KR100467294B1 - Sewn cover assembly and product foamed therewith - Google Patents

Abstract

The present invention relates to a sewing cover assembly of a type involving a foaming process including injection and curing of a liquid foam material, and the cover assembly is formed by sewing with a sewing machine using two different kinds of threads with a plurality of cover members. As a result, the needle hole is completely closed and sealed to prevent leakage of the liquid foam material through the needle hole. That is, one of the two yarns used is thicker than the other, and serves as a leakage preventing member in addition to the role of the sewing thread. In addition, the foam product according to the present invention is formed by injecting and curing a liquid foam material in the sewing cover assembly.

Description

Sewing Cover Assembly and Foam Product Formed Together {SEWN COVER ASSEMBLY AND PRODUCT FOAMED THEREWITH}

The present invention relates to a sewing cover assembly in which a foam layer is integrally formed, and a plurality of separate cover materials are sewn together and a sewing cover assembly formed by adding a foam layer through a foam process. The present invention also relates to a foam product formed by forming a foam cushion by a foam process in a sewing cover assembly.

Conventionally known as trim cover assemblies, the surface cover layer and the foam pad layer are integrally formed and used to cover a vehicle or automobile seat or part thereof, such as a headrest or an armrest. In particular, the headrest or armrest is formed by performing a foam process on it using a closed three-dimensional trim cover assembly. According to a conventional process for performing a foam process on the headrest or the armrest, a plurality of separate cover parts are sewn by a sewing machine to form a three-dimensional body of the trim cover assembly, and a liquid foam is formed inside the hollow of the sewn trim cover assembly. The material is injected and molded to form a foam cushion member.

The problem in this process is that the liquid foam material leaks through the needle point formed by the sewing machine needle at the seam area where the plurality of cover materials are sewn to form the trim cover assembly, that is, the seam area to which the trim cover assembly is bonded. Can be.

Various methods have been proposed to avoid this leakage problem. For example, Japanese Patent Application Laid-open No. Hei 8-309765 proposes an overlock sewing method, in which both ends of two cover members are arranged in parallel to each other and sewn together by an overlock method, where a thin thread and a coarse thread are used together forcibly. Each needle hole is closed to prevent leakage of the liquid foam material. In addition, Japanese Patent Application Laid-Open No. Hei 8-243271 sews using an elastic piece along a seam or seam where two cover members are sewn together, and the elastic piece fills the needle hole of the seam.

However, these prior arts have a problem of excessive cost, demanding sewing processes requiring a special sewing machine such as an overlock machine, and a problem of requiring a large number of various threads (Height 8-309765), a sewing cover. An additional process is required to sew the leakproof material at the seam of the assembly (Hpps 8-243271).

The present invention is to solve the above-mentioned defects of the prior art, to provide a sewing cover assembly that can completely and easily prevent the leakage of the liquid foam material through the needle hole.

Sewing cover assembly according to the present invention to realize this object is

As a form for performing a foam forming process of injecting and curing a liquid foam material with the sewing cover assembly,

A plurality of cover members each preformed into a predetermined shape,

The plurality of cover members are sewn into a sewing cover assembly of a predetermined form by a sewing machine using the first thread and the second thread,

The first chamber has elasticity and flexibility and is thicker than the second chamber.

Therefore, the first chamber is partially collapsed elastically by the second chamber, and is forcibly inserted together with the second chamber into the needle hole of the cover member arranged in parallel. Therefore, the needle hole itself is closed and sealed due to the forced insertion of the two threads into the needle hole to prevent the liquid foam material from leaking through the needle hole during the foaming process, where the liquid foam material is a sewing cover assembly of a predetermined shape. Is injected and cured.

Preferably, the first yarn has a thickness of about 5 to 20 times that of the second yarn.

One preferred form of the first yarn is thick wool and simple yarns; alternatively, twisted yarns formed by spinning and twisting long tape-like elastic materials such as wool nylon or nonwoven fabric materials may be used.

Another object of the present invention to provide a foam product formed integrally with the sewing cover assembly.

