JPS59230718A - Trim cover by ultrasonic fusion - Google Patents

Abstract

PURPOSE:To obtain a trim cover with a better appearance and a high fusion strength at a low cost by a method wherein a skin material, a wadding and a back base fabric are laminated sequentially on an ultrasonic wave receiving base having a fusing section with a necessary shape, compressed with an ultrasonic horn die and fused between necessary parts thereof by an ultrasonic vibration. CONSTITUTION:The upper layer of a skin material 1, the middle layer of a wadding 2 comprising ordinary urethane and the lower layer of a back base fabric 3 are laminated and fusion. Necessary parts 2a thereof are made to generate heat to fuse by an ultrasonic vibration thereby producing a trim cover. In this process, the skin material 1, the wadding 2 and the back base fabric 3 are laminated sequentially on an ultrasonic wave receiving base 5 having a fusing section 5a with a necessary fusing shape, compressed with ultrasonic horn dies 4, 4A, 4B and 4C divided into portions as required and are fused between necessary parts thereof under an ultrasonic vibration to produce a trim cover.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a trim cover and a trim cover fused by ultrasonic fusion.

BACKGROUND OF THE INVENTION Conventional techniques for trim covers used for surface materials such as seats will be explained with reference to FIGS. 1 to 5.

In the figure, reference numeral 1 indicates a skin material, 2 a wadding made of ordinary urethane made by relatively thinly slicing a cushion material such as urethane foam, 2a a fused portion between the skin material 1 and the wadding 2, and 3 a backing fabric.

Fig. 1 shows a trim cover for a seat in which the skin material 1, wadding 2, and back fabric 3 are fused together at a welding part 2a, where the skin material 1 and wadding 2 or the wadding 2 and the back fabric 3 are fused together at a welding line A. (X-X line in FIG. 2) is shown.

In FIG. 2, the skin 1 is provided with a large number of fine grooves a and b shown in FIG. 4 in parallel. These grooves a and b intersect with the fusion line A at portions Aa and Ab. In FIG. 1, the intersections Aa and Ab are omitted.

Figure 3 shows the fusion line A1 grooves a, b and intersection Aa in Figure 2.
An enlarged view of 1Ab is shown.

FIG. 4 is an enlarged cross-sectional view taken along line Y--Y in FIG. 3.

In the above, the shapes, numbers, and intersection angles of the grooves a and b with the fusion line A are not limited to those shown in the drawings, and the intersections a and b may be curved. The problem with the above conventional technology is that the parts Aa and Ab where the grooves a and b intersect with the fusion line are not fused to the wadding 2, or even if they are fused, the fusion strength is low. The fusion strength of the fused portion 2a is weaker than that of other parts to the wire attachment, and may vary.

The reason for this is that, although not shown in the drawings, if compression heating is performed along the ial welding line A, for example with a high frequency type or other heat fusion type, the intersection A
In the a and Ab portions, the density of the skin material 1 in the compressed space portions becomes a space compared to the other fused-type contact portions of the skin material 1, or the density of the skin material 1 in the compressed space portions is reduced. Therefore, in the case of high-frequency fusion, friction loss due to vibration of dielectric molecules is reduced, the amount of heat generated is small, and fusion does not occur or the fusion strength is weak. Even with other heat-sealing types, heat is transferred to the skin material 1 and the wadding material 2.
Since the transmission to the back base fabric 3 is not possible or weak at the intersections Aa and Ab, there is a drawback that the fusion strength is weak or there is no fusion at the intersections Aa and Ab.

(bl) In particular, when the intersection angle between the fusion line A and the groove a or between the fusion line A and the groove is small, the intersections Aa and Ab become long, and the above-mentioned drawbacks occur to a large extent.

(0) Compared to using low-melting point urethane foam or ordinary urethane foam impregnated with adhesive for wadding 2, it is cheaper to use ordinary urethane (the urethane generally used for machine-stitched trim covers). Although urethane has excellent physical properties such as elasticity, it is very difficult or impossible to fuse at intersections Aa and Ab because of its high melting point.

fdi In the case of high-frequency welding, if the skin material is a material with low dielectric loss or a material that easily generates sparks due to high-frequency voltage, such as polypropylene, welding cannot be performed especially at intersections Aa and Ab. Otherwise, sparks will occur and damage the epidermis.

