JP2014019060A - Molding method, and formed part - Google Patents

Abstract

[PROBLEMS] To sew a sewing thread sewn on a resin material when the sewing thread is sewn at a sewing position of the resin material or the sewing thread is arranged at the sewing location of the resin material so that the resin material and the sewing thread are integrated. Provided are a molding method and a molded product that can seal a gap between an outer peripheral surface and the resin material and can reduce resistance to a sewing tool during sewing.
An upper thread 1 and a lower thread 2 are sewed on a sewing portion 3a of a thermoplastic resin material 3 in a molten state, and the sewing portion 3a is cured to bond the thermoplastic resin material 3, the upper thread 1 and the lower thread 2 together. Integrate. Thereby, the thermoplastic resin material 3, the upper thread 1, and the lower thread 2 are integrated at the sewing location 3 a of the thermoplastic resin material 3.
[Selection] Figure 1

Description

  The present invention relates to a molding method and a molded product, for example, a molding method and a molded product in which a thermoplastic resin material and a sewing thread are integrated.

  Traditionally, for example, interior parts for automobiles such as instrument panels, console boxes, door trims, interior parts for homes such as furniture, clothing accessories such as bags, etc. can be sewn on the surface with a sewing thread. Design and merchandise are improved.

  By the way, when sewing threads are sewn to resin materials such as resin interior goods and resin miscellaneous goods with sewing machines, for example, resistance to sewing needles at the time of sewing is compared to when sewing threads are sewn to textile materials such as cloth. And a problem that the clearance between the outer peripheral surface of the sewing thread sewn on the resin material and the resin material becomes large.

  In addition, for example, automotive interior parts such as instrument panels, console boxes, door trims, etc., adhesive is applied to the back side of the resin material that has been sewn with sewing threads and stitched, or foamed urethane resin, etc. When the foam is molded, there may be a problem that the adhesive or the resin material leaks to the surface side through the gap formed around the sewing thread.

  For such a problem, Patent Document 1 discloses a technique of using a resin sewing thread, sewing the sewing thread on a plastic skin material, and then heating and melting the sewing thread to close the joint. ing.

Japanese Patent Laid-Open No. 3-1938

  According to the technique disclosed in Patent Document 1, since a joint can be sealed after a sewing thread is sewn on a plastic skin material, for example, a foam such as a foaming urethane resin on the back surface side of the skin material. Even in the case of molding, it is possible to prevent the foamable resin from leaking to the surface side of the skin material.

  However, in the technique disclosed in Patent Document 1, since the sewing thread is heated and melted after the sewing thread is sewn on the resin material, the problem that the resistance to the sewing needle at the time of sewing still increases can be solved. Absent. In addition, it is necessary to use a resin sewing thread, which causes a problem that it is difficult to apply a natural sewing thread with excellent design.

  The present invention has been made in view of the problems described above, and is a method in which a sewing thread is sewn at a sewing position of a resin material, or a sewing thread is arranged at a sewing position of a resin material so that the resin material and the sewing thread are integrated. In a method and a molded article, a molding method and a molded article that can seal a gap between the outer peripheral surface of a sewing thread sewn on a resin material and the resin material and reduce resistance to a sewing tool during sewing. The purpose is to provide.

  In order to achieve the above object, the molding method according to the present invention is a molding method in which a sewing thread is sewn or arranged at a sewing location of a thermoplastic resin material, and the thermoplastic resin material and the sewing thread are integrated. In this method, a sewing thread is sewn or placed at a sewing position in a melted state, the sewing position is cured, and the thermoplastic resin material and the sewing thread are integrated.

  Here, examples of the thermoplastic resin include thermoplastic elastomers such as styrene (SBC), olefin (TPO), vinyl chloride (TPVC), urethane (PU), ester (TPEE), and amide (TPAE). (TPE: Thermoplastic Elastomers).

  In addition, examples of the material for forming the sewing thread include polyester (PE) fiber, polyamide (PA) fiber, natural fiber, and the like, and it is preferable that the melting point is relatively higher than the thermoplastic resin to which the sewing thread is sewn. .

  According to the molding method described above, the resistance at the time of sewing the sewing thread on the thermoplastic resin material or arranging the sewing thread is reduced by sewing the sewing thread or arranging the sewing thread at the melted sewing location. be able to. In addition, when the sewing thread is sewn or placed on the thermoplastic resin material, the molten thermoplastic resin material impregnates between the fibers that form the sewing thread, so the sewing location is cured. It is possible to reliably seal a gap that may occur at the sewing location when the sewing is performed.

