JPS6336400B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention provides a trim cover for a seat or similar vehicle and house trim cover comprising a skin (first layer), a wading made of ordinary urethane (second layer) and a backing fabric (third layer). This invention relates to a method for manufacturing heat-sealed trim covers for interior materials, furniture, trunks, footwear, daily necessities, etc.

In the above-mentioned three-layer trim cover, if the melting temperature of the ordinary urethane foam used for wading is higher than the melting temperature of the vinyl leather of the outer skin (first layer), when the three layers are fused by heat, the outer skin may be heated. If the vinyl leather melts too much, problems such as an unpleasant shine, keloid formation, or tearing may occur.

Generally, when ordinary urethane foam (hereinafter abbreviated as ordinary urethane) is heated to about 130℃ and pressed with a mold, it begins to deform and melts at about 180℃. Also,
Vinyl leather deforms at about 110℃, melts and flows out at about 140℃.

Because of the above drawbacks, low melting point urethanes have conventionally been used, but low melting point urethanes are more than twice as expensive as ordinary urethanes and have significantly inferior physical properties. Therefore, the fused portion of ordinary urethane is impregnated with a fusing agent such as nylon powder, and while ordinary urethane does not melt, the impregnated nylon powder melts at about 110°C and maintains the deformation of ordinary urethane.
There is a method of manufacturing a trim cover in which the skin is fused and bonded to urethane by melting nylon powder, but this manufacturing method has the drawback of high costs due to the cost of nylon materials and the impregnation process.

The conventional manufacturing method will be explained with reference to FIGS. 1 to 3.

Figure 1 is a cross-sectional view of a trim cover consisting of a skin (first layer) 1, wading (second layer of ordinary urethane), and back base fabric (third layer) 3, and 4 is a fusion bond pressed by a fusion die. In this section, this manufacturing method will be explained with reference to FIG.

FIG. 2 shows an example of the above-mentioned three-layer welding method, in which a skin 1, Ordinary urethane 2 and back base fabric 3 are placed in this order, and insulating paper 6 is placed on top of them. The fused portion 4 of the outer skin 1, ordinary urethane 2, and back base fabric 3 is compressed by the heating device 7 fixed to the high-frequency equipment upper panel 8 and the pressing portion 5a, heated by the heating device 7, and fused by the high-frequency current at the same time. The three layers (trim cover) are fused together at the attachment part 4 (FIG. 1).

FIG. 3 is an enlarged view of the top of the pressing part 5a of the fusion mold 5 shown in FIG. It melts and becomes deformed by hanging downward, resulting in a deformed epidermis 1a, which forms a keloid or re-foams, or melts too much to expose the lining cloth on the back of the vinyl leather, or gives an unpleasant luster to the entire surface of the epidermis 1. Furthermore, the bonding strength may be reduced by flowing out of the part of the welded part 4 that is fused by the pressing part 5a, resulting in deterioration in quality and zero commercial value.

The present invention is proposed in view of the drawbacks of the conventional manufacturing method described above, and its gist is that when heat fusion is performed using a fusion mold, the surface of the first layer and the tip of the pressing part of the fusion mold Cooling gas is sprayed near the corner where the fusion mold contacts the surface of the first layer and the tip of the pressing part of the fusion mold at the same time, causing a thermal change in the surface of the first layer other than the part that contacts the fusion mold. According to the manufacturing method of the present invention, there is no need for nylon powder, the work is simple, and the defect rate can be reduced, making it possible to provide trim covers at low cost. becomes.

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

The method for preventing the occurrence of the skin deformation part 1a shown in FIG. What is necessary is to take a method of preventing the vinyl leather (skin 1) whose opposite side is heated and melted or softened from being pushed out or flowing out to the deformed portion 1a side. A number of examples of how to do this are described below.

