Method for manufacturing a product with an epidermis

Abstract

Provided is a method for manufacturing a product with a skin that can suppress defects caused by sewing a release paper. 【Solution means】The manufacturing method of the product 10 with a skin includes a first half-cutting step S30 of cutting the release paper 27 at the first position P1, a second half-cutting step S32 of cutting the release paper 27 at the second position P2, an arranging step S33 of overlapping two skin materials 20 so that the skin layers 21 of the skin materials 20 contact each other and arranging them in a state where the first position P1 is aligned, a first sewing step S34 of sewing the two skin materials 20 at the first position P1 and integrating them with the first stitch 11, a first peeling step S36 of peeling a part of the release paper 27, a folding-back step S38 of folding back with the first stitch 11 as a fulcrum, a second sewing step S40 of forming a second stitch 12 between the first position P1 and the second position P2, a second peeling step S44 of peeling the remaining release paper 27, and an attaching step S48 of attaching the integrated skin material 20 to the base material 50.

Description

Technical Field

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

Background Art

[0002] As a product with a skin in which the surface of a base material is covered with a skin material, for example, there are automotive interior parts incorporated in an instrument panel, a console, a door trim, a glove box, a pillar garnish, etc. of an automobile. 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 this skin layer, and is pasted on the surface of the base material with the cushion layer disposed between the skin layer and the base material.

[0003] Conventionally, a method of spraying a liquid adhesive on the surface of a base material and pasting 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, comprising a skin layer constituting the design surface of the interior part and a cushion layer having cushioning properties bonded to the back surface of this skin layer, and a double-sided adhesive sheet composed of an adhesive layer and a release paper adhered to one surface of this adhesive layer, the other surface of the adhesive layer of the double-sided adhesive sheet is adhered to its back surface and the skin material wound in a state having a certain width is sequentially fed out to a shape and size suitable for the base material, a pair of the skin materials in which only the release paper of the double-sided adhesive sheet is half-cut are sewn together with their surface sides facing each other so as to leave an area where stitches can be formed between the half-cut position and the end of each skin material, and integrated, With the stitches sewn for integrating the pair of skin materials as a boundary, the back sides are folded back so as to overlap each other, and in each of the regions in the integrated pair of skin materials, the folded portions of the respective skin materials are sewn together to form a double stitch in the integrated skin material. A method for manufacturing an automotive interior part, characterized in that, with the position of the half cut as a boundary, the release paper of the region with a larger area is peeled off from the adhesive layer adhered to the pair of skin materials, and the skin material integrated via the adhesive layer of the double-sided adhesive sheet is adhered to cover the base material.

[0005] The invention described in Patent Document 1 forms a double stitch by sewing and integrating two skin materials with release paper attached, and then further sewing the overlapping portions folded with the release paper sandwiched in each skin material.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] However, when sewing two skin materials with release paper attached, since the needle penetrates the three layers of the skin layer, the adhesive layer, and the release paper in each skin material, there is a risk that the sewing speed will decrease or the sewing accuracy will deteriorate, resulting in a deterioration in productivity.

[0008] In addition, there is a risk that problems will occur due to paper dust generated when the needle penetrates the release paper and mixing or adhering to the sewing part.

[0009] Furthermore, since the release paper is interposed in the manufactured interior parts, there is a risk of adversely affecting the appearance and touch.

[0010] The present invention provides a method for manufacturing a product with a skin layer that can suppress defects caused by sewing release paper.