  The sewing location of the thermoplastic resin material is a region including at least a location where the sewing thread is arranged in the thermoplastic resin material, and may include an area around the location where the sewing yarn is arranged. Good.

  Here, when the sewing thread is sewn to the sewing part of the thermoplastic resin material, the sewing thread may be sewn in a state where all the sewing parts set in the thermoplastic resin material are melted. The sewing thread may be sewn in a state where only a plurality of sewing locations around the sewing location to be sewn are melted among the sewing locations set in the resin material. In addition, the sewing part to be sewn is sequentially melted in synchronization with the movement of a sewing tool (for example, a sewing needle) for sewing the sewing thread to the sewing part of the thermoplastic resin material, and the sewing thread is sewn to the sewing part. May be.

  Further, when the sewing thread is disposed at the sewing location of the thermoplastic resin material, the sewing thread may be disposed in a state where all of the sewing locations set in the thermoplastic resin material are melted, or the thermoplastic resin. The sewing thread may be arranged in a state where only a plurality of sewing parts around the sewing part where the sewing thread is to be arranged among the sewing parts set in the material are melted. In addition, the sewing thread to be placed in synchronization with the movement of a sewing tool (for example, a sewing needle) for placing the sewing thread at the sewing place of the thermoplastic resin material is sequentially melted, and the sewing thread is placed at the sewing place. May be.

  In addition, when curing the sewing location where the sewing thread is sewn in the molten state, after sewing the sewing thread to all the sewing locations set in the thermoplastic resin material, the sewing location is cured at once. Alternatively, the sewing location where the sewing thread is sewn may be sequentially cured.

  In addition, when the sewing location where the sewing thread is arranged in the melted state is cured, the sewing location may be cured at once after the sewing yarn is arranged in all the sewing locations set in the thermoplastic resin material. Alternatively, the sewing portion where the sewing thread is arranged may be sequentially cured.

  As a method of curing the sewing portion, for example, a method of spraying a refrigerant on the entire thermoplastic resin material or a sewing portion to be cured, and a method of curing the entire thermoplastic resin material or a portion of the sewing portion to be cured to the cooling device. Examples thereof include a method of conveying and curing, and a method of cooling and curing a sewing portion where a sewing thread is sewn by natural cooling.

  As described above, the sewing parts to be sewn are sequentially melted in synchronization with the movement of the sewing tool and the sewing thread is sewn, or the sewing parts to be arranged in synchronization with the movement of the sewing tool are sequentially melted and sewn. When arranging a thread, use a sewing tool kept at a temperature equal to or higher than the melting temperature of the thermoplastic resin material and not higher than the heat resistance temperature of the sewing thread, and melt the cured sewing position with the sewing tool to the sewing position. It is preferable to sew the sewing thread or arrange the sewing thread.

  According to the molding method described above, without using a separate device for melting the sewing location of the thermoplastic resin material, the sewing location to be sewn of the thermoplastic resin material can be reliably melted by the sewing tool used in the sewing operation. Can do.

  Here, as a method for keeping the sewing tool warm, for example, a method for keeping the sewing tool warm by heat conduction or electromagnetic waves, a method for keeping the sewing tool warm by frictional heat with a thermoplastic resin material by ultrasonic vibration, and the like. it can.

  In addition, by adjusting the sewing speed according to the thermal conductivity of the sewing tool and thermoplastic resin material, the relative temperature between the sewing tool and the thermoplastic resin material, the thickness and shape of the sewing tool, etc., Since the amount of heat transfer to the plastic resin material can be adjusted and the amount of melt of the thermoplastic resin material can be adjusted, sewing suitable for the thickness of the sewing thread to be used and the interval between the sewing locations (sewing pitch) The molten state of the location can be formed.

  In addition, the above-described forming method can apply various sewing forms (sewing patterns). For example, the sewing thread is sewn from one side to the other side of the thermoplastic resin material or the sewing thread is used. The sewing thread may be sewn from the one surface of the thermoplastic resin material to the inside of the thermoplastic resin material, or the sewing thread may be disposed.

  In the molding method described above, after the sewing portion of the thermoplastic resin material is cured, a foam is molded on one surface side of the thermoplastic resin material or the other surface side of the thermoplastic resin material. The resin material, the sewing thread, and the foam may be integrated.

