above circumstances, the epidermis skin material which is shaped into a three-dimensional shape, the hook block top of the post of the post-type sewing machine Ategai under feeding member provided in said Kamadai the method of manufacturing a decorative stitched skin material while feeding the wood to advance and retract needle sewing needle holes of the lower feed member sewing decorative stitching, the the Kamadai, projects upwardly perpendicular to the feeding direction of the surface material A pair of lower presser members having a protruding wall structure facing each other in the first horizontal direction are formed, and a skin material receiving protrusion formed by arranging the lower feed member is provided between the pair of lower presser members. method of manufacturing a decorative stitching with a skin material to sew the decorative stitch I addressed to the skin material to the top of the received before Symbol skin material projections.

According to the second aspect of the present invention, the pair of lower pressing members are linearly extended upward from the shoulder portion and the epidermis, and the shoulder portion having a tapered shape upward when viewed from the first horizontal direction. The method for manufacturing an epidermis material with decorative stitches according to claim 1, wherein the head material to which the material is addressed is formed into a shape having the head material.

The invention of claim 3 comprises an upper feed member which has a through hole through which the sewing needle is inserted and feeds the skin material in cooperation with and cooperates with the lower feed member, and the first. Claim 1 or 2 is provided with an upper pressing member which is arranged at a position where the upper feeding member is sandwiched in the horizontal direction and which presses the skin material from the vertical direction between the pair of lower pressing members. The method for manufacturing a skin material with decorative stitches described above.

The invention of claim 4 is the method for manufacturing a skin material with decorative stitches according to claim 1, wherein the upper surface of the lower feed member is formed flat.

The invention according to claim 5 is any one of claims 1 to 4, wherein the skin material has a laminated structure having an outer layer made of an elastomer and a lining layer made of a foamed resin. It is a method of manufacturing the skin material with decorative stitches described in 1.

[Invention of claims 1 and 5]
In the invention of claim 1, since the sewn portion of the skin material is addressed to the upper part of the skin material receiving protrusion formed by projecting a part of the pot stand upward, it is compared with the case where the entire upper part of the pot stand is flat. As a result, wrinkles and sewing shrinkage are less likely to occur on the skin material. This makes it possible to reduce the occurrence of defective products.

The skin material preferably has a laminated structure having a surface material layer made of synthetic resin and a lining layer made of foamed resin from the viewpoint of shape retention of the skin material (claim 5). invention).

[Invention of claim 2]
According to the invention of claim 2 , it is possible to reduce the area of the portion of the epidermis material that is addressed to the epidermis material receiving projection, and the occurrence of wrinkles in the epidermis material due to the interference between the epidermis material and the epidermis material receiving projection. Can be suppressed.

[Invention of claims 3 and 4]
According to the invention of claim 3 , since the skin material can be fed in a comprehensive manner, it is possible to suppress the occurrence of wrinkles in the sewn portion of the skin material. Further , according to the invention of claim 4, since the upper surface of the lower feed member provided with the needle hole at the upper portion is flat, it is possible to appropriately form the decorative stitch.

Perspective view of an instrument panel using a skin material with decorative stitches according to an embodiment of the present invention. (A) Partially broken perspective view of the instrument panel, (B) Side sectional view Front view of post-type sewing machine View of Kamadai from the front Perspective view of Kamadai from one side in the left-right direction Perspective view of Kamadai seen from the other side in the left-right direction (A) side sectional view and (B) normal sectional view of the upper feed mechanism and the lower feed mechanism in a state where the upper pressing member sandwiches the skin material. (A) side sectional view, (B) normal sectional view of the upper feed mechanism and the lower feed mechanism in a state where the upper feed member sandwiches the skin material. Front view of Kamadai with the skin material applied to the skin material receiving protrusion Side view of the skin material receiving protrusion according to another embodiment

As shown in FIG. 1, the skin material 10 with decorative stitches of the present embodiment is used for the instrument panel 111 of the vehicle 110. As shown in FIG. 2A, the skin material 10 with decorative stitches is fixed to the surface of the base material 112 facing the front side to form the design surface of the instrument panel 111. The skin material 10 with a decorative stitch is formed by forming a decorative stitch S on the skin material 11.