To explain an example with reference to FIG. 4, one cooling pipe 10 is provided between each pressing part 5a of the fusion mold 5, and moderately cooled gas (air) is supplied from the outside to the cooling pipe 10. The pipe 10 is further provided with an appropriate number of cooling gas blow-off holes 10a, and the cooling gas is directed to the vicinity of the corner where the tip of the pressing part 5a located on both sides of each cooling pipe 10 contacts the surface of the skin 1, as indicated by arrows. By spraying as shown in FIG. 3, the occurrence of the skin deformation portion 1a shown in FIG. cooling pipe 1
0 is installed between each of the pressing parts 5a as described above, but if the space between the pressing parts 5a is narrow, the cooling pipe 10 is not passed through, although not shown, and the cooling pipe 10 is not passed between the skin 1 and the pressing parts 5a, 5a. Air may be allowed to pass through the space between them.
This method is also effective in preventing melting of the epidermis 1 due to cooling of the pressing portion 5a itself as shown in FIG. 7, which will be described later.

FIG. 5 similarly shows a case where the intervals between the pressing parts 5a are narrow, and the cooling gas blowing holes 11a formed in the cover 11 are provided to limit the cooling gas passages between the pressing parts 5a of the fusion mold 5. Each cover 11
The cooling gas is sprayed near the corner where the tip of the pressing portion 5a located on one side of the sheet contacts the surface of the first layer.

On the contrary, FIG. 6 shows the case where the distance between the pressing parts 5a is wide,
Cooling gas blow-off holes 10a formed in one cooling pipe 10 arranged near one side of the base of each pressing part 5a of the fusion mold 5 connect the tip of each pressing part 5a and the first layer 1.
Cooling gas is sprayed near the corner where the surface contacts the surface, as shown by the arrow.

FIG. 7 shows cooling gas blow-off holes 10a formed in two cooling pipes 10 arranged near both sides of the root of each pressing part 5a of the fusion mold 5, and a cooling gas blowing hole 10a formed by penetrating between both sides of the upper part of each pressing part 5a. The cooling gas blowing hole 5d blows cooling gas near the corner where the tip of each pressing portion 5a and the surface of the first layer 1 are in contact as shown by the arrows.

Therefore, according to such a method, a part of the gas from the cooling gas blowing hole 10a of the cooling pipe 10 is passed through the cooling gas blowing hole 5b of the pressing part 5a to cool the skins 1 on opposite sides. At the same time, the upper part of the pressing part 5a is cooled from inside, and the pressing part 5a is
By lowering its own temperature, the melting temperature of the epidermis 1 can be more effectively prevented. In this embodiment, cooling gas blow-off holes 5b, 5b are provided diagonally upward alternately from both sides of the upper part of the pressing part 5a.

One of the purposes of cooling the upper part of the pressing part 5a of the fusion mold 5 is to prevent the temperature of the front side of the skin 1 that is not in contact with the tip of the pressing part 5a from increasing excessively, and to cool the upper part of the pressing part 5a. A fused portion 4 where 5a is in contact with the epidermis 1
The purpose of this portion is to prevent the skin 1 from melting excessively and to accelerate cooling after embossing as shown in FIG. 14, which will be described later. Further, although not shown in the drawings, if the spacing between some of the pressing parts 5a is narrow and the cooling pipe 10 is not provided, the adjacent pressing parts 5a
The skin 1 and the pressing part 5a can be cooled from the opposite side by passing cooling gas from the cooling pipe 10 between them through the holes 5b.

FIG. 8 is a modification of FIG. 7, in which the fusion type 5
Cooling gas blow-off holes 5d branch from cooling gas passages 5c formed inside the upper part of each pressing part 5a and open on both sides of the upper part of the pressing part, so that corners where the tip of each pressing part and the surface of the first layer come into contact are provided. Cooling gas is blown around the area.

FIG. 9 shows that the cooling gas blowing holes 14a formed in the cooling pipes 14 attached to both sides of the upper part of each presser part 5a of the fusion type are used to connect the tip of each presser part and the first
Cooling gas is blown near the corner where the surface of the layer contacts, and has the same effect as the embodiment shown in FIG. The cross-sectional shape of the cooling pipe 14 may be circular, semicircular, or quadrilateral.