  According to the molding method described above, since the gap between the sewing locations is securely sealed by the cured thermoplastic resin material, for example, a sewing thread is sewn from one surface to the other surface of the thermoplastic resin material or Even when a sewing thread is disposed and a foam is molded on one side or the other side of the thermoplastic resin material, leakage of the foam to the opposite side of the thermoplastic resin material is reliably suppressed. be able to.

  Further, the molded product according to the present invention is a molded product in which a sewing thread is sewn at a sewing location of a thermoplastic resin material or a sewing thread is arranged so that the thermoplastic resin material and the sewing thread are integrated. The thermoplastic resin material and the sewing thread are integrated at the sewing location of the thermoplastic resin material.

  According to the molded product described above, since the thermoplastic resin material and the sewing thread are integrated at the sewing location of the thermoplastic resin material, a gap that may occur at the sewing location is reliably suppressed, and the sewing yarn is thermoplastic. Since it is firmly held by the resin material, it is possible to remarkably improve its design and commercial properties.

  Further, the molded product described above can be applied to various sewing forms, for example, the sewing thread is sewn from one side to the other side of the thermoplastic resin material or the sewing thread is arranged. The sewing thread may be sewn from the one surface of the thermoplastic resin material to the inside of the thermoplastic resin material, or the sewing thread may be arranged.

  Further, in the molded product described above, a foam is formed on one side of the thermoplastic resin material or on the other side of the thermoplastic resin material, and the thermoplastic resin material, the sewing thread, and the foam are integrated. It may be.

  According to the molded product described above, since the leakage of the foam to the opposite side (for example, the design surface side) of the thermoplastic resin material is surely suppressed, for example, while maintaining excellent design properties and commercial properties, Sound absorption and buffering properties can also be enhanced.

  As can be understood from the above description, according to the molding method and the molded product of the present invention, the outer peripheral surface of the sewing thread sewn on the thermoplastic resin material or disposed on the thermoplastic resin material and the thermoplastic resin material Can be securely sealed, and the resistance when sewing thread is sewn or placed on the thermoplastic resin material can be reduced, and the sewing thread can be sewn or sewn on the thermoplastic resin material. The workability and mass productivity when placing the yarn, and the design and merchantability of the molded product can be significantly improved.

BRIEF DESCRIPTION OF THE DRAWINGS It is the longitudinal cross-sectional view which typically demonstrated Embodiment 1 of the shaping | molding method of this invention, Comprising: (a) is the figure explaining the process of sewing a sewing thread | yarn to the sewing location of a molten state, (b) is It is the figure explaining the process of hardening a sewing location, (c) is the figure explaining the process of shape | molding a foam on the back surface side of a thermoplastic resin material. It is the longitudinal cross-sectional view which demonstrated Embodiment 2 of the shaping | molding method of this invention typically, Comprising: It is the figure explaining the process of sewing a sewing thread | yarn to the sewing location fuse | melted synchronizing with the motion of the sewing tool. It is the longitudinal cross-sectional view which demonstrated Embodiment 3 of the shaping | molding method of this invention typically, Comprising: (a) is the figure explaining the state which inserted the part of the warming sewing tool in the sewing location, (b ) Is a diagram illustrating a state in which a sewing thread is sewn to a sewing point melted by a warmed sewing tool, and (c) is a part of the warmed sewing tool after the sewing thread is sewn to the sewing part. It is a figure explaining the state inserted in the next sewing location. It is the longitudinal cross-sectional view which demonstrated Embodiment 4 of the shaping | molding method of this invention typically, Comprising: It is the figure explaining the state which sews a sewing thread | yarn to the sewing location fuse | melted with the warming sewing tool. It is the longitudinal cross-sectional view which typically demonstrated Embodiment 5 of the shaping | molding method of this invention, Comprising: It is the figure explaining the state which arrange | positions a sewing thread | yarn in the sewing location fuse | melted with the warming sewing tool.

  Hereinafter, embodiments of a molding method and a molded product according to the present invention will be described with reference to the drawings.

[First Embodiment of Molding Method]
FIG. 1 is a longitudinal sectional view schematically illustrating Embodiment 1 of the molding method of the present invention, and FIG. 1 (a) is a diagram illustrating a process of sewing a sewing thread on a sewing position in a molten state. FIG. 1 (b) is a diagram illustrating a process of curing a sewing location, and FIG. 1 (c) is a diagram illustrating a process of molding a foam on the back side of a thermoplastic resin material.