As shown in FIG. 2A, the base material 112 has a substantially L-shape in the side view, and the skin material 11 also has a substantially L-shape in the side view corresponding to the shape of the base material 112. The decorative stitch S is formed in the vicinity of the L-shaped corner portion of the skin material 11. Specifically, the skin material 11 has a ceiling wall 11T extending in the left-right direction and a front wall 11F hanging from the front end of the ceiling wall 11T, and a decorative stitch S is formed on the front end of the ceiling wall 11T. Has been done. The ceiling wall 11T is curved so that the upper side is convex. Further, the front wall 11F is provided with an protrusion 11S that protrudes forward in the shape of a pedestal as it goes downward.

As shown in FIG. 2B, the base material 112 is made of a synthetic resin. The skin material 11 has a laminated structure in which the lining layer 13 made of foamed resin is laminated on the back side of the outer layer 12 made of synthetic resin. As a result, the shape retention of the skin material 11 is stabilized. The outer layer 12 is made of, for example, a thermoplastic elastomer (TPO) or the like. The lining layer 13 is made of a foam (for example, PP foam or PE foam) having an appropriate cushioning property.

The skin material 10 with decorative stitches is manufactured as follows. First, the skin material 11 shaped into a three-dimensional shape corresponding to the shape of the base material 112 is prepared. The skin material 11 is obtained by molding a laminated sheet composed of a outer layer 12 and a lining layer 13.

Next, the decorative stitch S is formed on the skin material 11 by the post-type sewing machine 20 shown in FIG. As a result, the skin material 10 with decorative stitches is completed.

By the way, as described above, the decorative stitch S is formed at the L-shaped corner portion of the skin material 11. Here, when the decorative stitch S is formed, if the skin material 11 is deformed so as to flatten the corner portion of the skin material 11, there arises a problem that wrinkles and sewing shrinkage occur in the skin material 11. In order to prevent such a problem, in the present embodiment, the post-type sewing machine 20 is provided with a characteristic configuration. Hereinafter, the configuration of the post-type sewing machine 20 will be described in detail.

As shown in FIG. 3, in the post-type sewing machine 20, the sewing machine frame 21 has a needle drive mechanism 30 that drives the sewing needle 31 up and down, a hook mechanism 40 that forms a seam in cooperation with the needle drive mechanism 30, and a skin. A feed mechanism 60 or the like for transporting the material 11 along the feed direction X is attached.

The sewing machine frame 21 includes a sewing machine bed 22 that forms the lower part of the sewing machine frame 21 and extends in the left-right direction Y, a sewing machine arm 23 that forms the upper part of the sewing machine frame 21 and faces the sewing machine bed 22 from above, and the sewing machine bed 22. It is provided with an arm support portion 24 that is erected at one end and communicates with the sewing machine arm 23, and is formed in a substantially U-shape in front view as a whole. The left-right direction Y in which the sewing machine bed 22 and the sewing machine arm 23 extend is orthogonal to the feeding direction X.

The needle drive mechanism 30 includes a rotary weight (not shown) fixed to an upper shaft extending in the left-right direction Y in the sewing machine arm 23, and a crank rod whose upper end is rotatably connected to an eccentric portion of the rotary weight (FIG. (Not shown), a needle rod 32 rotatably connected to the lower end of the crank rod, and a sewing needle 31 supported by the lower end of the needle rod 32. When the upper shaft rotates in response to the driving force of a sewing machine motor (not shown), the rotation is converted into a reciprocating motion in the vertical direction Z via the rotary weight and the crank rod, and the needle rod 32 and the sewing needle 31 move in the vertical direction Z. Round trip to.

The hook mechanism 40 is provided on a post 25 erected upward from the sewing machine bed 22. The hook mechanism 40 includes a hook stand 41 fixed to the upper end of the post 25, a hook shaft (not shown) extending in the vertical direction Z in the post 25, and a hook shaft supported by the hook shaft in the hook stand 41. It is equipped with a horizontal hook (not shown) that rotates around. Then, when the lower shaft extending in the left-right direction Y in the sewing machine bed 22 rotates together with the above-mentioned upper shaft, the kettle shaft rotates via a gear (not shown), and the horizontal kettle rotates. As a result, the horizontal hook and the sewing needle 31 cooperate to form a seam.

As shown in FIG. 4, the kettle stand 41 is formed by attaching the needle receiving portion 43 to the kettle stand main body 42 accommodating the above-mentioned horizontal kettle. The shape of the Kamadai main body 42 viewed from above is such that a part of the circle is cut off, and the surface of the Kamadai main body 42 facing one side in the left-right direction Y is a substantially vertical mounting surface 42M. .. The needle receiving portion 43 is fixed to the mounting surface 42M.

