JPH04458B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a three-dimensional trim cover used for seats, similar vehicle door panels, vehicle interior parts, furniture, and the like.

First, manufacturing of a conventional trim cover will be explained.

Fig. 1 shows an example in which the front cushion FC and front back FB of the seat body are separate, and the connecting part is omitted. Fig. 1 shows the external appearance of the trim cover, and Fig. 2 shows the cross section taken along the line A-A. The part excluding the urethane mold 5 is the trim cover.

The trim cover is made by inserting and compressing the three layers of the outer layer 1, wading 2, and back base fabric 3 between the upper and lower molds (not shown) using a high-frequency fusing device, and passing a high-frequency current through them. The three layers mentioned above are fused together at the fused part 4.
The fused portion 4 in FIG. 2 is visually similar to a to d and e in FIG.
The fusion line 4A has a length of ~b and a width W.

Conventionally, the opposing surfaces of the upper mold and the lower mold are all on the same plane, so after the above three layers of the trim cover are fused to the upper mold and the lower mold at the welding part 4, the trim cover has a third layer. As shown in the figure, all of the fusion lines 4A are on the same plane.

Therefore, the fusion line 4A on the same plane in FIG.
The surface 5A of the urethane mold 5 in contact with the back base fabric 3 of the trim cover shown in FIG. 2 is a curved surface (corresponding to the curved surface of the outer skin 1 and the curve of the fusion line 4A in FIG. 1). When covering along , the fusion line 4 becomes curves a to d and e to h.

In the example of Fig. 1, a~b, c~d, e~f, g~
When viewed from the outside, h is a convex curve b to c and a concave curve f to g.

The fused part 4 has a width W by being pressed between an upper mold and a lower mold,
The outer skin 1, wading 2, and back base fabric 3 are fused together and formed into a hard layer. Therefore, if the fusion line 4A shown in FIG. 3, which is formed in a plane, is used by bending it as the curves a to d and e to h in FIG. (Cross section taken along the second line B-B) shows folded line wrinkles or
Linear cross section) results in small wavy wrinkles. The reason for this is that the urethane mold 5 shown in FIG.
Second, as seen in the cross section of FIG. , since the cross section is circular, bend it outward (a to b,
g to h, etc.) and the inner back base fabric 3 are compressed and wrinkles occur. When bent inward (b to c, f to g, etc.), the outer skin 1 is compressed and wrinkles occur. These wrinkles are likely to occur because the wadding 2 is soft, and furthermore, they cause folds and small wave wrinkles to occur in the fused wires 4, 4A.

If the thickness of the wading 2 in FIG. 5 is large and the depth W of the groove 2a is large, the fused portion 4,
Wrinkles and small waves occur at 4A. Furthermore, if the wall that is close to the right angle to the m to n fused parts 4, 4 of the skin 1 and the wadding 2 is bent inward or outward as described above, it may cause deformation such as buckling or falling (not shown). Cracks appear and the appearance quality deteriorates.

Creases, small waves, deformations, etc. shown in Figures 4A, 4B, and 5 greatly reduce the product value in terms of appearance.

Even with the conventional machine-stitched trim cover, if the groove 2a in Fig. 5 has a deep W, or a to b in Fig. 1,
When R of the curves such as g to h is particularly small, bad phenomena such as creases, small waves, and deformation occur depending on the material of the skin 1, as in the case of the high-frequency trim cover.

Compared to machine-sewn trim covers, conventional high-frequency welded covers are advantageous in terms of design because they can accommodate changes in the appearance of the welded line, and can save labor, but they do not have the drawbacks mentioned above. have.

As a countermeasure to these problems, there is a method of simultaneously fusing, for example, thick vinyl leather, etc., in contact with the backing fabric 3 to make the fused part thicker, but this method is relatively expensive due to the number of man-hours, material costs, etc. has little effect.

Even if the front cushion FC and front back FB shown in FIG. 1 are formed of a seat body with a trim cover that is ergonomically designed to adapt to the human body shape, the seat body still has the above-mentioned drawbacks.

The present invention has been made in view of the above-mentioned drawbacks of the conventional example, and it is an object of the present invention to eliminate the above-mentioned drawbacks and provide a seat body and similar products that are ergonomically excellent.

Hereinafter, one embodiment of the present invention will be described in detail with reference to the accompanying drawings.

The embodiment of the invention shown in FIG.
This is a three-dimensional trim cover that has all of the fusion lines 4A having the curves of ~h from the time of high-frequency molding, and FIG.
The fused portion 4 is shown in cross section of the fused line 4A from e to h in the figure. FIG. 7 shows a smooth fused portion 4 without creases, small waves, or other wrinkles as shown in FIGS. 4A and 4B.
(Fusion line 4A) is shown.

Figure 8 shows the fusion device and the fusion line 4 in Figures 6 and 7.
A, the shape of the fused portion 4 is shown upside down.