  In the illustrated example, the chain stitch using the upper thread 1 and the lower thread 2 is described as a sewing form of the sewing thread. However, for example, a main stitch, an edge stitch, a flat stitch, a safety stitch (interlock), or the like may be used. In the illustrated example, a single type stitch pattern is applied to a thermoplastic resin material. For example, the stitch pattern may be a double stitch, or a thermoplastic resin material, a thermoplastic resin material and a fiber material are stitched together. The form to do may be sufficient. Further, in the illustrated example, a form in which the sewing needle 5 is used as a sewing tool will be described, but any form may be used as long as the sewing thread can be sewn to the thermoplastic resin material.

  The molding method according to the first embodiment mainly includes a first step of sewing a sewing thread onto a melted sewing position shown in FIG. 1A and a second step of curing the sewing position shown in FIG. And the third step shown in FIG. 1C is a third step of forming a foam on the back side of the thermoplastic resin material.

  First, in the first step, an upper thread 1, a lower thread 2, and a thermoplastic resin material 3 are prepared. In the thermoplastic resin material 3, the upper thread 1 side is the front surface side, and the lower thread 2 side is the back surface side.

  Here, examples of the forming material of the upper thread 1 and the lower thread 2 include polyester (PE) fiber, polyamide (PA) fiber, natural fiber, and the like, which may include metal fiber, and are thermoplastic. The fiber material has a relatively higher melting point than the resin material 3.

  The forming material of the thermoplastic resin material 3 is, for example, styrene (SBC), olefin (TPO), vinyl chloride (TPVC), urethane (PU), ester (TPEE), amide (TPAE), etc. And more specifically, for example, polyphenylene sulfide (PPS), polyethylene (PE), polyethylene terephthalate (PET), polystyrene (PS), polypropylene (PP), polyamide ( PA), polyvinyl chloride (PVC), polycarbonate (PC), ABS resin and the like. Examples of the method for molding the thermoplastic resin material 3 include powder slush molding, vacuum molding, and spray molding.

  The prepared upper thread 1 is passed through the through hole 5a of the sewing needle 5 attached to the sewing machine (not shown), the lower thread 2 is set on the bobbin (not shown) of the sewing machine, and the thermoplastic resin material 3 is pressed against the sewing machine (not shown). Operate the sewing machine while holding it in place. At this time, in the first embodiment, as shown in FIG. 1A, a sewing device 3 (not shown) is used to set a sewing location 3a that is set in advance at a predetermined interval (sewing pitch) on the thermoplastic resin material 3. Melt with. In addition, the magnitude | size (for example, width) of the fusion | melting location 3a can be suitably set according to the thickness of the sewing thread to be used, the space | interval (sewing pitch) between the sewing locations 3a, etc.

  When the sewing machine is operated as described above, the sewing needle 5 is inserted into the inside of the sewing location 3a from the surface 3aa side of the molten sewing location 3a, and passes through the inside of the sewing location 3a, whereby the upper thread 1 is The thermoplastic resin material 3 extends to the back surface 3ab side through the inside of the sewing portion 3a. Here, the upper thread 1 extending to the back surface 3ab side of the sewing location 3a passes through the loop of the lower thread 2 formed on the back surface 3ab side.

  After passing the upper thread 1 through the loop of the lower thread 2, the sewing needle 5 is pulled out to the surface 3aa side of the sewing part 3a, the direction of the upper thread 1 is reversed, and the upper thread 1 is moved to the surface 3aa side of the sewing part 3a. Returning, the thermoplastic resin material 3 is moved by the sewing pitch, and the sewing needle 5 is inserted again into the melted sewing location 3a adjacent to the sewing location 3a, whereby the surface 3aa side of the thermoplastic resin material 3 is obtained. A stitch pattern is formed by the upper thread 1.

  Next, in the second step, as shown in FIG. 1B, for example, a coolant is sprayed on the sewing portion 3a of the thermoplastic resin material 3 and the thermoplastic resin material 3 is conveyed to a cooling device (not shown). Further, the sewing portion 3a of the thermoplastic resin material 3 on which the sewing thread composed of the upper thread 1 and the lower thread 2 is sewn is cured, and the sewing thread and the thermoplastic resin material 3 are integrated.

  Next, in the third step, the thermoplastic resin material 3 on which the sewing thread is sewn is placed in a mold (not shown), and a foaming synthetic resin such as a foaming urethane resin is provided on the back side of the thermoplastic resin material 3. The foam 4 is formed on the back surface side of the thermoplastic resin material 3 as shown in FIG. A sewing thread made of the thermoplastic resin material 3 and the foamed body 4 are integrally formed.