(e+ Fig. 5 is omitted when there is a recess C in the epidermis 1, but in the same way as above, for example, the fusion line A in Fig. 3 is in the recess C.
If it straddles the concave portion C, the concave portion C cannot be fused or its strength is weak.

Although not shown in the drawing, the recess C has a smaller area than the recess C in FIG. Also, when a large number of uneven portions are present on the skin 1, the same drawbacks as described above occur. The same applies even if there are uneven portions on the back side of the skin material 1.

(f+ When the skin 1 is made of textiles or the like, if a metal material is added to the materials used for dyeing, that part may be destroyed by sparks due to high frequency flow.

fg) As mentioned above, when fusion cannot be achieved by high frequency or other means, conventional methods have the drawback of having to resort to time-consuming sewing using a sewing machine.

SUMMARY OF THE INVENTION The present invention aims to solve the above-mentioned drawbacks of the conventional methods and to provide a method and product for fusing three layers of skin material, wadding, and back base fabric by ultrasonic fusing method. .

6 to 8 for a preferred embodiment of the present invention.
This will be explained in detail with reference to the drawings.

In FIG. 6, the outer skin 1, wadding 2 and back base fabric 3
3 and 4, and the ultrasonic horn type 4 connects the fusion lines A and A that intersect the grooves a and b shown in FIGS. 3 and 4.
It is located along. A space is created between the horn type 4 and the grooves a and b at intersections Aa and Ab.

When ultrasonic vibration is first applied to the ultrasonic horn die 4 between the horn die 4 and the ultrasonic pedestal 5, the vibration waves of the horn die 4 are as follows.
It is transmitted to the wadding 2 through the epidermis 1, and the intersection Aa
Since the vibration is transmitted to the wadding 2 below the horn mold 4, the 2 parts of the wadding below the horn mold 4 along the horn mold 4 have the effect of transmitting the entire ultrasonic vibration, and the horn mold 1
is compressed, and when the spaces at the intersection ha and kb are pushed up from below by the elasticity of the wadding 2, the intersection Aa
, A-b as well, the vibration of the horn mold 4 is directly transmitted to the wadding 2, so that the wadding 2 below the horn mold 4 is melted by the heat generated by the ultrasonic vibration.

At the same time, the ultrasonic vibration also melts the back base fabric 3 due to the transmission effect or direct effect, and the fusion line A shown in FIG.
It is fused at the fused part 2a.

In this case, if the skin 1 is also made of a material that generates heat due to ultrasonic vibration, the skin 1 in contact with the horn mold 4 will melt or soften.
Due to the pressure of the horn mold 4, the horn mold 4 is attached to the fused part Aa.
, contacts the bottom of Ab and directly transmits the vibration downward to the skin material 1.
, the wadding 2 and the back base fabric 3 generate heat, melt, and fuse together.

Although not shown in the drawings, the fusion effect can be further enhanced by interposing a suitable insulator between the ultrasonic horn pedestal 5 and the back fabric 3 to prevent heat generation due to ultrasonic vibrations from escaping.

In the current experiment regarding this method, an empire cloth is placed on top of the ultrasonic horn reception angle 5 shown in FIG. 6, a high cloth (also called high frequency cloth) is placed on top of that, and a backing cloth 3 is placed on top of that.

Empire cloth and high cloth generate heat due to ultrasonic vibration and prevent the heat from being transferred to the ultrasonic horn holder 5, and even though empire cloth becomes soft due to heat generation and heating, high cloth is made of cloth coated with silicone etc. Therefore, it is less likely to soften and has good mold releasability. Alternatively, glass fibers coated with, for example, I-fluorinated ethylene resin having excellent heat resistance and mold release properties may be used. The frequency in this case is 22KH2 in one embodiment.

In FIG. 6, the cross section of the ultrasonic horn mold 4 is as shown by the cross section 4a, and the tip of the cross section 4a is the fused portion 2a (FIG. 1).
It forms the

FIG. 7 is a sectional view corresponding to the cross section 4a in FIG. 6, and the positions of the skin 1, wadding 2, and back fabric 3 are reversed from those in FIG. 6, and in FIG. It is fused at the fusion part 5a (width t) of the sonic pedestal 5, and the width T of the ultrasonic horn mold 4 compresses the back base fabric 3, wadding 2, and skin material 1, giving ultrasonic vibration. , and is fused at the fused portion 5a (width t).