Means for Solving the Problems

[0011] The present invention is a method for manufacturing a product with a skin layer, comprising: a first half-cut step of cutting the release paper at a first position separated from one end of a skin material by a first distance, the skin material including a skin layer, a cushion layer having cushioning properties adhered to the back surface of the skin layer, and an adhesive layer having one surface adhered to the cushion layer and the other surface adhered with a peelable release paper; a second half-cut step of cutting the release paper at a second position separated from the one end of the skin material by a second distance greater than the first distance; an arranging step of arranging two pieces of the skin material so that the skin layers thereof are in contact with each other and the first positions are aligned; a first sewing step of sewing and integrating the two pieces of the skin material at the first position to form a first stitch after the arranging step; a first peeling step of peeling the release paper provided from the one end to the first position and the release paper provided from the first position to the second position for each of the two pieces of the skin material after the first sewing step; a folding step of folding each of the two pieces of the skin material with the first stitch as a fulcrum and attaching and overlapping the other surface of the adhesive layer between the one end and the first position and the other surface of the adhesive layer between the first position and the second position after the first peeling step; a second sewing step of sewing and integrating a polymerized portion between the first position and the second position for each of the two pieces of the skin material to form a second stitch after the folding step; a second peeling step of peeling the release paper provided from the second position to the other end of the skin material for each of the two pieces of the skin material; After the second peeling step, a pasting step of pasting the other surfaces of the adhesive layers of the two skin materials onto a base material is provided.

Effect of the Invention

[0012] According to the present invention, it is possible to suppress the problems caused by sewing the release paper during the production of the product with the skin.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Best Mode for Carrying Out the Invention

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

[0015] Typically, the target of the product with a skin is interior and exterior automotive parts such as an instrument panel, console, door trim, glove box, and pillar garnish of an automobile, but it is not limited thereto. For example, interior and exterior building parts may also be applicable. In the following description, a glove box of an automobile will be described as an example of the product with a skin.

[0016] As shown in FIG. 1, a glove box 1 disposed in the passenger compartment 2 of an automobile uses a product with a skin 10. As shown in FIGS. 2(A) and 2(B), the product with a skin 10 is configured by integrating two skin materials 20 with a first stitch 11 and attaching them onto a base material 50. Second stitches 12 are respectively formed near a concave boundary line 13 formed by the first stitch 11 on each of the two skin materials 20. Hereinafter, the two second stitches 12 disposed near the first stitch 11 may be referred to as double stitches. 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 extension direction.

[0017] Note that the example shown in FIG. 2 integrates two skin materials 20 with one first stitch 11. However, three or more skin materials 20 may be used, and adjacent skin materials 20 may be integrated with a first stitch 11, and second stitches 12 may be respectively formed near each first stitch 11.

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

[0019] (Skin material) The skin material 20 is a member that forms the outer shell (surface layer) part of the product 10 with skin. As shown in Fig. 2(B), the skin material 20 includes a skin layer 21 that constitutes the design surface of the product 10 with skin, a cushion layer 23 bonded to the back surface of the skin layer 21, and an adhesive layer 25 with one surface adhered to the cushion layer 23 and the other surface adhered to the base material 50.

[0020] Here, adhesiveness, academically speaking, refers to "the property of showing instantaneous adhesiveness to the surface of the adherend, being easily adhered with light pressure, and no adhesive remaining on the surface of the adherend after peeling". In other words, it is "a substance that fastens multiple materials by its wettability and anchoring property while remaining in a gel state". On the other hand, adhesion, academically speaking, refers to "the phenomenon of connecting the adherend by chemical or physical forces". In other words, it is "a substance that fastens multiple materials by the components crosslinking and becoming solid". Thus, although they are originally different, they are common in that they both fasten multiple materials, and generally, they may not be clearly distinguished in use. Therefore, in this specification, adhesiveness and adhesion are not distinguished, and the adhesive layer 25 may be an adhesive layer.

[0021] The skin layer 21 is mainly used for the purpose of improving the texture and touch of the product 10 with skin. The skin layer 21 is formed into a sheet shape with uniform thickness by synthetic leather (synthetic skin) made of vinyl chloride, thermoplastic elastomer (TPO), etc., and can be deformed in the thickness direction, etc. It is desirable that the skin layer 21 has a thickness of 0.35 to 1.5 mm. In addition, the skin layer 21 may be subjected to embossing (wrinkle pattern) processing as seen in leather products.

[0022] The cushion layer 23 is composed of, for example, a three-dimensional knitted fabric in which two woven fabrics are connected by elastic threads, a foamed material such as urethane foam, ethylene foam, or propylene foam, etc., and has elasticity. The cushion layer 23 is used to improve the touch feeling of the skin-attached product 10. As the cushion layer 23, it is desirable to use one having a thickness of 1.5 to 3.5 mm. The cushion layer 23 can be attached to the skin layer 21 with an adhesive, a double-sided tape, or an adhesive.