  According to the first embodiment described above, the resistance of the thermoplastic resin material 3 to the sewing needle 5 during sewing can be reduced, damage to the sewing needle 5 can be suppressed, and the sewing speed can be increased. Workability and mass productivity at the time of sewing can be improved. Further, when the upper thread 1 is passed through the sewing part 3a of the thermoplastic resin material 3, the molten thermoplastic resin material 3 impregnates between the fibers of the upper thread 1, so that a gap that may occur in the sewing part 3a is formed. It can be reliably blocked, for example, leakage to the surface side of the foam 4 can be suppressed, and the designability and commerciality of the molded product can be improved.

[Embodiment of molded product]
In the molded product molded by the molding method of the first embodiment described above, the thermoplastic resin material 3 and the upper thread 1 are integrated at the sewing location 3a of the thermoplastic resin material 3, and are generated at the sewing location 3a. The gap to be obtained is suppressed, the leakage of the foam 4 to the surface side of the thermoplastic resin material 3 is suppressed, and the upper thread 1 passing through the inside of the thermoplastic resin material 3 is firmly fixed to the thermoplastic resin material 3 Has been.

  Moreover, in the said molded article, sound absorption property, buffer property, etc. are improved by providing the foam layer which consists of the foam 4 in the back surface side of the thermoplastic resin material 3, and it has the outstanding design property and commercial property. ing.

[Second Embodiment of Molding Method]
FIG. 2 is a longitudinal cross-sectional view schematically illustrating Embodiment 2 of the forming method of the present invention, and illustrates a process of sewing a sewing thread onto a sewing location that is melted in synchronization with the movement of the sewing tool. FIG.

  The molding method of the second embodiment shown in FIG. 2 is different from the molding method of the first embodiment shown in FIG. 1 in the step (first step) of sewing the sewing thread to the sewing location in the melted state. The other steps are the same as those of the first embodiment shown in FIG. Therefore, detailed description of the same steps as those in Embodiment 1 is omitted.

  As shown in FIG. 2, in the second embodiment, the sewing portion 13a to be sewn is melted by a heating device (not shown) in synchronization with the movement of the sewing needle 15, and the sewing needle 13a is melted in the molten sewing portion 13a. 15 is inserted, and the upper thread 11 is passed through the inside of the sewing portion 13a.

  Next, the sewing needle 15 is pulled out to the surface 13aa side of the sewing location 13a, the direction of the upper thread 11 is reversed, the upper thread 11 is returned to the surface 13aa side of the sewing location 13a, and the thermoplastic resin material 13 is moved by the sewing pitch. . The sewing part 13a adjacent to the sewing part 13a is melted, and the sewing needle 15 is inserted into the sewing part 13a again to form a stitch pattern on the surface 13aa side of the thermoplastic resin material 13.

  After the stitch pattern is formed on the surface 13aa side of the thermoplastic resin material 13, the sewing portion 13a of the thermoplastic resin material 13 is cured as described with reference to FIGS. A foam is formed on the back surface side of the plastic resin material 13, and the sewing thread composed of the upper thread 11 and the lower thread 12, the thermoplastic resin material 13, and the foam are integrally formed.

  According to the second embodiment described above, by sequentially melting the sewing portion 13a to be sewn in synchronization with the movement of the sewing needle 15, the sewing portion 13a to be sewn can be efficiently melted, and sewing can be performed. Workability and mass productivity can be further improved.

[Third Embodiment of Molding Method]
FIG. 3 is a longitudinal sectional view schematically illustrating Embodiment 3 of the molding method of the present invention, and FIG. 3 (a) illustrates a state in which a part of the warmed sewing tool is inserted into a sewing location. FIG. 3B is a diagram illustrating a state in which a sewing thread is sewn to a sewing location melted by a warmed sewing tool, and FIG. 3C is a diagram in which a sewing thread is sewn to the sewing location. It is the figure explaining the state which inserted a part of sewing tool which kept warm later in the next sewing location.

  The molding method of the third embodiment shown in FIG. 3 is the same as the molding method of the second embodiment shown in FIG. 2 in the step (first step) of sewing the sewing thread to the sewing location. It is different in that the sewing portion is melted by using a sewing needle that is kept at a temperature equal to or higher than the melting temperature and lower than the heat resistance temperature of the sewing thread, and other steps are the same as those shown in the embodiment 1 or 2 shown in FIG. This is the same as the second embodiment. Therefore, detailed description of the same steps as those in the first and second embodiments is omitted.

