Manufacturing method for products with epidermis

Abstract

The present invention provides a method for manufacturing a surface-covered product that can suppress defects caused by sewing the peeling layer. [Solution] The manufacturing method for the skin-covered product 10 comprises a first half-cut step S30 in which the release paper 27 is cut at a first position P1, a second half-cut step S32 in which the release paper 27 is cut at a second position P2, an arrangement step S33 in which two skin materials 20 are placed on top of each other so that the skin layers 21 of the skin materials 20 are in contact with each other and are positioned with the first position P1 aligned, a first suturing step S34 in which the two skin materials 20 are sewn together at the first position P1 and integrated with a first stitch 11, a first peeling step S36 in which a portion of the release paper 27 is peeled off, a folding step S38 in which the first stitch 11 is folded back as a pivot point, and a second suturing step S40 in which a second stitch 12 is formed between the first position P1 and the second position P2.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a product with a skin.

Background Art

[0002] As products with a skin in which the surface of a base material is covered with a skin material, there are, for example, automotive interior parts incorporated into automobile instrument panels, consoles, door trims, glove boxes, pillar garnishes, and the like. This skin material is generally composed of a skin layer made of natural leather or synthetic leather and a cushion layer bonded to the back surface of the skin layer, and is bonded to the surface of the base material with the cushion layer arranged between the skin layer and the base material.

[0003] Conventionally, a method of spraying a liquid adhesive onto the surface of a base material and bonding a skin material thereto has been common, but improvement has been demanded from the viewpoint of environmental protection.

[0004] In contrast, Patent Document 1 describes the following invention. "In a method for manufacturing an automotive interior part produced by covering a base material with a skin material, said skin material comprises a skin layer constituting the design surface of said interior part and a cushioning cushion layer bonded to the back surface of said skin layer, and is wound in a state of having a constant width with the other surface of the adhesive layer of a double-sided adhesive sheet composed of an adhesive layer and a release paper bonded to one surface of said adhesive layer being bonded to the back surface of said skin material; sequentially feeding out said skin material to form a shape and size suitable for said base material, with a pair of said skin materials, in which only said release paper of said double-sided adhesive sheet has been half-cut, having their surface sides aligned with each other, sewing and integrating said respective skin materials such that a region where stitches can be respectively formed is left between said half-cut position and an end portion, To integrate the pair of surface materials, the seams are sewn together and the reverse sides are folded over so that they overlap, and in the integrated pair of surface materials, the folded portions of each surface material are sewn together in their respective regions to form a double stitch on the integrated surface material. A method for manufacturing an interior part for an automobile, characterized by peeling off the release paper from the adhesive layer attached to the pair of surface materials in the larger area region, using the half-cut position as the boundary, and then bonding the surface materials, which are integrated with the base material via the adhesive layer of the double-sided adhesive sheet, to cover them.

[0005] The invention described in Patent Document 1 involves sewn together two surface materials with the release paper still attached to form a single unit, and then further sewn together the overlapping portion of each surface material that has been folded over with the release paper in between to form a double stitch. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Patent No. 7059152 [Overview of the project] [Problems that the invention aims to solve]

[0007] However, if two pieces of outer material are sutured together with the release paper still attached, the needle will penetrate three layers in each piece of outer material—the outer layer, the adhesive layer, and the release paper—which may lead to a decrease in sewing speed and a deterioration in sewing accuracy, potentially reducing productivity.

[0008] Furthermore, there is a risk that paper dust generated when the needle penetrates the release paper may get mixed into or adhere to the sewn area, potentially causing problems.

[0009] Furthermore, the presence of release paper in the manufactured interior components could potentially negatively impact their appearance and tactile feel.

[0010] This invention provides a method for manufacturing a surfaced product that can suppress defects caused by sewing the peeling layer. [Means for solving the problem]

