Beading and its manufacturing method.

Abstract

The present invention provides a bead that suppresses squealing of a cylindrical portion and has high flexibility, and a method for manufacturing the same. [Solution] The device comprises a tubular portion, leg portions integrally formed in a band shape along the side surface of the tubular portion, and a core portion that is flexible and disposed inside the tubular portion in a state where it has sliding resistance against the inner wall surface without being bonded to the inner wall surface of the tubular portion. The core portion is disposed inside the tubular portion in a state where the outer surface of one or more braided cords is covered with a braided fabric made of a fibrous material including multiple heat-fusible yarns, which is preheated to melt the heat-fusible yarns and then cooled and solidified.

Description

[Technical Field]

[0001] The present invention relates to a bead and a method for manufacturing the same. [Background technology]

[0002] A vehicle seat covering material is known, which comprises a first fabric, a second fabric, and a narrow woven fabric. The narrow woven fabric includes a decorative portion that is generally rectangular in plan view, a first seam portion that is generally rectangular in plan view and connected to one widthwise edge of the decorative portion, and a second seam portion that is generally rectangular in plan view and connected to the other widthwise edge of the decorative portion. An end of the first fabric is overlapped and sewn to the first seam portion of the narrow woven fabric, and an end of the second fabric is overlapped and sewn to the second seam portion of the narrow woven fabric. The decorative portion of the narrow woven fabric includes one or more welting portions that include a hollow tubular weave portion extending in the length direction of the decorative portion, one or more braided cords arranged inside the tubular weave portion, and one or more insertion threads arranged inside the tubular weave portion. The insertion threads are thinner than the braided cords, and at least some of the warp threads that make up the tubular weave portion are heat-sealed threads (Patent Document 1).

[0003] A welting having a long, columnar column and a leg formed integrally in a band shape along the side of the column, the outer surface of the column and the leg being formed by a fabric body, the column being formed by covering a solid, columnar core with a first fabric body which is part of the fabric body, the leg being formed by a second fabric body which is also part of the fabric body, molten yarn which melts when heated is arranged inside the first fabric body and / or on the surface of the core, molten yarn is arranged inside the second fabric body, and the welting is formed in a state in which the first fabric body and the second fabric body are woven together with the core, and then heated to melt the molten yarn, which is then cooled and solidified (Patent Document 2). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6116775 [Patent Document 2] Japanese Patent Publication No. 2022-176521 Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention provides a bead that suppresses squealing of a cylindrical portion and has high flexibility, and a method for manufacturing the same. [Means for solving the problem]

[0006] In order to solve the above problem, the beading according to claim 1 is A cylindrical portion; a leg portion integrally formed in a strip shape along a side surface of the cylindrical portion; a core portion that is flexible and disposed inside the cylindrical portion in a state where it has sliding resistance to the inner wall surface without being bonded to the inner wall surface of the cylindrical portion; Equipped with It is characterized by:

[0007] The invention described in claim 2 is the beading described in claim 1, The core material portion is preheated in a state in which the outer peripheral surface of one or more braided cords is covered with a knitted fabric made of fibrous material including a plurality of thermal fusion yarns, and the thermal fusion yarns are melted and then cooled and solidified, and the core material portion is disposed inside the tubular portion. It is characterized by:

[0008] The invention described in claim 3 is the beading described in claim 2, The braided cord is a round braided cord, and the sliding resistance is due to unevenness formed on the surface of the core material portion. It is characterized by:

[0009] The invention described in claim 4 is the beading described in claim 2 or 3, The heat-sealing yarn is a heat-sealing polyester yarn. It is characterized by:

[0010] In order to solve the above problem, the method for manufacturing a beading edge according to claim 5 is as follows: A method for manufacturing a beaded edge comprising: a cylindrical portion; a leg portion integrally formed in a strip shape along a side surface of the cylindrical portion; and a core portion having flexibility and disposed inside the cylindrical portion in a state of having sliding resistance to the inner wall surface without being bonded to the inner wall surface of the cylindrical portion, a first step of warping the warp yarns so that the warp yarns do not include heat-sealing yarns in both side portions where the two tubular portions are woven, and the warp yarns include heat-sealing yarns in the central portion where the leg portions are woven; a second step of covering an outer peripheral surface of one or more braided cords with a braided fabric made of a fibrous material including a plurality of heat-fusible yarns, and then preheating and cooling the braided fabric to bond the braided cord to the braided cord, thereby preparing the core part; a third step of weaving the two tubular portions together while inserting the core portion therebetween and integrally weaving the leg portions to form an intermediate fabric body; a fourth step of sequentially heating and cooling the intermediate fabric body to bond the warp and weft yarns woven into the leg portion; and a fifth step of cutting the leg portion of the intermediate fabric body to obtain two welts. It is characterized by: [Effects of the Invention]

[0011] According to the invention as set forth in claim 1, it is possible to suppress noise from the cylindrical portion and to impart high flexibility to the cylindrical portion.

[0012] According to the invention as set forth in claim 2, it is possible to impart high flexibility to the cylindrical portion while imparting an appropriate sliding resistance between the core portion and the inner wall surface of the cylindrical portion.

[0013] According to the invention of claim 3, the braided cord can easily follow the curve when bent and easily maintain a circular cross section, and an appropriate restraining force can be applied between the inner wall surface of the tubular portion and the core portion.

[0014] According to the invention as set forth in claim 4, the outer peripheral surface can be solidified while maintaining the flexibility of the braid.

[0015] According to the invention as set forth in claim 5, the beading can be produced continuously. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a perspective view showing an example of an automobile seat using a beading according to an embodiment of the present invention. [Figure 2] 1 is a schematic cross-sectional view showing a state in which the beading according to the present embodiment is attached to an automobile seat. [Figure 3] 1 is a cross-sectional view showing the overall configuration of a bead according to the present embodiment, taken in a direction intersecting the longitudinal direction. FIG. [Figure 4] 1 is a schematic partial longitudinal cross-sectional view showing the overall configuration of a bead according to the present embodiment. FIG. [Figure 5] FIG. 2 is a vertical cross-sectional view showing an example of the configuration of a core portion. [Figure 6] FIG. 2 is a schematic diagram illustrating a first step in the process for manufacturing a bead according to the present embodiment. [Figure 7] FIG. 10 is a schematic diagram illustrating a second step in the process for manufacturing the bead according to the present embodiment. [Figure 8] FIG. 10 is a schematic diagram illustrating a third step in the process for manufacturing the bead according to the present embodiment. [Figure 9] FIG. 10 is a schematic diagram illustrating a fourth step in the process for manufacturing the bead according to the present embodiment. [Figure 10] FIG. 10 is a schematic diagram illustrating a fifth step in the process for manufacturing the bead according to the present embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0017] Next, the present invention will be described in more detail below with reference to the drawings, showing embodiments and specific examples, but the present invention is not limited to these embodiments and specific examples. Furthermore, in the following explanation using the drawings, it should be noted that the drawings are schematic and the ratios of the dimensions, etc. may differ from those of the actual product, and in order to facilitate understanding, illustrations of components other than those necessary for the explanation have been omitted as appropriate.

[0018] (1) Automotive seat configuration FIG. 1 is a perspective view showing an example of an automobile seat 100 using the beading 1 according to this embodiment, and FIG. 2 is a schematic cross-sectional view showing the beading 1 according to this embodiment attached to an automobile seat. Hereinafter, the configuration of an automobile seat 100 using the welt 1 according to this embodiment will be described with reference to the drawings.

[0019] The automobile seat 100 includes a seat cushion 110, a seat back 120, and a headrest 130. The seat cushion 110 is formed by placing a pad (not shown) as a cushioning material on a cushion frame (not shown) as a skeleton, and covering the surface of the pad with a cushion cover 140. The cushion cover 140 is formed by integrating multiple parts by sewing, and has a top panel portion 141 and a slit portion 142. A welt 1 is attached by being sewn integrally to the stitching portion between the top panel portion 141 and the slit portion 142.