  In the third embodiment, as described above, the sewing needle 25 that is kept at a temperature equal to or higher than the melting temperature of the thermoplastic resin material 23 and equal to or lower than the heat resistance temperature of the upper thread 21 is attached to the sewing machine (not shown). The sewing machine is operated through the upper thread 21 through the 25 through holes 25a. Here, examples of a method for keeping the sewing needle 25 warm include a method using heat conduction and electromagnetic waves, and a method using frictional heat with the thermoplastic resin material 23 caused by ultrasonic vibration.

  When the sewing machine is operated as described above, the sewing needle 25 is inserted into the sewing portion 23a from the surface 23aa side of the cured sewing portion 23a and comes into contact with the sewing needle 25 as shown in FIG. The heat of the sewing needle 25 is transferred to the surface side of the thermoplastic resin material 23 and the surface side of the thermoplastic resin material 23 is melted.

  When the sewing needle 25 enters the inside of the sewing portion 23a, the heat of the sewing needle 25 is gradually transferred to the thermoplastic resin material 23 around the sewing needle 25, and as shown in FIG. The surrounding thermoplastic resin material 23 is melted to form a melted sewing portion 23a. Then, by passing the sewing needle 25 through the inside of the sewing portion 23a in the molten state, the upper thread 21 extends to the back surface 23ab side through the inside of the sewing portion 23a of the thermoplastic resin material 23 and extends to the back surface 23ab side. The taken upper thread 21 passes through the loop of the lower thread 22 formed on the back surface 23ab side.

  After passing the upper thread 21 through the loop of the lower thread 22, the sewing needle 25 is pulled out to the surface 23aa side of the sewing part 23a, the direction of the upper thread 21 is reversed, and the upper thread 21 is moved to the surface 23aa side of the sewing part 23a. Returning, as shown in FIG. 3 (c), the thermoplastic resin material 23 is moved by the sewing pitch (in the figure, the sewing needle 25 is shown as being moved relative to the thermoplastic resin material 23). Then, the sewing needle 25 is inserted again into the cured sewing portion 23a adjacent to the sewing portion 23a, and a stitch pattern is formed by the upper thread 21 on the surface 23aa side of the thermoplastic resin material 23.

  After the stitch pattern is formed on the surface side of the thermoplastic resin material 23, the sewing portion 23a of the thermoplastic resin material 23 is cured as described with reference to FIGS. A foam is formed on the back surface side of the resin material 23, and the sewing thread composed of the upper thread 21 and the lower thread 22, the thermoplastic resin material 23, and the foam are integrally formed.

  In the third embodiment, the sewing speed is set according to the thermal conductivity of the sewing needle 25 and the thermoplastic resin material 23, the relative temperature between the sewing needle 25 and the thermoplastic resin material 23, the thickness and shape of the sewing needle 25, and the like. By adjusting, the amount of heat transfer from the sewing needle 25 to the thermoplastic resin material 23 during sewing can be adjusted, and the amount of melting of the thermoplastic resin material 23 can be adjusted. It is possible to form a melted state of the sewing portion 23a suitable for the thickness and the interval (sewing pitch) between the sewing portions 23a.

  Also, as shown in the figure, in Embodiment 3, the front side of the thermoplastic resin material 23 has a longer contact time with the sewing needle 25 that is kept warmer than the back side thereof, so that the thermoplastic resin material 23 The amount of melting on the front side is relatively greater than the amount of melting on the back side.

  According to the third embodiment described above, a sewing location that is a sewing target of the thermoplastic resin material 23 by the sewing needle 25 used in the sewing work without using a separate device for melting the sewing location 23a of the thermoplastic resin material 23. 23a can be melted. Further, even if the position where the sewing needle 25 is inserted with respect to the thermoplastic resin material 23 is deviated from the preset position, the sewing location of the thermoplastic resin material 23 can be reliably melted, Since the gap that may occur in the sewing location 23a can be reliably closed, workability and mass productivity at the time of sewing, and the design and commercial properties of the molded product to be molded can be further improved.

[Fourth Embodiment of Molding Method]
FIG. 4 is a longitudinal sectional view schematically illustrating Embodiment 4 of the molding method of the present invention, and is a diagram illustrating a state in which a sewing thread is sewn to a sewing location melted by a warmed sewing tool. .