This is because the longitudinal shape of the fused portion 5a in FIG. 7 is required to have a complicated and accurate shape such as a curved line, as shown in FIG. If welded part 5
Since it is difficult to vibrate a as an ultrasonic horn type 4, the horn type 4 shown in FIG. T)
t, so the horn type 4 is vibrated by dividing it so that it hits the entire surface.

Next, the functions and effects of the present invention will be described.

In the case of high-frequency welding, the wadding 2
No fusion was achieved or the fusion strength was weak.

Similar results are obtained with general heat fusion. Furthermore, materials with low dielectric loss or materials that generate sparks due to electric current, and even the above-mentioned ordinary urethane wadding 2, which cannot be fused using conventional high-frequency fusion methods, can be bonded to the required strength using the ultrasonic method of the present invention. It becomes possible to fuse.

The above method can naturally be used even when the epidermis is smooth and has no irregularities.

In addition, there is no wear and tear on secondary materials such as insulating paper used for high-frequency fusing, and even if there is, there is very little wear and tear, and defects do not occur much.
It is possible to obtain beautiful products at low cost and strong fusion strength.

・The manufacturing method and product according to the present invention described above are not limited to trim covers. For example, if hardboard or the like is used for the body of the backing fabric shown in Fig. 1, it can be applied as a door pad for a vehicle, and a similar method can be applied to a vehicle door pad. Figures 1 to 5 relate to conventional examples, such as interior parts for furniture, furniture, and other interior goods. A plan view, Fig. 3 is an enlarged view of the fusion line A and intersections a and b in Fig. 2, Fig. 4 is a sectional view taken along the Y-Y line in Fig. 3, and Fig. 5 shows the skin recess. Plan views, Figures 6 to 8 relate to the present invention, Figure 6 is a sectional view showing the manufacturing method, Figure 7 is a sectional view showing the relationship between the ultrasonic horn mold and the horn pedestal satrim cover, FIG. 8 is a sectional view taken along the line X--X in FIG. 7.

1. Epidermis, 2. Fist wadding, 2a.. Fusion part 3..
Back base fabric, 4...Ultrasonic horn type, 5...Ultrasonic horn holder, A...Fusion line, a, b...Groove of epidermis, A a,
A b... Intersection.

Qi 1 Diagram A ■ Figure 5 Calculation 67 Figure 7 Z8 Te 4B ~ Serigu Tears 1 and Procedural Amendments (Voluntary) June 8, 1981 Kazuo Wakasugi, Commissioner of the Patent Office 1, Indication of Case Patent Application Sho 105052 No. 2, 1958
Title of the invention Trim cover 3 by ultrasonic fusion, Person making the amendment Relationship to the case Applicant name Title Tachikawa Spring Co., Ltd. 6, Contents of the amendment ■ Title of the invention Trim cover 2 by ultrasonic fusion, Claims 1 In the trim cover manufacturing method, three layers are stacked: the upper skin material, the middle layer of regular urethane wadding, and the lower backing fabric, and the parts that need to be fused are heated by ultrasonic vibration and bonded together. Place the outer skin material, wadding, and backing fabric in this order on an ultrasonic pedestal with a shaped fusion part, and compress the required parts with a divided ultrasonic horn mold.
A method for manufacturing a trim cover characterized by fusion of necessary parts by applying ultrasonic vibrations.

2. In a trim cover in which three layers of a skin material with uneven surfaces, ordinary urethane wadding, and a backing fabric are stacked and fused together by heating the parts that need to be fused together by ultrasonic vibration, the above three layers are fused. A trim cover made by ultrasonic welding, characterized in that the three layers are fused to each other by compressing the parts that need to be attached and flattening the uneven parts of the skin material using an ultrasonic horn type.

3. Detailed description of the invention The present invention relates to bar manufacturing methods and trim covers.

BACKGROUND OF THE INVENTION Conventional techniques for trim covers used for sounding materials such as seats will be explained with reference to FIGS. 1 to 5.