Reference numeral 11 is an upper mold, and 10 is a lower mold. Lower mold 10
Add the outer skin 1, wading 2, and back base fabric 3 to e, f,
Install upper mold 1 from the beginning along the curves g and h.
1. When compressed with the lower die 10 and subjected to high frequency welding, the sixth
A three-dimensional trim cover with a desired curved surface can be obtained from the time of fusion shown in the figure.

9 shows a cross section taken along the line XX in FIG. 8, and FIG. 8 shows a cross section taken along the line YY in FIG. 9. Fusion part 4 (fusion line 4
The cross section of the upper mold 11 and lower mold 10 for molding A) is shown.

FIG. 10A shows a case where the heights of the welded parts 4 of each R (circular bend) in FIG. A trim cover having the following is also obtained. Furthermore, although not shown, lines e to h in FIG. 6 are straight lines when viewed directly from the outside, but they can also be changed to curved lines. Alternatively, it may have a cross section taken along the Z-Z line of the loop-shaped fusion wire 4A shown in FIGS. 10A and 10B.

If the front cushion FC shown in Fig. 1 requires a three-dimensional trim cover having a curved surface shaped like a human butt (the surface 5A of the urethane mold 5 is also shaped like a butt), use the loop-shaped fusion line shown in Fig. 10B. 4A is a fusion line whose curved surface corresponds to the required shape of the butt. Further, although the description will be omitted, the shape of the front back FB can also be made to correspond to the shape of the human back, thereby eliminating the drawbacks of the above-mentioned conventional example. in this case,
If necessary, instead of the wading 2, a three-dimensional urethane 2A described below having a shape corresponding to the tail shape may be used.

Fig. 11 shows an improved version of the conventional example shown in Figs. 4A, 4B, and 5, and the three-dimensional urethane 2A appears near point b above the A-A cross section in Fig. 1. The shape up to and the depth W of the groove 2a in Fig. 5
urethane mold or slab urethane is molded into the outer layer.Depending on the material, the skin 1 may also be formed in advance by heat processing depending on the mold. FIG. 11 shows an example of a three-dimensional trim cover in which the outer skin 1, the wadding 2A, and the back base fabric 3 are arranged in three layers before being fused. The trim cover after completion of the fusion is a three-dimensional trim cover having a deep groove with a width W as shown in FIG.

The skin 1 is installed along the lower molds 10A and 10B, and the three-dimensional urethane groove is installed,
A three-dimensional trim cover is molded. The three-dimensional urethane 2A can also be applied to the examples shown in other figures.

FIG. 12 shows a trim cover in which the outer skin 1 and one end of the separate outer skin 1A are folded inward and overlapped, and these, the wading 2, and the back base fabric 3 are fused together at the fusion part 4. In this case, the fused portion 4 where the skin 1A is folded and fused is, for example, e to f to g in FIG.
This is also a three-dimensional trim cover, although the illustration of the trim cover fused by the fusion line 4A like the lines .about.h is omitted.

First, connect one end of the epidermis 1A to the upper surface 10C and the upper surface 10.
The insides of D and 10E are made into concave shapes, and the molds are bent into a U-shape and inserted into the insides. As the upper mold 11 descends, the upper parts 10D and 10E also descend, and one end of the U-shape is rolled up, as shown in FIG. 12. When the material is folded in and brought into close contact, electricity is applied, and each material is fused at each necessary fused portion 4.

After fusion, when the upper mold 11 is raised, the upper parts 10E and 10D are raised upward by the spring 12, and the long groove 2a of the recess is formed in the lower mold 10 with the upper surface of the protrusion 10C.

Fig. 13 shows a bead 13 formed on a separate skin 1A from the skin 1, and a skin 1 partially overlapped with this,
A trim cover is shown in which the wadding 2 and the back base fabric 3 are fused together at a fused portion 4.

In this case, the bead 13 and the welded portion 4 are three-dimensional trim covers (not shown) that are fused together by welding lines e to f to g to h in FIG. 6, for example. The epidermis 1 and the epidermis 1A are separate bodies, but depending on the specifications, they may be a single epidermis.

Although the trim cover fusing device shown in FIG. 13 is not shown, it is the same as the example shown in FIG. 12.

First, put the tape-shaped ball 13 material into the lower mold 10.
The upper surface of the protrusion 10C and the inner side of the upper parts 10D, 10E are formed into a concave shape, and the upper parts 10D, 10 are bent into a U-shape and inserted inside the protrusion 10C.
E also descends, and when the tape-like bead 13 is rolled up into a bead shape, it is energized, and the necessary fused portion 4 is energized.
Each material is fused together.

In this case, the bead 13 is not in the form of a tape, but may be formed separately into a bead shape from the beginning. Also, the ball 13 shown in Figure 13
There may be no space in the center of the ball so that they are in close contact with each other, or another ball core may be inserted into this space.