For this purpose, the liquid foam material is injected and cured into the sewing cover assembly to form a foam cushioning member in an integrated manner, and the resulting foam product does not leak the liquid foam material through the needle hole of the cover assembly. The foam product can be manufactured and used in a desired form. For example, if the predetermined shape of the sewing cover assembly is a box-shaped three-dimensional trim cover assembly for a headrest, the foam product includes a headrest used in an automobile seat, and the head The rest arranges the headrest frame in the box-shaped three-dimensional trim cover assembly and is integrally installed with the foam cushion member. For example, if the desired shape of the sewing cover assembly is a box-shaped three-dimensional trim cover assembly for an armrest, the foam product includes an armrest for use in an automobile seat, and the armrest includes an armrest for the box-shaped three-dimensional trim cover assembly. The frame is disposed and integrally installed with the foam cushion member.

According to one aspect of the invention, due to the effect of completely filling the needle hole with coarse thread, at least one of the plurality of cover members may have a single layer structure including only one surface cover member, while the remaining one of the plurality of cover members is a surface cover. The layer and the foam pad layer may have a laminated structure of two or more layers.

Advantages and features of the present invention will become more apparent from the following preferred embodiments described in conjunction with the drawings.

1 is a partial cross-sectional view of a sewing cover assembly according to the present invention, illustrating a method in which two cover members are sewn together by a sewing machine using a first thread and a second thread.

Figure 2 is an enlarged plan view of one side showing the main portion of the sewing cover assembly of FIG.

3 is an illustration of one example of the form of a first chamber showing a method of forming in a twisted form;

4 is a partially exploded perspective view showing an example of another form of the first yarn in the form of a single yarn;

5 is an exploded cross-sectional view taken along the line V-V of FIG.

6 is a partially exploded cross-sectional view showing an example of a sewing cover assembly including a box-shaped three-dimensional trim cover assembly.

FIG. 7 is a schematic partial sectional view showing a case in which a foam product obtained by applying a foam process to the trim cover assembly of FIG. 6 is applied to a headrest shape. A diagram showing an example in which a headrest is manufactured.

FIG. 8 is a cross-sectional view schematically illustrating a case in which a foam product obtained by applying a foam process to the trim cover assembly of FIG. 6 is applied to an armrest shape, wherein a foam cushion member is formed together with a headrest frame in the trim cover assembly to be used for an automobile seat. A diagram showing an example in which a headrest is manufactured.

1 to 8, a sewing trim cover and a product in which a foam is formed together with the cover will be described as a preferred embodiment of the present invention.

1 shows a pair of separate first cover members 3 and second cover members 4, each covering member having a laminated structure of two layers and having a seam formed at the side ends, that is, at the edges, and two gerbers. The joint part J is formed between members. 2 is a view of the trim cover assembly formed in this way as seen from the second cover member 4 side. As shown in FIG. 1, the first cover member 3 has a first surface cover layer 31 and a first foam pad layer 32 (eg, slab polyurethane foam) therein, all of which are integrally formed. Formed together. In addition, the second cover member 4 is formed in the same manner, and has a second surface cover layer 41 which is integrally stacked and a second foam pad layer 42 therein. The first and second cover members 3 and 4 are formed of a material such as a woven fabric, a nonwoven fabric and a knitted fabric, and are trimmed in a predetermined shape in consideration of the shape of the desired trim cover assembly. Reference numerals 33 and 43 are formed by thermally dissolving and curing the outer surfaces of the corresponding first and second foam pad layers 32 or 42 as first and second hardened thin film layers. The thin film layer is intended to prevent penetration of the liquid foam material (see FIGS. 6A and 7) during the continuous foam process (described below). However, the present invention is not limited thereto, and other suitable penetration preventing means may be applied to the first and second foam pad layers 32 and 42.

As shown by the solid line and the dashed-dotted line in FIGS. 1 and 2, the two first and second cover members 3 and 4 use the first thread 1 and the second thread 2 to sewing machine M. FIG. ) Are sewn together in a straight line along each straight seam 3B and 4B. As in the most common sewing machine, the first thread 1 is wound around the bobbin MB disposed on the sewing machine table and transported outward toward the needle N. On the other hand, the second thread 2 is the sewing base body ( Located in M) and transferred to the first and second cover members 3 and 4 placed in parallel through the sewing needle N, the first chamber 1 and the second chamber 2 are covered during the sewing operation. Twist each other at regular intervals in the member. Here, in connection with the embodiment of the present invention, the first chamber 1 is a so-called "bobbin thread", and the second chamber 2 is a so-called "needle thread". According to the present invention, the second thread 2 (or needle thread) is a strong thread or a thread of relatively hard synthetic resin material, which is generally used with a sewing machine. In any case, the second yarn is intended to be used for sewing purposes of the present invention, and a preferred example is a synthetic resin yarn of yarn number "No. 8". In contrast, the first chamber 1 (or bobbin chamber) has a relatively large thickness with respect to the second chamber 2 as shown in FIG. A general example of the first chamber 1 in accordance with the intention of the present invention is a thick thread, which has elasticity and flexibility, is larger than the diameter of the second chamber 2 and has a specific elastic restoring force in the radial direction. The reason for having these characteristics is to prevent leakage of the liquid foam material and to obtain various advantages described later. The present invention can be implemented through the preferred embodiment described with reference to FIGS. 3 to 7. Of course, the present invention is not limited to this, and the first chamber 1 itself may have any shape as long as it can obtain the characteristics of elasticity and thickness (that is, large diameter) shown in FIGS. 2 and 5.