[0020] The seat back 120 has the same configuration as the seat cushion 110, and is formed by placing a back pad (not shown) as a cushioning material on a back frame (not shown) as a skeleton, and covering the surface with a back cover 150. The back cover 150 is formed by integrating multiple parts by sewing, and has a top panel portion 151, a slit portion 152, and a back surface portion (not shown). A welt 1 is attached by being sewn integrally to the sewing portion between the top panel portion 151 and the slit portion 152.

[0021] The top panel 151 of the back cover 150 has a two-layer structure in which a cover pad 151b made of a urethane slab is laminated on the back side of a surface 151a made of fabric or leather. The siding 152 of the back cover 150 is made only of a surface made of fabric or leather, and this surface may be the same as or different from the surface 151a of the top panel 151. Welting 1 has a tubular portion 11 that is cylindrical in cross section, a leg portion 12 that is integrally formed in a strip shape along the side of tubular portion 11, and a core portion 13 that is disposed inside tubular portion 11. Leg portion 12 of welting 1 is sandwiched between the surface side of skin 151a at the end of top plate 151 and the surface side of the end of stile 152, and is sewn together with sewing thread 160. Furthermore, tubular portion 11 of welting 1 is disposed at the boundary between top plate 151 and stile 152, enhancing the design. In the cushion cover 140, a welt 1 is sewn at the boundary between the top panel portion 141 and the gusset portion 142, similar to the back cover 150.

[0022] (2) Welting structure Fig. 3 is a cross-sectional view in a direction intersecting the longitudinal direction showing the overall configuration of the welt 1, Fig. 4 is a partial cross-sectional view in the longitudinal direction showing the overall configuration of the welt 1, and Fig. 5 is a vertical cross-sectional view showing an example configuration of the core portion 13. The configuration of the welt 1 will be described below with reference to the drawings.

[0023] (2.1) Cylindrical part and legs As shown in Fig. 3, the tubular portion 11 is a cylindrical piece of fabric enclosing the core portion 13 inside, and is woven integrally with the leg portion 12. The leg portion 12 is made of fabric and is plate-shaped, with the end portion 12b opposite the tubular portion 11 formed in a wavy shape when viewed from a direction intersecting the extension direction of the leg portion 12 (see Fig. 4). Specifically, the leg portion 12 is a band-like extending member, with approximately triangular notches 12c formed at predetermined intervals on the end portion 12b opposite the tubular portion 11.

[0024] The tubular portion 11 and the leg portions 12 are formed by weaving polyester fibers, and the leg portions 12 contain heat-sealing yarns 12a (see FIG. 6) that melt and soften when heated, but the tubular portion 11 does not contain heat-sealing yarns. Specifically, as shown in FIG. 6, the warp yarns used to weave the tubular portion 11 do not contain heat-sealing yarns, but the warp yarns used to weave the leg portions 12 contain heat-sealing yarns 12a. As an example, the warp yarns used to weave the tubular portion 11 are polyester yarns with a thickness of 330T (decitex), and the warp yarns used to weave the leg portions 12 are polyester yarns with a thickness of 220T, with heat-sealing yarns 12a made of polyester with a low melting point and a thickness of 33T (decitex) added in a predetermined ratio.

[0025] (2.2) Core As shown in Figure 5, the core part 13 is formed in a cylindrical shape in cross section, with the outer surface of one or more braided cords 131 covered with a braided fabric 132 made of fibrous material 133 including multiple heat-sealed threads 133a. The braided cord 131 is formed by weaving a braid-like knitted material into a tubular shape using a plurality of polyester fibers 131a. The braided cord 131 can be knitted, for example, using an 8-strand round braiding machine 50 (see FIG. 7). The knitting method of the braided cord 131 is not necessarily limited to the 8-strand round braiding machine 10, and may be knitted using a round braiding machine with less than or more than 8 struts. However, an 8-strand round braided cord has an outer surface that is more likely to be uneven than a 16-strand round braided cord, and can provide an appropriate binding force between the inner wall surface 11a of the tubular portion 11 and the core portion 13. In this embodiment, the round braided cord is made using eight polyester threads with a thickness of 2000T (decitex) to 4000T (decitex).