  The molding method of the fourth embodiment shown in FIG. 4 differs from the molding method of the third embodiment shown in FIG. 3 in the sewing form in the step (first step) of sewing the sewing thread to the sewing location. The other steps are the same as those in the third embodiment shown in FIG. Therefore, detailed description of the same steps as those in Embodiment 3 is omitted.

  Specifically, in Embodiment 3 shown in FIG. 3, a sewing thread composed of an upper thread and a lower thread is used, and the sewing thread extends from the front surface (one surface) to the back surface (the other surface) of the thermoplastic resin material. In the fourth embodiment shown in FIG. 4, the upper thread is sewn on a thread or wire embedded in the thermoplastic resin material, and the surface (one surface) of the thermoplastic resin material is sewn. The sewing thread is sewn to the inside.

  That is, in the fourth embodiment, the sewing needle 35 that is kept at a temperature equal to or higher than the melting temperature of the thermoplastic resin material 33 and equal to or lower than the heat resistance temperature of the upper thread 31 is attached to the sewing machine (not shown). When the sewing machine is operated through the upper thread 31 through the hole 35a, the sewing needle 35 is inserted into the sewing portion 33a from the surface 33aa side of the cured sewing portion 33a, and is sewn to the thermoplastic resin material 33 around the sewing needle 35. The heat of the needle 35 is gradually transferred, and the thermoplastic resin material 33 around the sewing needle 35 is melted to form a melted sewing portion 33a.

  Before the upper thread 31 introduced into the sewing portion 33a in the molten state by the sewing needle 35 inserted into the sewing portion 33a reaches the back surface 33ab of the sewing portion 33a, the sewing needle 35 is moved to the sewing portion 33a. The upper thread 31 is pulled out to the surface 33aa side, for example, around a metal wire 36 embedded in the thermoplastic resin material 33, the direction is reversed, and the sewing thread 33a is returned to the surface 33aa side. Then, the thermoplastic resin material 33 is moved by the sewing pitch, the sewing needle 35 is inserted again into the cured sewing portion 33a adjacent to the sewing portion 33a, and the upper thread is placed on the surface 33aa side of the thermoplastic resin material 33. A stitch pattern by 31 is formed.

  After the stitch pattern is formed on the surface side of the thermoplastic resin material 33, as described with reference to FIGS. 1B and 1C, the sewing portion 33a of the thermoplastic resin material 33 is cured, and the thermoplastic resin A foam is formed on the back side of the resin material 33, and the upper thread 31, the wire 36, the thermoplastic resin material 33, and the foam are formed integrally.

  According to the above-described fourth embodiment, the sewing needle 35 can be sewn on a thread or wire previously embedded in the thermoplastic resin material 33 to form a stitch pattern. The mass productivity can be further improved by reducing the thickness of the thermoplastic resin material 33. For example, even when the foam is molded on the back surface side of the thermoplastic resin material 33, the foam leaks to the front surface side of the thermoplastic resin material 33. Can be reliably suppressed, and the design and commercial properties of the molded product can be further enhanced.

[Fifth Embodiment of Molding Method]
FIG. 5 is a longitudinal cross-sectional view schematically illustrating Embodiment 5 of the molding method of the present invention, and is a diagram illustrating a state in which sewing threads are arranged at a sewing location melted by a warmed sewing tool. .

  The molding method of the fifth embodiment shown in FIG. 5 is different from the molding method of the third embodiment shown in FIG. 3 in the sewing form in the step (first step) of sewing the sewing thread to the sewing location. The other steps are the same as those in the third embodiment shown in FIG. Therefore, detailed description of the same steps as those in Embodiment 3 is omitted.

  Specifically, in Embodiment 3 shown in FIG. 3, a sewing thread made of an upper thread and a lower thread is used, and the upper thread and the lower thread are sewn to form a stitch pattern, whereas FIG. In the fifth embodiment, a sewing thread consisting only of an upper thread is used, and the upper thread is arranged at a sewing location of the thermoplastic resin material to form a stitch pattern.

  That is, in the fifth embodiment, a sewing needle 45 that is kept at a temperature higher than the melting temperature of the thermoplastic resin material 43 and lower than the heat resistance temperature of the upper thread 41 is attached to the sewing machine (not shown), and the sewing needle 45 is threaded. When the sewing machine is operated by passing the upper thread 41 through the hole 45a, the sewing needle 45 is inserted into the sewing portion 43a from the surface 43aa side of the cured sewing portion 43a, and is sewn to the thermoplastic resin material 43 around the sewing needle 45. The heat of the needle 45 is gradually transferred, and the thermoplastic resin material 43 around the sewing needle 45 is melted to form a melted sewing portion 43a.