The needle receiving portion 43 projects upward from the upper surface of the kettle stand main body 42. From another point of view, it can be said that the upper end portion of the needle receiving portion 43 projects a part of the kettle stand 41 (specifically, one end portion in the left-right direction Y) upward. The skin material receiving protrusion 50 according to the present invention is formed by a portion of the needle receiving portion 43 arranged above the main body 42 of the kettle stand.

The needle receiving portion 43 includes a fixed base 44 fixed to the main body 42 of the kettle base and a movable base 46 that moves in the vertical direction with respect to the fixed base 44. As shown in FIGS. 4 to 6, the fixed base 44 extends in the left-right direction Y with the fixed wall 44A which is vertically fixed on the mounting surface 42M, the facing wall 44B which faces the fixed wall 44A in the left-right direction Y, and the left-right direction Y. It is composed of a pair of connecting walls 44C and 44C that communicate the fixed wall 44A and the facing wall 44B. The movable base 46 is housed in a storage hole 45 surrounded by a fixed wall 44A, a facing wall 44B, and a pair of connecting walls 44C and 44C.

As shown in FIGS. 5 and 6, each of the upper portion of the fixed wall 44A and the facing wall 44B has a shoulder portion 51 that is tapered upward and a head that extends linearly upward from the shoulder portion 51. A section 52 and a section 52 are provided. Specifically, the shoulder portion 51 is formed in a trapezoidal shape that becomes narrower in the feed direction X as it goes upward, and the head portion 52 is formed in a band shape in which the width in the feed direction X is substantially constant. The skin material receiving protrusion 50 is composed of a shoulder portion 51 and a head portion 52.

As shown in FIG. 4, the movable base 46 is formed in a substantially Y shape branched from the upper end portion of the base portion 47 extending in the vertical direction Z, and is sandwiched between the two branch portions 48, 48. It has a character groove 48M. A needle hole 46A through which the sewing needle 31 is inserted is formed at the bottom of the V-shaped groove 48M. Further, the upper surfaces of the two branch portions 48, 48 are arranged flush with each other, and the upper surface of the movable base 46 is flat.

As shown in FIGS. 7 (A) and 8 (A), the width of the feed direction X of the movable base 46 is narrower than the width of the feed direction X of the head 52 of the fixed wall 44A and the facing wall 44B. It has become. The movable base 46 is hidden behind the fixed wall 44A or the facing wall 44B when viewed from the left-right direction Y.

By the way, the post-type sewing machine 20 of the present embodiment is a comprehensive feed sewing machine, and the feed mechanism 60 in the post-type sewing machine 20 includes an upper feed mechanism 61 as shown in FIGS. 4, 7 and 8. A lower feed mechanism 65 is provided. The upper feed mechanism 61 includes an upper feed member 62 arranged above the movable base 46, and an upper pressing member 63 arranged above the fixed wall 44A and the facing wall 44B of the fixed base 44. The upper feed member 62 is driven so as to draw an elliptical locus centered on an upper feed axis (not shown) extending in the left-right direction Y in conjunction with the vertical movement of the sewing needle 31, and while moving in the vertical direction Z. Move in the feed direction X. The upper pressing member 63 is driven linearly along the vertical direction Z. The upper feed member 62 and the upper presser member 63 are driven so that when one member is arranged at the lower end of the movable range, the other member is arranged at the upper end of the movable range (FIG. 7 (FIG. 7). B) and FIG. 8 (B)).

As shown in FIGS. 5 and 6, the upper feed member 62 includes a base portion 62B extending in the vertical direction Z and a feed leg portion 62K protruding from the lower end of the base portion 62B in the feed direction X. ing. The base portion 62B is fixed to the first shaft 62S that moves in the vertical direction Z in response to the power from the drive source of the upper feed member 62. The feed leg portion 62K is formed flat in the vertical direction Z, and has a through hole 62A through which the sewing needle 31 is inserted.

The upper presser member 63 includes a base portion 63B extending in the vertical direction Z, and presser leg portions 63K and 63K that are bifurcated from the lower end of the base portion 63B and protrude in the feed direction X. The base portion 63B is fixed to a second shaft 63S (see FIG. 6) that moves in the vertical direction Z by receiving power from a drive source of the upper pressing member 63. The presser legs 63K and 63K are arranged so as to sandwich the feed leg 62K of the upper feed member 62 in the left-right direction Y.