[0026] As shown in Fig. 5, the knitted fabric 132 is formed by braiding a cylindrical braid 131 using a plurality of polyester fibers 131a with a plurality of polyester fibrous materials 133 including heat-sealing yarns 133a so as to cover the outer peripheral surface of the braided cord 131. The braiding is basically performed in the same manner as for making a round braid.

[0027] Specifically, the knitted fabric 132 is braided with 20 to 30 fibrous materials 133, each set of fibrous materials 133 being a combination of a polyester thread having a thickness of 280T (decitex) and two heat-sealing yarns 133a made of polyester with a low melting point and having a thickness of 33T (decitex). If the number of fibrous materials 133 is less than this, gaps are likely to be formed on the outer surface of the braided cord 131, and when heated, the amount of melted heat-sealing yarns 133a may be reduced, which may weaken the bond to the braided cord 131. Furthermore, if the braiding is denser or the number of fibers is greater than this, the amount of melted heat-sealing yarns 133a may be greater than necessary when heated, which may impair the flexibility of the core portion 13.

[0028] In this way, the core material portion 13, in which the outer surface of the braided cord 131 is covered with a braided fabric 132 made of a fibrous material 133 containing multiple heat-sealed threads 133a, is preheated to melt the heat-sealed threads 133a, and then cooled and solidified, and is then placed inside the tubular portion 11 without adhering to the inner wall surface 11a. The outer surface of core portion 13 is easily uneven because the outer peripheral surface of braided cord 131, which is an 8-ply round braided cord, is covered with knitted fabric 132 made from fibrous material 133 including heat-sealed yarn 133a. As a result, core portion 13 has a certain sliding resistance against inner wall surface 11a of tubular portion 11, suppresses slippage relative to tubular portion 11, and even if slippage does occur, core portion 13 is highly flexible, making it possible to suppress noise in tubular portion 11.

[0029] (3) Welding manufacturing method Fig. 6 is a schematic diagram for explaining the first step in the manufacturing process of beading 1, Fig. 7 is a schematic diagram for explaining a part of the second step in the manufacturing process of beading 1, Fig. 8 is a schematic diagram for explaining the third step in the manufacturing process of beading 1, Fig. 9 is a schematic diagram for explaining the fourth step in the manufacturing process of beading 1, and Fig. 10 is a schematic diagram for explaining the fifth step in the manufacturing process of beading 1. The manufacturing method of beading 1 will be explained below with reference to the drawings.

[0030] (3.1) First step In the first step shown in Figure 6, multiple cones 21 wound with warp yarns are set on a warper, and the warp yarns corresponding to the tubular portion 11 and the leg portion 12 are wound onto a beam 22. At this time, the warp yarns in both side portions 23 where the tubular portion 11 is woven do not include heat-sealed yarns, while the warp yarns in the central portion 24 where the leg portion 12 is woven include heat-sealed yarns 12a. Specifically, in both side portions 23, polyester yarns with a thickness of 330T (decitex) are arranged at a density of 37 yarns / 25.4 mm. In the central portion 24, polyester yarns with a thickness of 280T are mixed with heat-sealed yarns 12a made of polyester with a low melting point and a thickness of 33T at a predetermined ratio, and arranged at a density of 130 yarns / 25.4 mm.

[0031] (3.2) Second step In the second step shown in FIG. 7, the outer peripheral surface of one or more braided cords 131 is covered with a knitted material 132 made by braiding fibrous material 133 containing multiple heat-sealing threads 133a, thereby producing the core portion 13.

[0032] As shown in Fig. 7, the braid 131 is knitted by a so-called round braiding machine 50 having the same mechanism as a conventional one. The round braiding machine 50 operates as follows, for example. That is, as shown in Fig. 7(a), when threads 131a (strands) are pulled out from a plurality of carriers 52 carrying bobbins 51, the carriers 52 are moved along a predetermined path by a moving mechanism 53 provided below. This movement changes the positional relationship of the pulled-out threads as the threads 131a are let out, and the round braid 131 is braided. The braid 131 is taken up by a take-up roller (not shown) and discharged.