In the figure, reference numeral 1 indicates a skin material, 2 a wadding made of ordinary urethane made by relatively thinly slicing a cushion material such as urethane foam, 2a a fused portion between the skin material 1 and the wadding 2, and 3 a backing fabric.

FIG. 1 shows a seat in which the skin material 1, wadding 2, and back fabric 3 are fused at the fusion line A, that is, the skin material 1 and wadding 2, and the wadding 2 and back fabric 3 are fused at the fusion part 2a. 2 shows a cross section of the trim cover (taken along line I-X in FIG. 2).

In FIG. 2, the skin 1 is provided with many fine grooves a and b shown in FIG. 4 in parallel. These grooves a and b are @N
The N-line colors intersect at the Aa section and Ab section. In FIG. 1, the intersections Aa and AD are omitted.

FIG. 3 shows an enlarged view of the fusion N line A% grooves a, 'b and intersections Aa, Ab, etc. in FIG. 2.

FIG. 4 is an enlarged view of the cross section taken along the line ■-IV in FIG. 3.

In the above, the shape, number, and angle of intersection of structures a and b with the fusion line A are not limited to those shown in the drawings, and
The fusion line A may be curved. The problem with the above prior art is the intersection Aa of the grooves a and b and the fusion line A.
．． , In Ab, the skin material 1 is not fused to the wadding 2, or even if it is fused, the fusion strength of the fused part 2a is weaker than that of other parts of the fused part 2a, and it varies. Sometimes there are.

The reason for this is that, although not shown, if compression heating is performed along the fusion line A using, for example, a high frequency type or other heat fusion type, the intersection A
Parts a and Ab are spaces or other skin materials 1
The density of the skin material 1 in the compressed interfertility part is lower than that in the contacting part of the @layer type. Therefore, in the case of using high frequency and low temperature waves, there is less frictional loss due to the vibration of dielectric molecules, and the amount of heat generated is so low that fusion does not occur or the fusion bond strength is weak. Even with other heat-sealing types, heat cannot be transmitted to the skin material I, wadding 2, and back base fabric 3 at the intersections Aa, Ab, or is weak, so the fusion strength is weak or fused at the intersections Aa1Ab. There is a drawback that it does not.

(b) In particular, when the intersection angle between the fusion N line A and the groove a or between the fusion layer line A and the groove is small, the intersections Aa, AI) become long and the above-mentioned drawbacks occur to a large extent.

(C) Compared to using low-melting point urethane foam or ordinary urethane foam impregnated with adhesive for wadding 2, ordinary urethane (the urethane generally used for machine-stitched trim covers) is cheaper. , and has excellent physical properties such as elasticity, but since urethane usually has a high melting point, it is very difficult to create a melt layer at intersections Aa, Ab, etc. It is difficult or impossible to do so.

(d) In the case of high frequency welding, if the skin material is a material with low dielectric loss or a material that easily generates sparks due to high circular wave electric fields, such as polypropylene, it is especially important to A melt layer may not be formed, or sparks may occur, damaging the epidermis. Alternatively, if a flame retardant or other coating treatment is applied to the back side of the skin, sparks may occur as described above depending on the material of the coating.

(e) Fig. 5 shows a case in which there is a recess C in the skin 1, which is omitted from illustration, but similar to the above, for example, if the fusion layer line A in Fig. 3 straddles the recess C, the recess C cannot be fused. Strength is weak.

Although not shown in the drawing, the recess C is smaller than the recess C in FIG. When the skin 1 has a large number of irregularities in terms of area, the same drawback as described in 7 above occurs. The same applies even if there are uneven portions on the back side of the skin material 1. Furthermore, although not shown in the figure, since threads and fibers are used on the surface of general Tsunashima textiles and non-woven fabrics, there are small ivl protrusions on the entire surface and there are spaces between the threads, so it is difficult to use conventional fusion fabrics. In the deposition method, the strength of the fusion layer may be weak. Furthermore, the same drawbacks as described above occur when a gap is created between two or more overlapping skins.

ff) When the skin 1 is made of a textile or the like, if a metal material is added among the materials used for dyeing, the high frequency current may cause sparks to destroy that part.