[0023] The first stitch 11 is, as will be described in detail later, a seam formed by a thread attached to a needle by passing the needle through two skin materials 20. The first stitch 11 is provided for the purpose of sewing and integrating the two skin materials 20, and is configured by being arranged in a straight line. The first stitch 11 may be visible from the outside or may not be visible.

[0024] The second stitch 12 is, as will be described in detail later, a seam formed by a thread attached to a needle by passing the needle through the front and back of the overlapping portion 28 formed by folding back each skin material 20 with the first stitch 11. The second stitch 12 is provided above and below with the first stitch 11 (boundary line 13) interposed therebetween, and is configured by being arranged in a straight line along the first stitch 11 substantially parallel to the first stitch 11.

[0025] The second stitch 12 is for producing a high-class feeling by giving the skin-attached product 10 an appearance as if genuine leather is used by pseudo-reproducing the sewing of the parts of the skin layer 21 in the skin layer 21, and is provided for the purpose of decoration (ornamentation). Such a form of stitch is also called a decorative stitch, and not only when arranged in a straight line, but various designs can be adopted.

[0026] Unlike the first stitch 11, the second stitch 12 is exposed outside the skin layer 21. Therefore, the thread used for the second stitch 12 preferably has higher decorativeness 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] Since both the thread used for the first stitch 11 and the thread used for the second stitch 12 pass through the adhesive layer 25 described later or pass between the adhesive layers 25 when sewing, it is preferable that they have non-stick properties so that the adhesive does not adhere. Similarly, it is preferable that the needle used for the first stitch 11 and the needle used for the second stitch 12 also have non-stick properties so that the adhesive does not adhere. The thread and / or the needle may be surface-treated with a coating agent having non-stick properties so that, for example, the adhesive layer 25 does not adhere.

[0028] Next, an embodiment of a manufacturing method for manufacturing the skin-equipped product 10 configured as described above will be described with reference to FIGS. 3 to 6. As shown in FIG. 3, the manufacturing method of the present embodiment includes a first half-cutting step S30, a second half-cutting step S32, an arranging step S33, a first sewing step S34, a first peeling step S36, a folding-back step S38, a second sewing step S40, a tape attaching step S42, a second peeling step S44, a third peeling step S46, and an attaching step S48. Note that the tape attaching step S42 and the third peeling step S46 are not necessarily required. Also, two or more separate steps may be performed in one step, or other steps may be added.

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

[0030] Here, the skin material 20 used in the manufacturing method of the present embodiment will be described in more detail. As shown in FIG. 4(A), the skin material 20 includes a skin layer 21, a cushion layer 23 having cushioning properties bonded to the back surface of the skin layer 21, and an adhesive layer 25 having one surface adhered to the cushion layer 23 and a release paper 27 that can be peeled off adhered to the other surface. Note that since the release paper 27 is peeled off when attached to the base material 50, it does not exist in the product 10 with skin. However, when the skin layer 21 is the surface of the skin material 20, the release paper 27 is adhered to the back surface of the skin material 20 at the initial stage of manufacturing.

[0031] The adhesive layer 25 is a double-sided adhesive sheet having one surface adhered to the cushion layer 23 and a release paper 27 that can be peeled off adhered to the other surface. The release paper 27 is composed of a paper serving as a base material and a release layer in contact with the other surface of the adhesive layer 25. Since the release paper 27 is not actively penetrated by the needle in both the first stitching step S34 and the second stitching step S40 as described later, there are no particular restrictions on the material, thickness, etc., and a general one can be adopted.

[0032] The skin material 20 configured as described above is accommodated, for example, in a state of being wound around a roller. And at the time of manufacturing the product 10 with skin, it is supplied from the roller and cut to a predetermined length. Note that, among the ends of the skin material 20, the end on the side integrated by the first stitch 11 (the right end in the figure) is referred to as the first end 20A.