[0033] 7(b), the braided cord 131 is fed at a constant speed by a feeding mechanism (not shown) using the braided cord 131 as a core material, while tension is applied to the braided cord 131. Then, bobbins 51 around which fibrous material 133 including a plurality of thermally fusible yarns 133a is wound are moved along a predetermined trajectory by a moving mechanism 53, and the fibrous material 133 is fed out successively from each bobbin 51 while tension is applied to the fibrous material 133, thereby knitting a knitted fabric 132 on the outer peripheral surface (periphery) of the braided cord 131.

[0034] Next, the braided cord 131 covered with the knitted fabric 132 braided with fibrous material 133 containing heat-sealing yarns 133a is preheated and then cooled. The heat-sealing yarns 133a covering the outer surface of the braided cord 131 melt and solidify, bonding the braided cord 131 to the knitted fabric 132 that wraps around the braided cord 131. This forms a flexible core portion 13. The second step can be performed separately from the first step, and may be performed after, before, or in parallel with the first step.

[0035] (3.3) Third step In the third step shown in Figure 8, the two tubular portions 11 and the leg portion 12 located between them are woven together. Specifically, polyester weft yarns having a thickness of 280T (decitex) are passed through the warp yarns wound around the beam 22 from the side portions 23 that do not contain heat-sealed yarns and the warp yarns from the center portion 24 that contain heat-sealed yarns 12a at a density of 112 threads / 25.4 mm to weave the intermediate fabric body 30. At this time, the two tubular portions 11 are woven in a hollow weave, and the core portion 13 produced in the second step is inserted into them during weaving. The intermediate fabric body 30 is a long object in which the leg portion 12 is integrated between two tubular portions 11 with the core portion 13 disposed inside.

[0036] (3.4) Fourth step 9, the intermediate fabric body 30 woven in the third step is sequentially heated and cooled, whereby the thermally fused yarns 12a woven into the leg portions 12 melt and solidify, bonding the warp and weft yarns woven into the leg portions 12. At this time, since the tubular portion 11 does not contain any thermally fused yarns, the core portion 13 arranged inside the tubular portion 11 is not bonded to the inner wall surface 11a of the tubular portion 11 (see FIG. 3), and the unevenness of the outer surface of the core portion 13 creates an appropriate sliding resistance between the core portion 13 and the inner wall surface 11a of the tubular portion 11. Furthermore, since the warp and weft threads of the leg portion 12 are bonded to each other, rigidity is ensured even if the fabric is thin, and the threads are less likely to fray from the cut ends when cut in the next fifth step.

[0037] (3.4) Fifth step In the fifth step shown in Figure 10, the leg portion 12 is pressed against a cutting roller 26 having a wavy cutting blade 25 extending circumferentially on the side of the cylinder, thereby cutting the leg portion 12 in a wavy shape to obtain two beaded edges 1. The cutting blade 25 is formed as a convex portion protruding radially from the side of the cutting roller 26, and a cylindrical roller (not shown) with a parallel axis is arranged on the opposite side of the cutting roller 26, sandwiching the leg portion 12 between them, so that when the leg portion 12 is passed between the two rollers, the leg portion 12 is pressed by the two rollers and is cut in a wavy pattern by the cutting blade 25. This cutting process is performed continuously downstream of the fourth heat setting process in synchronization with the heat setting process. At this time, the warp and weft yarns of the leg portion 12 are bonded to each other by the melting and solidification of the heat fusion yarns 12a, so even when cut, the yarns are less likely to fray from the cut ends. Furthermore, cutting can be performed by thermal fusion, laser cutting, or ultrasonic cutting, and the cut surface can be melted and solidified to effectively prevent fraying.