Although not shown in the drawings in each of the fusion devices described above, the upper mold and the lower mold may be arranged upside down.

Next, the method for manufacturing a three-dimensional trim cover according to the present invention has the following effects.

(a) As mentioned above, appearance defects such as creases, small waves, and deformation of the fusion line of the trim cover do not occur, and the appearance is improved. Furthermore, the lower mold 10,
Along the drawing shapes such as 10A, 10B, 10C, 10D, 10E, etc.
After installing wading 2 and back base fabric 3, upper mold 1
The three-dimensional trim cover shown in FIG. 6 is obtained by compressing in step 1 and fusing with electricity. This three-dimensional shape matches the shape of the front side of the urethane mold 5, so even if it is covered with this, not only the fused portion but also the skin other than the fused portion will be wrinkled.
No deformation occurs. In contrast, in the conventional planar trim cover shown in FIG. 3, wrinkles also occurred in the portion of the skin that was not fused.

(b) Eliminate appearance defects that occur when the wading 2 is thick and the groove 2a is deep, as in the examples shown in Figures 4A, 4B, and 5, or when the radius of the fusion line is particularly small. It can be improved.

(c) If the width W of the fused portion is made narrower, depending on the specifications of the skin 1, the fused line will not be visible from the outside, and a product with the same feel as a machine-sewn trim cover can be obtained.

(d) The three-dimensional trim cover shown in FIGS. 10A and 10B, which has a curved surface adapted to the shape of the human buttocks, is a three-dimensional trim cover shaped like a seated body, taking into consideration the ergonomic distribution of body pressure when seated. , the effect of improving riding comfort is significant.

(e) Significant improvements can be expected in labor saving, cost reduction, and improved product quality.

For convenience, the present invention has been described as a three-dimensional trim cover for a seat, and the manufacturing method has been described as high-frequency welding. Of course, there are variations and modifications, and for example, it can be applied not only to seat trim covers, but also to vehicle door pads, instrument panels, and other vehicle interior items or furniture. In some cases, the base fabric is replaced with a hardboard panel and the wading is replaced with molded urethane, and in some cases, ultrasonic welding or other heat welding methods are used instead of high frequency welding.

[Brief explanation of drawings]

Figures 1 to 5 relate to conventional trim covers, and Figure 1 is a perspective view of a seat showing the trim cover;
FIG. 2 is a cross-sectional view taken along line A-A in FIG.
Figure 3 is a perspective view of the trim cover, Figure 4A,
Figure B is a cross-sectional view taken along the line B-B in Figure 2, Figure 5 is a cross-sectional view showing the grooves of the trim cover, Figures 6 and subsequent figures are embodiments of the present invention, and Figure 6 is a perspective view of the three-dimensional trim cover. 7 is a sectional view of the trim cover showing the wrinkle-free fused portion, FIG. 8 is a sectional view of the fusion device, and FIG. 9 is a sectional view taken along line X-X in FIG.
Fig. 10A is a sectional view of a fusion mold showing examples of different heights of the fusion part, Fig. 10B is a plan view showing a fusion line corresponding to the butt type, and Fig. 11 is Fig. 4A and Fig. 4B. FIG. 12 is a cross-sectional view of an embodiment in which one skin is folded back and fused, and FIG. 13 is a beveled fusion device. It is a sectional view of an example of wearing. 1,1A... Epidermis, 2... Wading, 2a...
...Groove, 3...Back base fabric, 4...Fusion part, 4A...Fusion line, 5,5A...Urethane mold, 10,1
0A, 10B... lower mold, 11, 11D, 11E...
...Upper mold, 12...Guide pin, 13...Ball.

Claims (1)

[Claims] 1. In a trim cover manufacturing method in which a skin, wadding, back base fabric, etc. are laminated and their required parts are heat-sealed, a curved shape of the trim cover is formed that complements each other symmetrically. The skin, wadding, and backing fabric are stacked and inserted between the upper mold and the lower mold, heated, and the necessary parts are fused in a line shape using high frequency. A method for producing a three-dimensional trim cover by high-frequency welding to a curved member surface, characterized in that the attachment part includes a curved surface and the trim cover is three-dimensionally formed. 2. The method of manufacturing a three-dimensional trim cover according to claim 1, wherein the skin is divided into a plurality of parts, one of which is folded in and fused to the other end. 3. A method for manufacturing a three-dimensional trim cover according to claim 1, in which the bead is fused to a part of the skin. 4. The method for manufacturing a three-dimensional trim cover according to claim 1, wherein the wading or the skin is also formed into a desired three-dimensional shape in advance. 5. A method for manufacturing a three-dimensional trim cover according to claim 1, in which a seating curved surface is formed taking into consideration the shape of a human sitting body.