[0011] The present invention A method for manufacturing a product with an epidermis, A first half-cut step involves cutting the release layer at a first position, which is a distance from one end of a surface material comprising a surface layer and an adhesive layer provided on the back side of the surface layer, with a release layer that can be peeled off being attached to the other side opposite to one side of the surface layer. A second half-cut step in which the release layer is cut at a second position located at a second distance greater than the first distance from one end of the surface material, Arrangement step: Place two of the surface materials on top of each other so that the surface layers of the surface materials are in contact with each other, and align them in a first position. After the arrangement step, a first suturing step is performed in which the two surface materials are sewn together at the first position to form a first stitch, and the two surface materials are integrated with the first stitch, After the first suturing step, a first peeling step is performed to peel off the release layer provided from one end to the first position and the release layer provided from the first position to the second position for each of the two surface materials, After the first peeling step, each of the two surface materials is folded back using the first stitch as a pivot point, and the other side of the adhesive layer between the one end and the first position and the other side of the adhesive layer between the first position and the second position are attached and overlapped in a folding step, The method includes a second sewing step, in which, after the folding step, the overlapping portion of each of the two surface materials is sewn together between the first position and the second position to form a second stitch. [Effects of the Invention]

[0012] According to the present invention, defects caused by sewing the peeling layer during the manufacture of products with a surface can be suppressed. [Brief explanation of the drawing]

[0013] [Figure 1] Fig. 1 is a perspective view of the interior of a vehicle compartment provided with a glove box which is a skinned product according to an embodiment of the present invention. [Figure 2] Fig. 2(A) is an enlarged view of portion A in Fig. 1, and Fig. 2(B) is a cross-sectional view taken along line B-B in Fig. 2(A). [Figure 3] It is a flow diagram of an embodiment of a method for manufacturing a skinned product. [Figure 4] Fig. 4(A) is a cross-sectional view of a skin material, Fig. 4(B) is a diagram showing one sheet of skin material half-cut by a first half-cutting step S30 and a second half-cutting step S32, Fig. 4(C) is a diagram showing a state where two sheets of skin material are overlapped in an arranging step S33, Fig. 4(D) is a diagram showing a state where the two sheets of skin material are sewn and integrated in a first sewing step S34, and Fig. 4(E) is a diagram showing a state where part of release paper is peeled off in a first peeling step S36. [Figure 5] Fig. 5(A) is a diagram showing a state where a first end portion of each skin material is folded back in a folding step S38, Fig. 5(B) is a diagram showing a state where second stitches are formed on each skin material in a second sewing step S40, and Fig. 5(C) is a diagram showing a state where an adhesive tape is attached in a tape attaching step S42. [Figure 6] Fig. 6(A) is a diagram showing a state where release paper is peeled off in a second peeling step S44 and a third peeling step S46, and Fig. 6(B) is a diagram showing a state where the skin material is attached to a base material in an attaching step S48. MODE FOR CARRYING OUT THE INVENTION

[0014] Hereinafter, an embodiment of a method for manufacturing a skinned product will be described. First, a skinned product manufactured by applying the manufacturing method of the present embodiment will be described with reference to Fig. 1 and Fig. 2.

[0015] Products with a skin are typically, but not limited to, automotive interior and exterior parts such as automotive instrument panels, consoles, door trims, glove boxes, and pillar garnishes, and may also be, for example, interior and exterior parts of buildings. In the following description, a glove box of an automobile is taken as an example of the product with a skin for explanation.

[0016] As shown in Figure 1, the glove box 1 disposed in the compartment 2 of an automobile uses the skinned product 10. As shown in (A) and (B) of Figure 2, the skinned product 10 is configured by integrating two skin materials 20 with a first stitch 11 and affixing the integrated skin material onto a base material 50. In each of the two skin materials 20, a second stitch 12 is formed in the vicinity of the concave boundary line 13 formed by the first stitch 11. Hereinafter, the two second stitches 12 disposed in the vicinity of the first stitch 11 may be referred to as double stitches. In addition, in the following description, for convenience, the direction in which the stitch lines of the first stitch 11 and the second stitch 12 extend is referred to as the boundary extending direction.

[0017] Note that, in the example illustrated in Figure 2, two skin materials 20 are integrated by one first stitch 11, but three or more skin materials 20 may be used, adjacent skin materials 20 may be integrated by the first stitch 11, and the second stitch 12 may be formed in the vicinity of each first stitch 11 respectively.

[0018] (Base Material) The base material 50 is a member that forms the skeleton part of the skinned product 10, and ensures the rigidity of the skinned product 10. The base material 50 is formed into a product shape by performing resin molding such as injection molding using a resin material such as polypropylene or polyethylene. The base material 50 may have a non-planar surface (three-dimensional surface) such as a curved surface, a bent surface, or an uneven surface.