In Fig. 10, there are four fusion molds 5, for example two on each side on the left and right.
In the case of a high-frequency equipment of a shuttle-type table having two parts, the outer skin 1, ordinary urethane (wading) 2, back base fabric 3, etc. above the pressing part 5a are omitted from illustration. When the lower die 9 rises, the joint between the cooling source pipe 12 where the cooling pipes 10 of each pressing part 5a gather and the external air supply pipe 13 are automatically connected to supply air to each of the cooling pipes 10. do. When the lower mold 9 descends, the cooling source pipe 12 and the external air supply pipe 13 are separated. At this time, the supply pipe 13
The automatic valve mounted on the side is closed. When the lower die 9 is raised, the valve is automatically opened. The cooling air supply time is from pressurizing the material to be heated, energizing, cooling, and releasing the pressure.

Next, although not shown in the drawings, since the method of supplying air differs depending on the type of high-frequency equipment, a method of supplying air to the pipe 10 will be described next.

One fusion mold 5 can be used as a high frequency equipment lower plate 9 or upper mold 8
When the cooling source pipe 12 and the external air supply pipe 13 rise or fall, the fusion mold 5 rises or falls, so the cooling source pipe 12 and the external air supply pipe 13 may remain connected. Also, in the case of a shuttle type in which one fusion mold 5 slides sideways together with the high-frequency equipment lower mold 9, the cooling source pipe 12 and the external air supply pipe 13 remain connected, and the supply pipe 13 side is used as a rubber hose for movement. supply air.

In the case of a turntable type high frequency equipment, a branch pipe may be attached to each fusion mold 5 from the rotation center of the table, or a joint may be inserted from the outer periphery of the table during the fusion process to send air. In the above method, a method is provided to automatically supply cooling gas only to the process requiring cooling.

As shown in Fig. 11, a separate hanging piece 17 is fused and cooled on the lower surface at the same time as the fused part 4 is fused. Used when

In FIG. 12, a button-shaped portion 15 is formed on the upper surface of the skin 1 at the time of fusion, and a hanging piece 17 is fused on the lower surface, followed by cooling.

The embodiment shown in FIG. 13A has a gusset 1b and a bevel 16.
Two kinds of skins, the vinyl leather skin of the pointed part 1c and the fabric skin of the bead part 16a and the bent part 1d, ordinary urethane 2 and back base fabric 3 are fused together, molded and cooled at the same time. The gusset 1b refers to the side surface of the seat, the bulge 1c refers to the peripheral edge of the upper surface of the seat, and the bent portion 1d refers to the central portion of the seat surrounded by the bulge 1c.

This embodiment is an example in which the bending portion 1d is made of a fabric skin, and the calf portion 1c is made of a vinyl skin, which is used in a general seat. The beads 16, 16a are also generally made of vinyl.

Figure 13B shows an example in which the regular urethane 2 and back base fabric 3 on the left and right sides of the bevel 16a were made into one continuous piece of regular urethane 2 and back base fabric 3, whereas they were separate pieces in Figure 13A. is the same as above.

Fig. 13C shows a case in which a beaded shape 1f is formed on the skin 1 at the same time as the three layers are fused together, and the manufacturing method is the same.

In Fig. 13D, a bead 16b of a different color from the skin 1 is fused onto the bead 1f of Fig. 13C, and is made beautiful by taking into account the color contrast. Since the above epidermis 1 is cooled in the same manner as described above, this is an example in which the present invention is effectively implemented.