As shown in FIGS. 7B and 8B, the lower feed mechanism 65 includes a lower feed member 66 composed of a movable base 46 and a lower presser member 67 composed of a fixed base 44. I have. The lower feed member 66 (movable base 46) is driven so as to draw an elliptical locus centered on a lower feed shaft (not shown) extending in the left-right direction Y in conjunction with the upper feed member 62, and is driven in the vertical direction Z. It moves in the feed direction X while moving. The lower pressing member 67 (fixed base 44) is fixed to the kettle stand main body 42 as described above, and does not move in the vertical direction Z or the feeding direction X.

The upper feed member 62 and the lower feed member 66 rotate in opposite directions when viewed from the left-right direction Y. Then, the upper feed member 62 and the lower feed member 66 move in the feed direction X with the skin material 11 sandwiched between them, so that the skin material 11 is fed in the feed direction X (FIGS. 7 (A) and 8 (A)). ..

When the upper feed member 62 and the lower feed member 66 are separated from each other from the state where the skin material 11 is sandwiched, the upper presser member 63 sandwiches and fixes the skin material 11 between the upper feed member 62 and the lower feed member 67 (FIG. 7 (A). ) And FIG. 7 (B)). Then, when the upper feed member 62 and the lower feed member 66 approach each other in the vertical direction Z to sandwich the skin material 11, the upper presser member 63 separates from the lower presser member 67 and releases the skin material 11 (FIG. 8). (A) and FIG. 8 (B)). As shown in FIGS. 4 and 5, the fixed wall 44A has a shape that extends in the left-right direction Y at the upper end portion. As a result, the portion of the fixed wall 44A that sandwiches the skin material 11 with the upper pressing member 63 can be enlarged, and the holding of the skin material 11 can be stabilized.

This concludes the description of the configuration of the post-type sewing machine 20 according to the present embodiment. As described above, in the post-type sewing machine 20, the needle receiving portion 43 has a configuration in which the needle receiving portion 43 protrudes upward from the kettle base main body 42, and the needle receiving portion 43 projects a part of the kettle base 41 upward. The material receiving protrusion 50 is configured. Then, the sewn portion of the skin material 11 is addressed to the skin material receiving protrusion 50, and the decorative stitch S is formed on the skin material 11. Here, as described above, the sewn portion of the skin material 11 is an L-shaped corner portion of the skin material 11, and the corner portion is addressed to the skin material receiving projection 50. Then, as shown in FIG. 9, the corner portion is lifted upward, and the other portion of the skin material 11 does not interfere with the kettle stand 41. As a result, the decorative stitch S can be formed without deforming the skin material 11, and the occurrence of wrinkles and sewing shrinkage on the skin material 11 is suppressed.

Next, the action and effect of the method for producing the skin material 10 with decorative stitches according to the present embodiment will be described. In the present embodiment, the skin material 11 shaped to the shape corresponding to the base material 112 is prepared, and the decorative stitch S is formed on the skin material 11 by the post-type sewing machine 20. Here, the post-type sewing machine 20 is provided with a skin material receiving protrusion 50 formed by projecting a part of the pot base 41 located at the upper end of the post 25 upward. Then, when the decorative stitch S is formed, the sewn portion of the skin material 11 is addressed to the upper portion of the skin material receiving protrusion 50. Therefore, in the present embodiment, wrinkles and sewing shrinkage are less likely to occur in the skin material 11 as compared with the case where the sewn portion of the skin material 11 is addressed to the pot stand 41 having a flat upper surface as a whole. This makes it possible to reduce the occurrence of defective products of the skin material 10 with decorative stitches.

Further, since the skin material receiving protrusion 50 is arranged on a part of the outer edge portion (specifically, one end portion in the left-right direction Y orthogonal to the feed direction X), the skin material 11 interferes with the pot stand 41. It becomes easy to avoid, and it becomes possible to suppress the occurrence of wrinkles in the skin material 11.

Further, the skin material receiving protrusion 50 has a shoulder portion 51 having a tapered shape upward and a head portion 52 extending linearly upward from the shoulder portion 51, and has an upwardly pointed shape. Therefore, it is possible to reduce the area of the portion of the skin material 11 that is addressed to the skin material receiving protrusion 50, and the occurrence of wrinkles in the skin material 11 due to the interference between the skin material 11 and the skin material receiving protrusion 50 is generated. It becomes possible to suppress. Here, even when the skin material receiving protrusion 50 is formed in a shape consisting of only the head 52 without the shoulder portion 51 (that is, a vertically long rectangular shape when viewed from the left-right direction Y), the skin material 11 is also formed. Although it is possible to reduce the area of the portion addressed to the skin material receiving protrusion 50 in the above embodiment, in the present embodiment, since the skin material receiving protrusion 50 is provided with the shoulder portion 51, the strength of the skin material receiving protrusion 50 is increased. It is planned to be up.