3 shows an example of a method of forming the shape according to the first chamber 1. For example, as shown by reference 1A, a long tape of elastic and flexible material may be used, which is wound around the bobbin MB. As shown, when the long tape 1A is supplied from the bobbin, the long tape 1A is automatically folded into a substantially U-shaped folded tape 1B about the center line, and the folded tape 1B is a twisted thread form of a substantially circular cross section. Is spun into. This spinning is performed by the well-known thread twisting spinning mechanism, and the detailed description is abbreviate | omitted here. In this form, it is preferable to use a long tape such as wool nylon, nonwoven fabric, etc., which is 5 to 20 times thicker than the second yarn 2 after being spun with twisted yarn. In particular, when using wool nylon, wool nylon tape having a thickness of 5 mm and a thickness of 1 to 2 mm is most preferable. Therefore, the initial flat tape state of the base seal material is deformed and swells to form a column or a spiral formed of a plurality of spiral layers as shown in FIG. 3. This twist structure is effective for amplifying radial expansion force in the yarn itself with elasticity, that is, radial elastic restoring force.

Alternatively, instead of the twisted thread shape, as shown in FIG. 4, a simple thread shape having a circular cross section may be generally used, in which case, in addition to elasticity and flexibility, the thickness of the second chamber 2 may be 5-20. You will have the thickness of the belly. Of course, the real material to be used must have a radial elastic resilience as in the twisted form. In this case, wool yarn or other suitable elastic yarn is preferred. This simple thread is wound directly around the bobbin (MB) is fed from the needle (N) during direct sewing from there.

In any case, it is preferable that the first chamber 1 has the size of about 5 to 20 times larger than the thickness of the second chamber 2 and has the elasticity and flexibility as described above.

In operation, as shown in Figs. 1 and 2, the first chamber 1 is supplied to the needle N regardless of the twisted thread form or the simple thread form, and the first and second cover members arranged in parallel ( 3) (4) are twisted together with the second chamber (2) at regular intervals, and as a result are sewn together with the cover member along a predetermined line, leaving the edges (3A) (4A). As shown in Figs. 2 and 5, the first chamber 1 is partially and elastically collapsed at a predetermined interval by the second chamber 2, as indicated by reference numeral " 10 ". A part of the deformed portion 10 of the first chamber 1 is forcibly inserted into the needle hole O together with the second chamber 2. In this way, the forced insertion of both the first and second seals 1 and 2 can be completely closed and sealed to prevent leakage. The radial restoring force of the first chamber 1 itself serves to assist the positive filling and closing of the needle hole O.

Based on the sewing operation, a plurality of separate cover members may be sewn together to form a three-dimensional trim cover assembly. 6 shows a box-shaped basic three-dimensional trim cover assembly A, which is formed by sewing at the joint J'J 'using the first chamber 1 and the second chamber 2.

As shown in FIG. 6, the liquid foam material 6A is injected into the trim cover assembly A through the nozzle N. As shown in FIG. The sewn trimcover assembly A then hardens the liquid foam material 6A to undergo a foam process. During seam formation, all seams or needle holes O in the joints J (J ') are completely closed and sealed by the first chamber 1 and the second chamber 2 as described above, so that the needle holes ( There is no leakage of the liquid foam material 6A through O). As a result, the foam cushion 6 is produced inside the trim cover assembly A without leakage to the outside. The resulting foam product, i.e., the entire foam unit consisting of the trim cover assembly and the foam cushion, can be used as part of an automotive seat or an application fitted to the seat as shown in FIGS.