Fig. 14 shows a case in which an embossed pattern 1e or a large designed pattern is formed on the skin 1 using a mold having an embossed pattern or design pattern at the same time as the fusion part 4 is fused, and only the skin 1 or ordinary urethane 2 is molded. do. Although not shown in the drawings, it is also possible to form the same shape as the perforated seam on the fused portion 4 using the fused pressing portion 5a. If the mold temperature is high after embossing, if the vinyl is released from the pressing part 5a before it hardens, the embossed part will become inaccurate.
It is necessary to lower the temperature of a.

FIG. 15 shows an example in which a hard board 18 is used in place of the back base fabric 3, and the ordinary urethane 2 is thin, fused and cooled by the above manufacturing method, and is used as a vehicle interior material such as a door pad. be.

In FIG. 2, heating is performed by the heating device 7, but the temperature of the heat generated by the high-frequency current of the object to be welded,
As an example of a material with a high dielectric constant that produces a higher calorific value and a higher temperature, it is possible to use a sheet made of ferrite powder combined with silicone resin in place of the heating device 7. can be abolished.

Furthermore, in the above embodiments, it has been explained that air is used for cooling, but not only air but also other gases suitable for cooling can be used.

Above, we have explained that the heating method is based on high-frequency current, but it is not limited to this.
As a heat source for the apparatus using the lower mold, for example, heating the mold using high-temperature steam, high-temperature fluid, gas flame, etc., or ultrasonic waves, etc. can also be applied.

In the present invention, the skin is not limited to vinyl leather, and the first layer (skin) of the three layers is made of a second layer, such as ordinary urethane or non-woven fabric, which has a temperature at which it deforms, melts, or flows out due to heat, such as woven or nonwoven fabric. This can be applied to cases where the temperature is lower than the temperature at which heat-fused fibers are deformed, melted, or flowed out due to heat.

This manufacturing method is not limited to trim covers, but has a wide range of applications, including vehicle door pads, carpets, interior items such as roofing, furniture, and daily necessities.

According to the manufacturing method of the present invention, ordinary urethane is used as wading and nylon powder is not used as a welding material as in the past, so there are fewer steps and costs can be reduced.Furthermore, since it is cooled during welding, the skin melts. No excessive melting or leakage of the dressing area.
In addition to forming beads and other shapes, accurate fused parts can be obtained and the skin surface has a good finish, so there are very few defective products, and this has a great effect on improving quality and reducing costs.

[Brief explanation of the drawing]

FIG. 1 is a sectional view of the trim cover, FIG. 2 is a sectional view of a conventional fusion equipment, FIG. 3 is an enlarged sectional view of the upper part of the pressing part in FIG. The figure is a cross-sectional view of an example of fusion equipment, Figure 5 is a cross-sectional view of a cooling method, Figure 6 is a cross-sectional view of another fusion and cooling device, and Figures 7, 8, and 9 are each a different one. Fig. 10 is a cross-sectional view showing the cooling gas supply and closure, Fig. 11 is a cross-sectional view of an example in which the sling is fused together with fusion, and Fig. 12 is a sectional view of the button at the same time as fusion. A cross-sectional view of an example of forming the shape part and fusing the suspension,
Fig. 13A is a cross-sectional view of an example in which vinyl and fabric are fused to the outer skin, Fig. 13B is a cross-sectional view of an example in which the wading and the backing fabric are each one piece, and Fig. 13C is a cross-sectional view of an example in which the wading and backing fabric are fused together. Cross-sectional view of an example of forming a shape, 13th
Figure D is a cross-sectional view of an example in which beads of different colors are superimposed on a bead shape, Figure 14 is a cross-sectional view of an example in which an embossed pattern is formed on the skin along with fusion, and Figure 15
The figure is a sectional view of an example in which hardboard is used and fused to the third layer instead of the backing cloth. 1... Epidermis, 1a... Epidermal deformation part, 1b... Gusset part, 1c... Calf part, 1d... Curved part,
1e...Embossed pattern, 1f...Bead shape, 2
...Normal urethane (wading), 3,3a...
Back base fabric, 4... Fusion part, 5... Fusion type, 5a...
Pressing part, 5b, 5c...Air hole, 5d, 10a,
11a, 14a...Cooling gas outlet, 6...Insulating paper, 7...Heating device, 8...High frequency equipment upper mold, 9
...High frequency equipment lower mold, 10, 14...Cooling pipe, 11...Cover, 12...Cooling source pipe, 1
3...External air supply pipe, 15...Button-shaped portion, 16, 16a, 16b...Bubble, 17...
Hanging, 18...hardboard.