[0019] (Skin Material) The surface material 20 is a component that forms the outer shell (surface layer) of the surfaced product 10. As shown in Figure 2(B), the surface material 20 comprises a surface layer 21 that constitutes the design surface of the surfaced product 10, a cushion layer 23 bonded to the back surface of the surface layer 21, and an adhesive layer 25 on one side that is bonded to the cushion layer 23 and on the other side that is bonded to the base material 50.

[0020] Here, adhesiveness, academically speaking, refers to "the property of exhibiting instantaneous adhesion to the surface of an adherend, easily adhering with light pressure, and leaving no adhesive residue on the adherend surface after peeling." In other words, it refers to "the fastening of multiple materials through wettability and anchoring properties while the components remain in a gel-like state." On the other hand, bonding, academically speaking, refers to "the phenomenon of connecting adherends by chemical or physical force." In other words, it refers to "the fastening of multiple materials by cross-linking components to become solid." Thus, although the two are fundamentally different, they share the commonality of fastening multiple materials, and in general, they are not always used with a clear distinction between them. Therefore, in this specification, adhesiveness and bonding are not distinguished, and the adhesive layer 25 may be an adhesive layer.

[0021] The surface layer 21 is primarily used to improve the texture and feel of the surfaced product 10. The surface layer 21 is formed from synthetic leather (faux leather) made of polyvinyl chloride, thermoplastic elastomer (TPO), etc., into a sheet of uniform thickness, and can be deformed in the thickness direction, etc. It is desirable that the surface layer 21 has a thickness of 0.35 to 1.5 mm. The surface layer 21 may also be treated with a grain (wrinkle pattern) finish, similar to that seen in leather products.

[0022] The cushion layer 23 is composed of, for example, a three-dimensional knitted fabric made by connecting two knitted fabrics with elastic yarn, or a foamed material such as urethane foam, ethylene foam, or propylene foam, and has elasticity. The cushion layer 23 is used to improve the tactile feel of the surface-covered product 10. It is desirable that the cushion layer 23 has a thickness of 1.5 to 3.5 mm. The cushion layer 23 can be attached to the surface layer 21 with adhesive, double-sided tape, or adhesive sealant.

[0023] The first stitch 11, as will be described in more detail later, is a seam formed by the thread attached to the needle when the needle penetrates the two pieces of outer material 20. The first stitch 11 is provided for the purpose of sewing the two pieces of outer material 20 together and integrating them, and is configured by being arranged in a straight line. The first stitch 11 may or may not be visible from the outside.

[0024] The second stitch 12, as will be described in more detail later, is a seam formed by thread attached to a needle when the needle penetrates both sides of the overlapping portion 28 formed by folding each surface material 20 with the first stitch 11. The second stitch 12 is provided above and below the first stitch 11 (boundary line 13) and is arranged to form a straight line along the first stitch 11, approximately parallel to the first stitch 11.

[0025] The second stitch 12 is provided for decorative purposes, as it simulates the stitching of parts of the surface layer 21, giving the surfaced product 10 an appearance similar to that of genuine leather and creating a sense of luxury. This type of stitch is also called decorative stitching, and various designs can be used, not just in a straight line.

[0026] Unlike the first stitch 11, the second stitch 12 is exposed to the outside of the epidermal layer 21, so it is preferable that the thread used for the second stitch 12 has higher decorative properties than the thread used for the first stitch 11. The thread used for the first stitch 11 may be the same as or different from the thread used for the second stitch 12.

[0027] The thread used for the first stitch 11 and the thread used for the second stitch 12 both pass through or between the adhesive layer 25, which will be described later, when suturing, so it is preferable that they be non-adhesive to prevent the adhesive from adhering to them. Similarly, it is preferable that the needle used for the first stitch 11 and the needle used for the second stitch 12 also be non-adhesive to prevent the adhesive from adhering to them. The thread and / or needle may be surface-treated with a non-adhesive coating agent, for example, to prevent the adhesive layer 25 from adhering to them.

[0028] Next, an embodiment of a manufacturing method for producing the surface-covered product 10 configured as described above will be explained with reference to Figures 3 to 6. As shown in Figure 3, the manufacturing method of this embodiment comprises a first half-cut step S30, a second half-cut step S32, a placement step S33, a first suturing step S34, a first peeling step S36, a folding step S38, a second suturing step S40, a tape application step S42, a second peeling step S44, a third peeling step S46, and an adhesive step S48. Note that the tape application step S42 and the third peeling step S46 are not necessarily required. Furthermore, two or more separate steps may be performed in a single step, and other steps may be added.