[0038] (4) Effects of beading The welt 1 according to this embodiment is configured to include a tubular portion 11, leg portions 12 formed integrally in a strip shape along the side surface of the tubular portion 11, and a flexible core portion 13 disposed inside the tubular portion 11 in a state where it has sliding resistance against the inner wall surface 11a without being bonded to the inner wall surface 11a of the tubular portion 11. The core portion 13 is preheated in a state where the outer surface of one or more braided cords 131 is covered with a knitted fabric 132 made of fibrous material 133 containing multiple heat-sealing yarns 133a, and the heat-sealing yarns 133a are melted, and the outer surface is cooled and solidified in a state where it is easy for the outer surface to become uneven. As a result, the core portion 13 has sliding resistance against the inner wall surface 11a, suppressing slippage relative to the tubular portion 11, and even if slippage does occur, it has high flexibility and can suppress noise in the tubular portion 11. In particular, the braided cord 131 that constitutes the core portion 13 is an 8-strand round braided cord, which makes it easy for the braided cord 131 to conform when bent and easily maintain a circular cross section, and can impart an appropriate restraining force between the inner wall surface 11a of the tubular portion 11 and the core portion 13.

[0039] Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments and various modifications can be made within the scope of the gist of the present invention as set forth in the claims. For example, the core portion 13 may be formed in a cylindrical cross-sectional shape by covering the outer surface of a bundle 131A (not shown) formed by bundling a plurality of fibrous materials 131a substantially without twisting with a braid 132 made of fibrous materials 133 including a plurality of thermally fused yarns 133a. This allows the core portion 13 to be imparted with various flexibility by adjusting the linearity or number of the fibrous materials 131a. [Explanation of symbols]

[0040] 1. Beading 11: Cylindrical portion; 11a: Inner wall surface 12···Leg portion, 12a···Heat-sealing thread (leg portion) 13... Core material portion, 131... Braided cord, 132... Knitted fabric, 133... Fibrous material, 133a... Heat-sealed yarn 22 beam, 23 side portion, 24 center portion, 25 cutting blade, 26 cutting roller 50... Round braiding machine, 51... Bobbin, 52... Carrier, 53... Moving mechanism 100····Automobile seat, 110····Seat cushion, 120···Seat back, 130···Headrest, 140···Cushion cover, 141, 151···Top plate portion, 142, 152····Cover portion 142, 150···Back cover 150

Claims

1. A cylindrical portion; a leg portion integrally formed in a strip shape along a side surface of the cylindrical portion; a core portion that is flexible and disposed inside the cylindrical portion in a state where it has sliding resistance to the inner wall surface without being bonded to the inner wall surface of the cylindrical portion; Equipped with A beaded edge characterized by a beaded edge.

2. The core material portion is preheated in a state in which the outer peripheral surface of one or more braided cords is covered with a knitted fabric made of fibrous material including a plurality of thermal fusion yarns, and the thermal fusion yarns are melted and then cooled and solidified, and the core material portion is disposed inside the tubular portion.

2. The beading of claim 1.

3. The braided cord is a round braided cord, and the sliding resistance is due to unevenness formed on the surface of the core material portion.

3. The beading of claim 2.

4. The heat-sealing yarn is a heat-sealing polyester yarn.

4. The beading according to claim 2 or 3.

5. A method for manufacturing a beaded edge comprising: a cylindrical portion; a leg portion integrally formed in a strip shape along a side surface of the cylindrical portion; and a core portion having flexibility and disposed inside the cylindrical portion in a state of having sliding resistance to the inner wall surface without being bonded to the inner wall surface of the cylindrical portion, a first step of warping the warp yarns so that the warp yarns do not include heat-sealing yarns in both side portions where the two tubular portions are woven, and the warp yarns include heat-sealing yarns in the central portion where the leg portions are woven; a second step of covering an outer peripheral surface of one or more braided cords with a braided fabric made of a fibrous material including a plurality of heat-fusible yarns, and then preheating and cooling the braided fabric to bond the braided cord to the braided cord, thereby preparing the core portion; a third step of weaving the two tubular portions together while inserting the core portion therebetween and integrally weaving the leg portions to form an intermediate fabric body; a fourth step of sequentially heating and cooling the intermediate fabric body to bond the warp and weft yarns woven into the leg portion; and a fifth step of cutting the leg portion of the intermediate fabric body to obtain two welts. A method for manufacturing a beaded edge.

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