  After the upper thread 41 is introduced into the molten sewing area 43a by the sewing needle 45 inserted into the sewing area 43a, the sewing needle 45 is pulled out to the surface 43aa side of the sewing area 43a, and the direction of the upper thread 41 is changed. It reverses and it returns to the surface 43aa side of the sewing location 43a. At that time, by releasing the tension (thread tension) of the upper thread 41, the upper thread 41 is arranged in a state of being bent in the melted sewing portion 43a. Then, the thermoplastic resin material 43 is moved by the sewing pitch, and the sewing needle 45 is inserted again into the cured sewing portion 43a adjacent to the sewing portion 43a, and the upper thread is placed on the surface 43aa side of the thermoplastic resin material 43. 41 is formed.

  The sewing needle 45 inserted into the sewing portion 43a may be pulled out to the front surface 43aa side of the sewing location 43a after the upper thread 41 extends to the back surface 43ab of the sewing location 43a, or the back surface of the sewing location 43a. You may pull out to the surface 43aa side of the sewing location 43a before reaching 43ab.

  After the stitch pattern is formed on the surface side of the thermoplastic resin material 43, the sewing portion 43a of the thermoplastic resin material 43 is cured as described with reference to FIGS. A foam is molded on the back side of the resin material 43, and the upper thread 41, the thermoplastic resin material 43, and the foam are molded integrally.

  According to the fifth embodiment described above, for example, the lower thread disposed on the back surface side of the thermoplastic resin material 43 can be omitted, so that the production cost of the molded product can be suppressed and the merchantability can be further improved. It can be further enhanced.

  The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and there are design changes and the like without departing from the gist of the present invention. They are also included in the present invention.

DESCRIPTION OF SYMBOLS 1 ... Upper thread (sewing thread), 2 ... Lower thread (sewing thread), 3 ... Thermoplastic resin material, 3a ... Sewing location of thermoplastic resin material, 4 ... Foam, 5 ... Sewing needle

Claims (10)

A molding method in which a sewing thread is sewn or arranged at a sewing location of a thermoplastic resin material, and the thermoplastic resin material and the sewing thread are integrated.
A molding method in which a sewing thread is sewn or placed at a sewing position in a melted state, the sewing position is cured, and the thermoplastic resin material and the sewing thread are integrated.   2. The sewing thread is sewn or the sewing thread is placed at a sewing place that is melted in synchronization with the movement of the sewing tool for sewing the sewing thread or placing the sewing thread at the sewing place of the thermoplastic resin material. The forming method as described.   The sewing thread is sewn to the sewing location or the sewing thread is arranged while the cured sewing location is melted with a sewing tool kept at a temperature equal to or higher than the melting temperature of the thermoplastic resin material and lower than the heat resistance temperature of the sewing thread. Item 3. The molding method according to Item 2.   The molding method according to any one of claims 1 to 3, wherein the sewing thread is sewn or the sewing thread is arranged from one surface to the other surface of the thermoplastic resin material.   The molding method according to any one of claims 1 to 3, wherein the sewing thread is sewn or the sewing thread is arranged from one surface of the thermoplastic resin material to the inside of the thermoplastic resin material.   After the sewing location of the thermoplastic resin material is cured, a foam is formed on one surface side of the thermoplastic resin material or the other surface side of the thermoplastic resin material, and the thermoplastic resin material, sewing thread, and foam are formed. The molding method according to claim 4 or 5, wherein: A molded product in which a sewing thread is sewn or arranged at a sewing location of a thermoplastic resin material, and the thermoplastic resin material and the sewing thread are integrated,
A molded product in which the thermoplastic resin material and a sewing thread are integrated at a sewing location of the thermoplastic resin material.   The molded product according to claim 7, wherein the sewing thread is sewn or arranged from one side to the other side of the thermoplastic resin material.   The molded product according to claim 7, wherein the sewing thread is sewn from the one surface of the thermoplastic resin material to the inside of the thermoplastic resin material, or the sewing thread is arranged.   10. A foam is formed on one side of the thermoplastic resin material or on the other side of the thermoplastic resin material, and the thermoplastic resin material, the sewing thread, and the foam are integrated. The molded product described.

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