[0029] For example, the manufacturing method of this embodiment may include a die-cutting step in which the surface material 20 is die-cut using a predetermined die (for example, a Thomson die) in order to cut the surface material 20 into a predetermined outer shape. The die-cutting step may be performed simultaneously with the first half-cutting step S30, simultaneously with the second half-cutting step S32, or simultaneously with the first half-cutting step S30 and the second half-cutting step S32.

[0030] Here, the surface material 20 used in the manufacturing method of this embodiment will be described in more detail. As shown in Figure 4(A), the surface material 20 comprises a surface layer 21, a cushioning layer 23 bonded to the back surface of the surface layer 21, and an adhesive layer 25 on which one side is adhered to the cushion layer 23 and the other side has a release paper 27 that can be peeled off. The release paper 27 is peeled off when the surface material is attached to the base material 50 and is therefore not present in the surface-covered product 10. However, if the surface layer 21 is the surface of the surface material 20, the release paper 27 is adhered to the back surface of the surface material 20 in the initial stages of manufacturing.

[0031] The adhesive layer 25 is a double-sided adhesive sheet with one side adhered to the cushion layer 23 and the other side to which a release paper 27 is attached. The release paper 27 consists of a base paper and a release layer that contacts the other side of the adhesive layer 25. As will be described later, the release paper 27 is not actively penetrated by a needle in both the first suturing process S34 and the second suturing process S40, so there are no particular restrictions on the material or thickness of the release paper, and a general type can be used.

[0032] The surface material 20, configured in this way, is stored, for example, wound on a roller. During the manufacture of the surfaced product 10, it is supplied from the roller and cut to a predetermined length. The end of the surface material 20 that is integrated by the first stitch 11 (the right end in the figure) is referred to as the first end 20A.

[0033] (First half-cutting process) In the first half-cutting process S30, as shown in Figure 4(B), the release paper 27 is cut at a first position P1, which is a distance L1 away from the first end 20A of the surface material 20. The first distance L1 corresponds to the length from the first end 20A to the first stitch 11 where the two surface materials 20 are joined together. Therefore, the first distance L1 is set to a distance that allows for folding, as described later, while taking design considerations into account.

[0034] In the first half-cutting step S30, as long as the release paper 27 is cut, part or all of the adhesive layer 25 may be cut together, but it is preferable that the entire adhesive layer 25 is cut, as shown in Figure 4(B). This prevents the needle from penetrating the adhesive layer 25 when sewing the two skin materials 20 together in the first suturing step S34 described later, as the needle passes between the cut pieces of adhesive layer 25.

[0035] (Second half-cutting process) In the second half-cutting step S32, the release paper 27 is cut at a second position P2 that is a second distance L2 greater than the first distance L1 from the first end 20A of the surface material 20. The second distance L2 is approximately twice the distance of the first distance L1, or longer than twice the distance of the first distance L1. In the second half-cutting step S32, as long as the release paper 27 is cut, part or all of the adhesive layer 25 may be cut together, but it is preferable that the entire adhesive layer 25 is cut, as shown in Figure 4(B). This makes it possible to match the depth of the half-cut with that of the first half-cutting step S30, and makes it easier to adjust the half-cut.

[0036] The first half-cutting process S30 and the second half-cutting process S32 may be performed in this order, in the reverse order, or simultaneously.

[0037] (Placement process) In the placement process S33, as shown in Figure 4(C), the two epidermal materials 20 that have been half-cut at the first position P1 and the second position P2 via the first half-cut process S30 and the second half-cut process S32 are placed on top of each other so that the epidermal layers 21 are in contact with each other, and are placed with the first position P1 aligned, that is, with the first position P1 aligned when viewed from the overlapping direction (up and down direction in Figure 4). The two placed epidermal materials 20 are then held in this state. The method of holding is not particularly limited, but the two epidermal materials 20 are held so that they do not shift during suturing.

[0038] Alternatively, instead of arranging the two surface materials 20 with their first position P1 aligned after the first half-cutting step S30 and the second half-cutting step S32, the first half-cutting step S30 and the second half-cutting step S32 may be performed with the two surface materials 20 overlapping so that their surface layers 21 are in contact with each other, resulting in the two surface materials 20 being overlapped so that their surface layers 21 are in contact with each other and arranged with their first position P1 aligned.