(g) As mentioned above, when fusion cannot be achieved by high frequency or other means, conventionally there has been a drawback in which the user has no choice but to resort to time-consuming sewing using a sewing machine.

The present invention was made in order to eliminate all the drawbacks of the above-mentioned conventional examples.In the past, it was not possible to form a fusion layer due to the material, shape, smoothness, coating material, etc. of the skin material of the trim cover, but by using the ultrasonic fusion method, The object of the present invention is to provide a method and product for fusing three layers: a skin material, a wadding material, and a backing fabric.

6 to 8 for a preferred embodiment of the present invention.
This will be explained in detail with reference to the drawings.

In FIG. 6, the outer skin 1, wadding 2 and back base fabric 3
The ultrasonic horn pedestal 5 (its thickness is indicated by the width t of the dotted hatch) is placed under the grooves a and 0 shown in FIGS. 3 and 4. It is placed in desecration of the fusion N@A that intersects with the . Intersections Aa and AbK are formed between the ultrasonic horn pedestal 5 and the grooves a and b.

Pressure is applied to the ultrasonic horn mold 4 (its thickness is indicated by the width T of the dotted line hatch), and the space between the ultrasonic horn pedestals 5 is sealed, and the ultrasonic horn mold 4 is exposed to ultrasonic waves. When the vibration i+1] is given, the wave from the imaging part of the ultrasonic horn type 4 is transmitted to the wadding 2 through the back base fabric 1 hill, and is transmitted to the intersection Aa of the epidermis 1,
Since the vibration is transmitted by Abi, the wadding part 2 below the ultrasonic horn mold 4 attached to the ultrasonic horn pedestal 5 has the effect of transmitting the entire ultrasonic vibration, and furthermore, since the pressure is reduced by the ultrasonic horn mold 4, the surface Material 1 is sewn, and the intersection Aa, Al)
When the space is pushed down by the elasticity of the wadding 2 from above, the ultrasonic horn type 4 is also applied to the intersections Aa and Ab.
Since the vibrations are directly transmitted from the wadding 2, the wadding 2 below the ultrasonic horn mold 4 is melted by the heat generated by the ultrasonic vibrations. At the same time, the ultrasonic vibration also melts the skin 1 due to the transmission effect or direct effect, and the skin 1 is bonded at the fused portion 2a of the fused N line A in FIG.

In this case, if the skin 1 is made of a material that generates heat due to ultrasonic vibration, the skin 1 in contact with the ultrasonic horn holder 5 will melt or soften, and the pressure of the ultrasonic horn mold 4 will cause the ultrasonic horn holder 4 to melt or soften. contacts the bottoms of the welded parts Aa and Ab, and directly transmits the vibration wJ from above, causing the skin material 1, wadding 2, and back fabric 3 to generate heat, melt, and fuse together.

In the case of high frequency fusion, insulating paper must be used, but the ultrasonic fusion of this method usually does not require the use of insulating paper. However, depending on the type of material to be welded, it is necessary to promote heat generation, so although not shown, an appropriate insulator is placed between the ultrasonic horn mold 4 and the backing fabric 3 to promote heat generation due to ultrasonic vibration. If it is interposed, the fusion effect can be further enhanced.

Regarding this method, in the current experiment, the skin 1 and wadding 2 were placed on the ultrasonic horn pedestal 5 shown in Fig. 6, and the back fabric 3 was placed on top of that. (Also called a cross) wo, and then put an empire cross on top of it. Heat is generated by the vibration of the Empire Cross and High Cross Id sonic horn type 4, and the skin 1, wadding 2,
To promote heat generation of the back base fabric 3. Even though Empire Cloth softens due to heat generation, High Cloth is made of cloth coated with silicone, etc., so it is less likely to soften and has good mold releasability. Alternatively, for example, a glass fiber coated with a polytetrafluoroethylene resin having excellent heat resistance and mold release properties, or any other material having the same purpose as above may be used. The frequency in this case is 22 KH2 in one embodiment.

In FIG. 6, the cross section of the ultrasonic horn pedestal 5 is such that the tip of the ultrasonic horn pedestal 5 forms the fitting part 2a (FIG. 1), as shown by the cross section 5a.

In FIG. 6, the entire diagram may be turned upside down.