[0033] (First half-cut step) In the first half-cut step S30, as shown in FIG. 4(B), the release paper 27 is cut at a first position P1 that is separated from the first end 20A of the skin material 20 by a first distance L1. The first distance L1 is a distance corresponding to the length from the first end 20A to the first stitch 11 where two skin materials 20 are integrated. Therefore, the first distance L1 is set to a distance that allows for folding as described later while considering the design.

[0034] In the first half-cut step S30, as long as the release paper 27 is cut, part or all of the adhesive layer 25 may be cut together. However, as shown in FIG. 4(B), it is preferable that all of the adhesive layer 25 is cut. Thereby, when the two skin materials 20 are stitched together in the first stitching step S34 described later, the needle does not penetrate the adhesive layer 25 and passes between the cut adhesive layers 25, so that the adhesion of the adhesive layer to the needle can be suppressed.

[0035] (Second half-cut step) In the second half-cut step S32, the release paper 27 is cut at the second position P2 which is farther than the first distance L1 from the first end 20A of the skin material 20 by a second distance L2 greater than the first distance L1. The second distance L2 is approximately twice the first distance L1 or longer than twice the first distance L1. In the second half-cut step S32, as long as the release paper 27 is cut, part or all of the adhesive layer 25 may be cut together. However, as shown in FIG. 4(B), it is preferable that all of the adhesive layer 25 is cut. Thereby, the depth of the half-cut can be made uniform with the first half-cut step S30, and the adjustment of the half-cut becomes easy.

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

[0037] (Arrangement step) In the arrangement step S33, as shown in FIG. 4(C), the two skin materials 20 half-cut at the first position P1 and the second position P2 through the first half-cut step S30 and the second half-cut step S32 are overlapped so that the skin layers 21 are in contact with each other, and in a state where the first positions P1 are aligned, that is, in a state where the first positions P1 are made to coincide when viewed from the overlapping direction (the vertical direction in FIG. 4). Then, the two arranged skin materials 20 are held in this state. The holding method is not particularly limited, but the two skin materials 20 are held so that they do not shift during stitching.

[0038] Instead of arranging the two skin materials 20 in a state where the first position P1 is aligned after the first half-cut step S30 and the second half-cut step S32, the first half-cut step S30 and the second half-cut step S32 may be performed in a state where the two skin materials 20 are overlapped such that the skin layers 21 contact each other. As a result, the two skin materials 20 may be overlapped such that the skin layers 21 contact each other and arranged in a state where the first position P1 is aligned.

[0039] (First stitching step) Subsequently, in the first stitching step S34, as shown in FIG. 4(D), the two skin materials 20 are stitched and integrated at the first position P1 using a stitching device such as a sewing machine. More specifically, the needle of the stitching device is relatively moved along the first position P1 in the boundary extending direction (the front-back direction in FIG. 4), and the two skin materials 20 are stitched between the release papers 27 that are half-cut and separated at the first position P1, that is, so that the thread passes through the cutting line. Thereby, the first stitch 11 is formed.

[0040] (First peeling step) In the first peeling step S36, as shown in FIG. 4(E), for each of the two skin materials 20, the release paper 27 provided from the first end 20A to the first position P1 and the release paper 27 provided from the first position P1 to the second position P2 are peeled off. At this time, even if the needle penetrates the release paper 27 temporarily in the first stitching step S34, since the distance between the thread and the end of the release paper 27 is short, the release paper 27 is peeled off in the first peeling step S36, and the release paper 27 does not remain on the first stitch 11.

[0041] (Folding-back step) In the folding-back step S38, after the first peeling step S36, as shown in Fig. 5(A), for each of the two skin materials 20, it is folded back with the first stitch 11 as a fulcrum, and the other surface of the adhesive layer 25 between the first end portion 20A and the first position P1 and the other surface of the adhesive layer 25 between the first position P1 and the second position P2 are pasted and overlapped. As a result, the first end portion 20A is folded back to the second position P2 or near the second position P2, and an overlapping portion 28 is formed between the first position P1 and the second position P2. In the overlapping portion 28, the skin layer 21, the cushion layer 23, the adhesive layer 25, the adhesive layer 25, the cushion layer 23, and the skin layer 21 are laminated in this order from the skin layer 21 side. Until the first peeling step S36 shown in Fig. 4(E), the skin layers 21 of the two skin materials 20 were overlapped so as to be in contact with each other, but after the folding-back step S38 shown in Fig. 5(A), the skin layers 21 of the two skin materials 20 are unfolded so as to be substantially in a straight line with the first stitch 11 as a fulcrum.