[0039] (1st suturing process) Next, in the first suturing step S34, as shown in Figure 4(D), the two outer skin materials 20 are sewn together at the first position P1 using a suturing device such as a sewing machine. More specifically, the needle of the suturing device is moved relative to the first position P1 in the boundary stretching direction (front-back direction in Figure 4), so that the thread passes between the half-cut release paper 27 that is separated at the first position P1, i.e., along the cutting line, and the two outer skin materials 20 are sewn together. This forms the first stitch 11.

[0040] (First peeling process) In the first peeling step S36, as shown in Figure 4(E), the release paper 27 extending from the first end 20A to the first position P1 and the release paper 27 extending from the first position P1 to the second position P2 are peeled off from each of the two surface materials 20. At this time, even if the needle were to penetrate the release paper 27 in the first suturing step S34, the distance between the thread and the end of the release paper 27 is short, so the release paper 27 is peeled off in the first peeling step S36 and does not remain on the first stitch 11.

[0041] (Folding process) In the folding process S38, after the first peeling process S36, as shown in Figure 5(A), each of the two surface materials 20 is folded back using the first stitch 11 as a pivot point, and the other side of the adhesive layer 25 between the first end 20A and the first position P1 is attached and overlapped with the other side of the adhesive layer 25 between the first position P1 and the second position P2. As a result, the first end 20A is folded back to or near the second position P2, and an overlapping section 28 is formed between the first position P1 and the second position P2. In the overlapping section 28, the surface layer 21, cushion layer 23, adhesive layer 25, adhesive layer 25, cushion layer 23, and surface layer 21 are laminated in order from the surface layer 21 side. Up to the first peeling step S36 shown in Figure 4(E), the two surface layers 21 of the surface material 20 were overlapping so that they were in contact with each other. However, after the folding step S38 shown in Figure 5(A), the surface layers 21 of the two surface material 20 are unfolded so that they are in an almost straight line, with the first stitch 11 as the pivot point.

[0042] (Second suturing process) In the second suturing process S40, after the folding process S38, as shown in Figure 5(B), the front and back of the overlapping portion 28 of each of the two outer material 20 are sewn together between the first position P1 and the second position P2 to form the second stitch 12. Specifically, the front and back of the overlapping portion 28 are sewn together at the third position P3 between the first position P1 and the second position P2 using a sewing device such as a sewing machine. More specifically, the needle of the sewing device is moved relative to the third position P3 in the boundary stretching direction (front and back direction in Figure 5) so that the thread passes through the overlapping portion 28 where the release paper 27 is not interposed, and the front and back of the overlapping portion 28 are sewn together. This forms the second stitch 12. The third position P3 is not particularly limited as long as it is between the first position P1 and the second position P2, and is determined considering the aesthetic design of the appearance.

[0043] (Tape application process) In the tape application process S42, as shown in Figure 5(C), the adhesive tape 14 is applied to the back surface of the overlapping portion 28 of the two surface materials 20, that is, to the surface layer 21 on the side of the first end 20A of the overlapping portion 28 formed by folding back the first end 20A. It is preferable to apply one adhesive tape 14 across the back surface of the overlapping portion 28 of the two surface materials 20. It is also preferable that the release paper 15 is peelably attached to the side of the adhesive tape 14 opposite to the side that is attached to the surface layer 21.

[0044] (Second peeling process) In the second peeling step S44, as shown in Figure 6(A), the release paper 27 provided on each of the two surface materials 20 is peeled off, extending from the second position P2 to the second end (not shown) opposite to the first end 20A of the surface material 20.

[0045] (Third peeling process) In the third peeling step S46, as shown in Figure 6(A), the release paper 15 of the adhesive tape 14 that was attached to the back surface of the overlapping portion 28 in the tape application step S42 is peeled off. As a result of these second peeling steps S44 and third peeling steps S46, the adhesive layer 25 and the adhesive surface of the adhesive tape 14 are exposed over the entire back surface of the two surface materials 20.

[0046] The second peeling step S44 and the third peeling step S46 may be performed in this order, in the reverse order, or simultaneously.

[0047] (Pasting process) In the application process S48, after the second peeling process S44 and the third peeling process S46, the adhesive layers 25 of the two surface materials 20 and the adhesive tape 14 are attached to the base material 50, as shown in Figure 6(B). Preferably, the base material 50 has recesses 51 for accommodating the overlapping portion 28. This allows the overlapping portion 28, which is thicker than other parts, to be accommodated in the recesses 51, thus avoiding the overlapping portion 28 adversely affecting the aesthetic appearance.