Also, since T>t, if the width of the fusion wire is at the middle gate of T, there is no risk of it coming off.

FIG. 7 is a sectional view corresponding to the cross sections 4'A, 5a, the skin 1, the wadding 2, and the back base fabric 3 in FIG. 6, and in FIG. 5a (width t), the width T of the ultrasonic horn mold 4 disarms the backing fabric 3, wadding 2, and skin material 1, applies ultrasonic vibration, and fuses the fused portion 5a (width t). ). 4 in Figure 8
A cross section taken along the line ■-■ shows 4A in FIG. The ultrasonic horn type 4 shown in FIG. 8 is configured to vibrate separately the ultrasonic horn type 4 which is divided in the longitudinal direction (4A, 4B, 40, etc.). 7 and 8 may all be turned upside down. Furthermore, if the fusion wire is short, the ultrasonic horn mold 4 may be one piece without being divided as described above.

Next, the functions and effects of the present invention will be described.

In the case of high frequency welding, as described in the above fa) (D) (c) fdl or (e), the wadding 2 was not fused or the fusion strength was weak due to the space between the intersections Aa and Ab. . Similar results are obtained with general heat fusion. Furthermore, the above (c) (dl (f) (g)
As described in the above, materials with low dielectric loss or materials that generate sparks due to electric current, and even the above-mentioned ordinary urethane wadding 2, which cannot be fused using the conventional high-frequency fusion method, can be strengthened by the ultrasonic method of the present invention. It becomes possible to fuse the

The above method can of course be used even when the surface has fine irregularities such as embossing, or when the epidermis has no irregularities and is smooth.

In addition, there is no wear and tear on secondary materials such as insulating paper used for high-frequency fusing, and even if there is, there is very little wear and tear, and defects do not occur much.
It is possible to obtain beautiful products at low cost and strong fusion strength.

The manufacturing method according to the present invention is not limited to the above-mentioned product + rito + J muka bar. For example, if the body of the backing fabric shown in Fig. 1 is made of hardboard, etc., it can be applied as a door pad for a vehicle, and a similar method can be applied to a vehicle. It can also be applied to interior items, furniture, and other interior items.

4 Brief Description of the Drawings Figures 1 to 5 relate to the conventional example, where Figure 1 is a cross-sectional view of the trim cover taken along line I-I in Figure 2, Figure 2 is a partial plan view of the trim cover, and Figure 2 is a partial plan view of the trim cover. Figure 3 is an enlarged view of the fusion layer line A, grooves a, b, and intersections Aa and Ab in Figure 2, Figure 4 is a sectional view taken along line 1l-IV in Figure 3, and Figure 5 is the skin recess. 6 to 8 relate to the present invention, and FIGS. 6 and 7 are cross-sectional views showing the manufacturing method, the ultrasonic horn mold, and the relationship between the ultrasonic horn pedestal and the trim cover, 8th
The figure is a sectional view along the line ■-■ in FIG. 7.

1. Epidermis, 2. Wadding, 2a. Fusion part, 3.
・Back base fabric, 4, 4 A, 4 B, 4.0...
Ultrasonic horn type, 5... Ultrasonic horn pedestal, A... Fusion wire, a, b... Groove of epidermis, Aa, Ab... Intersection.

Figure 1 -Ib-1 Figure 6 Diagram death Figure 8 ΔC

Claims (2)

[Claims] (1) The necessary fusion is achieved in a trim cover in which three layers are stacked: the upper skin material, the middle layer of ordinary urethane wadding, and the lower backing fabric, and the parts that need to be fused are heated and fused together using ultrasonic vibrations. The skin material, wadding, and backing fabric are placed on top of each other in this order on an ultrasonic pedestal that has a welded part in the shape of a fusion bond, and the required parts are compressed with a divided horn mold and ultrasonic vibrations are applied. A method for manufacturing a trim cover characterized by fused parts. (2) In a trim cover in which the three layers of a skin material having an uneven surface, ordinary urethane wadding, and a backing fabric are stacked and fused together by heating the parts that need to be fused together using ultrasonic vibration, the three layers are fused together. A trim cover made by ultrasonic welding, characterized in that the three layers are welded together by compressing the parts that require welding and flattening the uneven parts of the skin material using an ultrasonic horn type.