Further, in the present embodiment, in the post-type sewing machine 20, since the skin material 11 can be totally fed, wrinkles can be suppressed from being generated in the sewn portion of the skin material 11. Moreover, since the upper surface of the lower feed member 66 (movable base 46) provided with the needle hole 46A at the upper part is flat, it is possible to suppress the occurrence of pitch variation and sagging when forming the decorative stitch S, and the decorative stitch S is formed. Can be properly formed.

[Other Embodiments]
The present invention is not limited to the above embodiments, and for example, embodiments as described below are also included in the technical scope of the present invention, and various other than the following, as long as they do not deviate from the gist. It can be changed and implemented.

(1) In the above embodiment, the skin material 10 with decorative stitches is used for the instrument panel 111, but may be used for vehicle interior materials such as door trims, pillar garnishes, and console boxes, for example.

(2) In the above embodiment, the decorative stitch S is a single type, but it may be a double stitch or various forms.

(3) In the above embodiment, the sewn portion of the skin material 11 on which the decorative stitch S is formed may have an angular shape or a curved surface with an R.

(4) In the above embodiment, the skin material receiving protrusion 50 is arranged at the outer edge portion of the pot stand 41, but may be disposed at the central portion or the portion near the center. In this case, the hook housed in the hook stand 41 may be a vertical hook.

(5) In the above embodiment, the skin material receiving projection 50 may be formed in a vertically long rectangular shape when viewed from the left-right direction Y (FIG. 10 (A)), or may be formed in a trapezoidal shape (FIG. 10 (A)). FIG. 10 (B).

(6) In the above embodiment, the skin material receiving protrusion 50 is formed in a flat shape in the left-right direction Y, but may be formed in a conical shape or a square pyramid shape, for example.

(7) In the above embodiment, the post-type sewing machine 20 may be configured to include only the upper feed mechanism 61 or only the lower feed mechanism 65. When only the upper feed mechanism 61 is provided, the movable base 46 may be fixed to the fixed base 44.

10 Skin material with decorative stitch 11 Skin material 20 Post type sewing machine 25 Post 31 Sewing needle 41 Kamadai 42 Kamadai body 43 Needle receiving part 45 Fixed base 46 Movable base 62 Top feed member 63 Top presser member 66 Down feed member 67 Bottom presser member S Decorative stitch

Claims (5)

Needling the skin material which is shaped into a three-dimensional shape, the hook block top of the post of the post-type sewing machine Ategai, the needle hole of the lower feed member while feeding the skin material under feed member provided in the Kamadai In the manufacturing method of the skin material with decorative stitches, the decorative stitches are sewn by advancing and retreating.
A pair of lower presser members having a protruding wall structure are formed on the kettle stand so as to project upward and face each other in the first horizontal direction orthogonal to the feed direction of the skin material, and the pair of lower presser members are provided between the pair of lower presser members. A skin material receiving protrusion formed by arranging the lower feed member is provided, and the lower feed member is arranged.
Method of manufacturing a decorative stitching with a skin material to sew the decorative stitch I addressed to the skin material to the top of the received before Symbol skin material projections. When the pair of lower pressing members are viewed from the first horizontal direction, a shoulder portion having a tapered shape upward and a head portion extending linearly upward from the shoulder portion and to which the skin material is addressed. The method for producing an epidermis material with decorative stitches according to claim 1, wherein the shape has the above. The post-type sewing machine has a through hole through which the sewing needle is inserted, and the upper feed member that feeds the skin material in conjunction with and cooperates with the lower feed member, and the upper feed member in the first horizontal direction. The skin material with decorative stitches according to claim 1 or 2, which is arranged at a position where the skin material is sandwiched between the pair of lower presser members and the upper presser member which presses the skin material from above and below. Manufacturing method. Method for manufacturing a decorative stitched surface material according to any one of claims of claims 1 to 3 previously formed flat upper surface of the front SL under feeding member. The skin with decorative stitches according to any one of claims 1 to 4, wherein the skin material has a laminated structure having an outer material layer made of an elastomer and a lining layer made of a foamed resin. Material manufacturing method.

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