[0048] As explained above, according to this embodiment, the application of adhesive is unnecessary, and environmental degradation can be suppressed. Furthermore, in the first sewing process S34 in which the first stitch 11 is formed, the two outer material 20 are sewn at the first position P1 where the release paper 27 was cut in the first half-cut process S30, that is, along the cut line of the cut release paper 27. Therefore, the needle basically penetrates only two layers of each outer material 20: the outer layer 21 and the adhesive layer 25. Consequently, compared to the conventional case where the needle penetrates three layers: the outer layer 21, the adhesive layer 25, and the release paper 27, it is possible to suppress the deterioration of productivity due to reduced sewing speed and worsening sewing accuracy.

[0049] Furthermore, in the first peeling step S36, the release paper 27 provided from the first end 20A of the surface material 20 to the first position P1, and the release paper 27 provided from the first position P1 to the second position P2 of the surface material 20 are peeled off, followed by folding (folding step S38), and in the second sewing step S40, the front and back of the overlapping section 28 are sewn to form the second stitch 12. In the overlapping section 28, the surface layer 21, cushion layer 23, adhesive layer 25, adhesive layer 25, cushion layer 23, and surface layer 21 are laminated in each surface material 20, and the release paper 27 is not interposed. Therefore, it is possible to avoid problems caused by paper dust generated when the needle penetrates the release paper 27 getting mixed into or adhering to the sewing part.

[0050] Furthermore, in the second suturing process S40, when feeding out the two integrated outer material 20, the thickness of the two outer material 20 is reduced compared to the conventional case where release paper is interposed, allowing them to be fed out at a uniform speed and suppressing misalignment during sewing.

[0051] Furthermore, since the manufactured surface-covered product 10 does not contain release paper 27, the roughness caused by the presence of release paper 27 can be avoided, which would otherwise affect the appearance and feel. However, if a surface-covered product with release paper 27 is attached to a vehicle, mold may grow on the release paper 27 due to environmental changes and temperature fluctuations. However, since the surface-covered product 10 of this embodiment does not contain release paper 27, mold will not grow on the release paper 27 even after the surface-covered product 10 has been attached to a vehicle for a long period of time, thus improving the reliability of the product.

[0052] Furthermore, as described above, in the tape application process S42, it is preferable to attach one side of the adhesive tape 14 to the surface of the surface layer 21 of the overlapping portion 28 facing the base material 50. This fixes the overlapping portion 28 to the base material 50, thus maintaining the positional accuracy of the double stitch. In addition, it is possible to avoid the risk of the overlapping portion 28 moving or deforming due to vibration or impact, and the risk of shape change or deterioration due to long-term use is reduced, thereby improving the reliability of the product.

[0053] Although various embodiments have been described above with reference to the drawings, it goes without saying that the present invention is not limited to these examples. It is clear to those skilled in the art that various modifications or alterations can be conceived within the scope of the claims, and these will naturally also fall within the technical scope of the present invention. Furthermore, the components of the above embodiments may be combined in any way without departing from the spirit of the invention.

[0054] For example, genuine leather may be used instead of synthetic leather as the surface layer 21. Furthermore, the manufacturing method of this embodiment is not limited to automotive interior parts, but can be broadly applied to surface-covered products having stitching on the surface of the surface layer 21.

[0055] This specification contains at least the following information. Note that the components etc. in parentheses indicate those corresponding to the embodiments described above, but are not limited thereto.