7 is an example in which the manufactured foam product is used as the main body of the headrest H. In this case, the headrest frame with the stay 8 is pre-installed in the sewing trim cover assembly A in the process of forming the headrest. And then a foaming process is carried out as described above to produce a foam cushion 6 which is integral with the headrest frame in the trimcover assembly A, resulting in the headrest H of FIG. . This headrest H can be attached to the seat for the car (S).

8 shows an example in which the foam product is used as the main body of the armrest AM (aka, armrest). In the armrest forming process of this example, the armrest frame is positioned in advance in the sewing trim cover assembly A, and then subjected to a foaming process as described above to form the foam cushion 6 together with the armrest frame in the trim cover assembly A. It forms integrally, and as a result, an armrest (AM) product as shown in FIG. 8 is manufactured. Reference numeral R denotes a support bracket for supporting the armrest, and the armrest AM is attached to the vehicle seat S.

According to the present invention, the elastic first thread 1 is inserted into the needle hole O together with the ordinary thin second thread 2 by a general sewing machine, and as a result, forced filling of the needle hole O is effectively performed. It is made to the maximum to completely close and seal the hole itself, so that the leakage of the liquid foam material 6A can be completely prevented. Therefore, the first thread 1 is used as a leakage preventing member as well as a sewing thread function, and as a result, there is no need to use other special leakage preventing members as found in the prior art. This consequently makes it possible to simplify the general sewing operation as in the prior art while directly using the conventional conventional sewing machine.

As described above, the needle hole is completely filled to obtain the following effects.

(1) The first and second foam pad layers 32 and 42 in the trim cover assembly may be smaller in thickness and density than ordinary pads, so that the sewing needle can penetrate smoothly and enter the sewing work accordingly. Can increase the ease and speed.

(2) In the first and second cover members 3 and 4, the first and second surface cover layers 31 and 41 are formed as seams in the first and second edges 3A and 4A. No foam pad layer is added to this boundary region. As a result, the cover members can be easily arranged in parallel in the first and second edges 3A and 4A, which facilitates sewing together. Therefore, the smoothness and speed of the sewing operation can be improved.

(3) As can be understood from reference numerals 5 in Figs. 6, 7 and 8, some cover members may be formed only in a single layer structure, not in a laminated structure of two layers of reference numerals 3 and 4. As described above, the insertion of the coarse thread allows the needle hole formed in the joint portion J 'to be completely closed and sealed even in the single layer cover member. This single layer cover member 5 is preferably added to the non-exposed side of the trim cover assembly which is not visible from the outside. That is, in the case of the headrest H of FIG. 7, the cover member is attached to the bottom side of the headrest which is hardly seen. In addition, in the case of the armrest AM of FIG. 8, the single-layer cover member 5 is attached to the rear surface wall side of the armrest which is hardly seen.

Although preferred embodiments have been described as described above, the present invention is not limited thereto, and various changes and modifications may be made by those skilled in the art without departing from the following claims and their technical ideas.

Claims (4)

In the sewing cover assembly is a foam forming process in which the liquid foam material is injected and cured together integrally, It is provided with a plurality of cover members, each preformed in a predetermined shape, The plurality of cover members are sewn into a sewing cover assembly of a predetermined type by a sewing machine having sewing needles and bobbin means by using a first thread and a second thread, and the second thread is supplied to the sewing needle, and the first thread is Thread is supplied from the bobbin means toward the sewing needle, And said first yarn comprises a twisted thread formed by twisting an elongated tape having elasticity and flexibility, said sewing thread assembly being thicker than said second yarn. The method of claim 1, Sewing thread assembly, characterized in that the first yarn is formed of wool yarn, wool nylon material or non-woven fabric material. Formed integrally with the sewing cover assembly by a foam process and at the same time a foam product comprising a plurality of cover members and foam cushioning member, The plurality of cover members are each preformed into a predetermined shape, The plurality of cover members are sewn into a sewing cover assembly of a predetermined type by a sewing machine having sewing needles and bobbin means by using a first thread and a second thread, and the second thread is supplied to the sewing needle, and the first thread is Thread is supplied from the bobbin means toward the sewing needle, The first chamber has elasticity and flexibility and is thicker than the second chamber, The foam cushion member is a foam product, characterized in that formed integrally with the predetermined shape of the sewing cover assembly by a foam process of injecting and curing a liquid foam material. The method of claim 1, Each of the plurality of cover members is a sewing cover assembly, characterized in that a laminated structure of two or more layers including a surface cover layer and a foam padding layer integrated with the surface cover layer.