Claims (1)

[Scope of Claims] 1. Heat-sealing required portions of the material of the first layer material and the second layer in contact with the material whose temperature is higher than that of the first layer material due to thermal deformation, fusion, etc. using a fusion mold. In this case, cooling gas is sprayed near the corner where the surface of the first layer and the tip of the pressing part of the fusion mold contact, thereby simultaneously cooling the surface of the first layer and the tip of the pressing part of the fusion mold. A method for producing a heat-sealable trim cover, characterized in that the first layer is melt-bonded without causing any thermal change to the surface of the first layer other than the portion in contact with the melt-bonding mold. 2 Cooling gas blow-off holes formed in the cooling pipes arranged between each of the pressing parts of the fusion type allow the corner parts where the tips of the pressing parts located on both sides of each cooling pipe and the surface of the first layer contact each other. A method for manufacturing a heat-sealable trim cover according to claim 1, characterized in that cooling gas is blown into the vicinity. 3 Cooling gas blow-off holes formed in the cover to define cooling gas passages between each of the fused pressing parts allow the tip of the pressing part located on one side of each cover to connect with the surface of the first layer. 2. A method for manufacturing a heat-sealable trim cover according to claim 1, wherein cooling gas is blown near the contacting corners. 4 Cooling gas blow-off holes formed in one cooling pipe placed near one side of the base of each pressing part of the fusion type allow cooling gas to be supplied near the corner where the tip of each pressing part contacts the surface of the first layer. A method for producing a heat-sealable trim cover according to claim 1, wherein the trim cover is sprayed. 5 Cooling gas blowing holes formed in two cooling pipes placed near both sides of the base of each fusion type pressing part and cooling gas blowing holes formed penetrating between both sides of the upper part of each pressing part make each pressing part Claim 1, characterized in that the cooling gas is blown near the corner where the tip of the first layer contacts the surface of the first layer.
The manufacturing method of the heat-fused trim cover described in Section 1. 6 Cooling gas blow-off holes that branch from cooling gas passages formed inside the upper part of each fusion-type pressing part and open on both sides of the upper part of the pressing part bring the tip of each pressing part into contact with the surface of the first layer. 2. The method of manufacturing a heat-sealable trim cover according to claim 1, wherein cooling gas is blown near the corners. 7 Cooling gas blowing holes formed in the cooling pipes installed on both sides of the upper part of each pressing part of the fusion type are used to blow cooling gas near the corner where the tip of each pressing part and the surface of the first layer touch. A method for manufacturing a heat-sealable trim cover according to claim 1, characterized in that: 8 Each cooling pipe that supplies cooling gas to each cooling gas outlet or the cooling source pipe where each cooling gas passage converges and the external air supply pipe that supplies cooling gas are automatically connected during the cooling process, and after cooling is completed. 8. The method of manufacturing a heat-sealed trim cover according to any one of claims 2 to 7, wherein the external air supply pipe is automatically separated, and the valve of the external air supply pipe is automatically closed. 9 Heat-fuse the button shape, embossed shape, and machine-sewn shape, or the bottom part and the hanging part, or the gusset part, the bead part, and the calyx part, or the calyx part, the bead part, and the bent part on the first layer. A method for manufacturing a heat-sealable trim cover according to claim 1, wherein the trim cover is cooled while the trim cover is attached. 10. The method of manufacturing a heat-sealable trim cover according to claim 1, wherein a beaded portion is formed in the first layer, and a beaded portion of another color is superimposed and fused on the first layer, and then cooled.