[0056] (1) A method for manufacturing a product with an epidermis (product with an epidermis 10), A first half-cut step (first half-cut step S30) is performed to cut the release paper at a first position (first position P1) located a first distance (first distance L1) from one end (first end 20A) of the surface material (surface material 20), which comprises a surface layer (surface layer 21), a cushioning layer (cushion layer 23) having cushioning properties bonded to the back surface of the surface layer, and an adhesive layer (adhesive layer 25) on which a release paper (release paper 27) that can be peeled off is attached to one side and the other side is attached to the cushion layer. A second half-cut step (second half-cut step S32) in which the release paper is cut at a second position (second position P2) located at a second distance (second distance L2) greater than the first distance from one end of the surface material, Arrangement step (arrangement step S33): Arrangement step (arrangement step S33) involves overlapping two of the surface materials so that the surface layers of the surface materials are in contact with each other and aligning them to a first position, After the arrangement step, a first suturing step (first suturing step S34) is performed in which the two surface materials are sewn together at the first position to form a first stitch (first stitch 11), and the two surface materials are integrated with the first stitch. After the first suturing step, a first peeling step (first peeling step S36) is performed to peel off the release paper provided from one end to the first position and the release paper provided from the first position to the second position for each of the two surface materials, After the first peeling step, each of the two surface materials is folded back using the first stitch as a pivot point, and the other side of the adhesive layer between the one end and the first position and the other side of the adhesive layer between the first position and the second position are attached and overlapped in a folding step (folding step S38), After the folding step, a second sewing step (second sewing step S40) is performed in which the overlapping portion (overlapping portion 28) between the first position and the second position of each of the two surface materials is sewn together to form a second stitch (second stitch 12), A second peeling step (second peeling step S44) is performed to peel off the release paper that is provided on each of the two surface materials from the second position to the other end (first end) of the surface material, The process includes, after the second peeling step, an attachment step (attachment step S48) in which the other sides of the adhesive layers of the two surface materials are attached to the base material (base material 50), A method for manufacturing products with the outer layer intact.

[0057] According to (1), in the first sewing process that forms the first stitch, the two outer material pieces are sewn at the first position where the release paper was cut in the first half-cut process, so the needle basically penetrates two layers of each outer material: the outer layer and the adhesive layer. Therefore, compared to the conventional method in which the needle penetrates three layers: the outer layer, the adhesive layer, and the release paper, it is possible to suppress the deterioration of productivity caused by a decrease in sewing speed and a deterioration in sewing accuracy.

[0058] Furthermore, since the release paper provided from one end of the surface material to the first position and the release paper provided from the first position to the second position of the surface material are removed in the first peeling step, and then the second stitch is formed in the second sewing step, there is no need to sew the surface material with a three-layer structure as in the conventional method. Therefore, it is possible to avoid problems caused by paper dust generated when the needle penetrates the release paper getting mixed into or adhering to the sewn part.

[0059] Furthermore, since the manufactured products with the outer layer do not contain release paper, the rough texture caused by the release paper can be avoided, which can negatively impact the appearance and feel. In addition, mold and other contaminants will not grow on the release paper, improving the reliability of the product.

[0060] (2) A method for producing the product with the skin on as described in (1), In the first suturing step, at the first position, the two pieces of the outer material are sewn together along the cutting line between the release paper provided from one end to the first position and the release paper provided from the first position to the second position. A method for manufacturing products with the outer layer intact.

[0061] According to (2), since the cut lines of the cut release paper are sewn together, the needle is prevented from penetrating the release paper. Even if the needle does penetrate the release paper in some places, the distance between the edge of the release paper and the point of penetration is extremely small, so the release paper is peeled off in the first peeling step and no part of the release paper remains inside.

[0062] (3) A method for producing a product with an epidermis as described in (1) or (2), In the folding step, each of the two surface materials is folded back so that one end overlaps with or is close to the second position. A method for manufacturing products with the outer layer intact.

[0063] According to (3), in the folding process, by folding the surface material so that one end overlaps with or is close to the second position, the release paper provided from the second position to the other end of the surface material can be easily peeled off in the second peeling process.

[0064] (4) A method for producing a product with an epidermis as described in (1) or (2), Prior to the aforementioned bonding step, the process further includes a tape bonding step (tape bonding step S42) in which one side of an adhesive tape (adhesive tape 14) is bonded to the surface of the surface layer of the polymerized portion facing the substrate. In the tape application step, the other side of the adhesive tape is attached to the substrate. A method for manufacturing products with the outer layer intact.

[0065] According to (4), by attaching adhesive tape to the surface of the surface layer of the polymerized portion and then attaching it to the substrate via the adhesive tape, it is possible to prevent the polymerized portion, where the first and second stitches are provided, from moving or deforming due to vibration or impact. In addition, the effects of shape changes and deterioration over time due to long-term use can be suppressed, thereby improving the reliability of the product.

[0066] (5) A method for producing the skinned product described in (4), In the tape application process, a removable release paper (release paper 15) is attached to the other side of the adhesive tape. Prior to the aforementioned application step, the process includes a third peeling step (third peeling step S46) in which the release paper is peeled off from the other side of the adhesive tape. A method for manufacturing products with the outer layer intact.

[0067] According to (5), by retaining the release paper of the adhesive tape until just before it is applied to the substrate, defects caused by unintended adhesion and a decrease in productivity can be suppressed.

[0068] (6) A method for producing a product with an epidermis as described in (1) or (2), In the first half-cutting step, the release paper and the adhesive layer are cut. A method for manufacturing products with the outer layer intact.

[0069] According to (6), by cutting the adhesive layer in addition to the release paper in the first half-cutting step, the needle does not penetrate the adhesive layer when sewing the two skin materials together in the first suturing step, thus suppressing the adhesion of the adhesive layer to the needle.

[0070] (7) A method for producing a product with an epidermis as described in (1) or (2), The aforementioned product with a surface covering is an interior part of an automobile. A method for manufacturing products with the outer layer intact.

[0071] According to (7), it is possible to manufacture highly reliable automotive interior parts. [Explanation of symbols]

[0072] 11. First Stitch 12. Second stitch 14 Adhesive tape 15 Release paper 20 Skin material 20A 1st end (one end) 21 Epidermal layer 23 Cushion layer 25 Adhesive layer 27 Release paper 28 Polymerization section 50 Base material L1 1st distance L2 2nd distance P1 1st position P2 2nd position S30 First Half-Cut Process S32 Second Half-Cutting Process S34 1st suturing process S36 First peeling process S38 Folding process S40 2nd suturing process S42 Tape application process S44 Second peeling process S46 Third peeling process S48 Application Process

Claims

1. A method for manufacturing a product with an epidermis, A first half-cut step involves cutting the release layer at a first position, which is a distance from one end of a surface material comprising a surface layer and an adhesive layer provided on the back side of the surface layer, with a release layer that can be peeled off being attached to the other side opposite to one side of the surface layer. A second half-cut step in which the release layer is cut at a second position located at a second distance greater than the first distance from one end of the surface material, Arrangement step: Place two of the surface materials on top of each other so that the surface layers of the surface materials are in contact with each other, and align them in a first position. After the arrangement step, a first suturing step is performed in which the two skin materials are sewn together at the first position to form a first stitch, and the two skin materials are integrated with the first stitch. After the first suturing step, a first peeling step is performed to peel off the release layer provided from one end to the first position and the release layer provided from the first position to the second position for each of the two surface materials, After the first peeling step, each of the two surface materials is folded back using the first stitch as a pivot point, and the other side of the adhesive layer between the one end and the first position and the other side of the adhesive layer between the first position and the second position are attached and overlapped in a folding step, The process includes a second sewing step, in which, after the folding step, the overlapping portion of each of the two surface materials is sewn together between the first and second positions to form a second stitch. A method for manufacturing products with the outer layer intact.

2. A method for producing a product with an epidermis according to claim 1, A second peeling step is performed to peel off the release layer provided on each of the two surface materials from the second position to the other end of the surface material, The process includes, after the second peeling step, an attachment step of attaching the other side of the adhesive layer of the two surface materials to the substrate, A method for manufacturing products with the outer layer intact.

3. A method for manufacturing a product with an epidermis according to claim 1 or 2, In the first suturing step, at the first position, the two surface materials are sewn together along the cutting line between the release layer provided from one end to the first position and the release layer provided from the first position to the second position. A method for manufacturing products with the outer layer intact.

4. A method for manufacturing a product with an epidermis according to claim 1 or 2, In the folding step, each of the two surface materials is folded back so that one end overlaps with or is close to the second position. A method for manufacturing products with the outer layer intact.

5. A method for manufacturing a product with a skin according to claim 2, The process further includes a tape application step of attaching one side of an adhesive tape, on which a release layer that can be peeled off is attached to the other side, to the surface of the surface layer of the polymerized portion facing the substrate. A method for manufacturing products with the outer layer intact.

6. A method for manufacturing a product with an epidermis according to claim 5, The process includes a third peeling step, which is performed before the aforementioned application step, in which the release layer is peeled off from the other side of the adhesive tape. A method for manufacturing products with the outer layer intact.

7. A method for manufacturing a product with an epidermis according to claim 1 or 2, In the first half-cutting step, the release layer and the adhesive layer are cut. A method for manufacturing products with the outer layer intact.

8. A method for manufacturing a product with an epidermis according to claim 1 or 2, The aforementioned product with a surface covering is an interior part of an automobile. A method for manufacturing products with the outer layer intact.

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