[0042] (Second sewing step) In the second sewing step S40, after the folding-back step S38, as shown in Fig. 5(B), for each of the two skin materials 20, the front and back of the overlapping portion 28 are sewn 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 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 relatively moved along the third position P3 in the boundary extending direction (the front and back direction in Fig. 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. As a result, the second stitch 12 is formed. Since the third position P3 is not particularly limited as long as it is between the first position P1 and the second position P2, it is determined in consideration of the design property (designability) of the appearance.

[0043] (Tape sticking step) In the tape sticking step S42, as shown in FIG. 5(C), an adhesive tape 14 is stuck to the back surface of the overlapping portion 28 of the two skin materials 20, that is, the skin layer 21 on the side of the first end portion 20A of the overlapping portion 28 formed by folding back the first end portion 20A. It is preferable to stick one adhesive tape 14 across the back surface of the overlapping portion 28 of the two skin materials 20. Further, it is preferable that a release paper 15 is releasably stuck to the surface of the adhesive tape 14 opposite to the surface stuck to the skin layer 21.

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

[0045] (Third peeling step) In the third peeling step S46, as shown in FIG. 6(A), the release paper 15 of the adhesive tape 14 stuck to the back surface of the overlapping portion 28 in the tape sticking step S42 is peeled off. By these second peeling step S44 and third peeling step S46, the adhesive layer 25 and the adhesive surface of the adhesive tape 14 are exposed over the entire area on the back surfaces of the two skin materials 20.

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

[0047] (Sticking step) In the sticking step S48, after the second peeling step S44 and the third peeling step S46, as shown in FIG. 6(B), the adhesive layer 25 and the adhesive tape 14 of the two skin materials 20 are stuck to the base material 50. It is preferable that a recess 51 for accommodating the overlapping portion 28 is formed in the base material 50. Thereby, the overlapping portion 28 having a large thickness can be accommodated in the recess 51 with respect to other portions, and the possibility that the overlapping portion 28 adversely affects the design of the appearance can be avoided.

[0048] As described above, according to the present embodiment, spraying of the adhesive becomes unnecessary, and deterioration of the environment can be suppressed. Further, in the first stitching step S34 for forming the first stitch 11, at the first position P1 where the release paper 27 was cut in the first half-cut step S30, that is, the two skin materials 20 are sewn along the cutting line of the cut release paper 27. Therefore, the needle basically penetrates only the two layers of the skin layer 21 and the adhesive layer 25 of each skin material 20. Accordingly, compared with the case where the needle penetrates the three layers of the skin layer 21, the adhesive layer 25, and the release paper 27 as in the prior art, it is possible to suppress deterioration of productivity due to a decrease in sewing speed or deterioration of sewing accuracy.

[0049] Further, after peeling off the release paper 27 provided from the first end 20A of the skin material 20 to the first position P1 and the release paper 27 provided from the first position P1 to the second position P2 in the first peeling step S36, folding (folding step S38), in the second stitching step S40, the front and back of the overlapping portion 28 are sewn to form the second stitch 12. The overlapping portion 28 is formed by laminating the skin layer 21, the cushion layer 23, the adhesive layer 25, the adhesive layer 25, the cushion layer 23, and the skin layer 21 in each skin material 20, and the release paper 27 is not interposed. Therefore, it is possible to avoid the occurrence of problems caused by paper dust generated when the needle penetrates the release paper 27 from being mixed into or adhering to the sewing portion.

[0050] Further, also when feeding out the two integrated skin materials 20 in the second stitching step S40, compared with the case where a release paper is interposed as in the prior art, the thickness of the two skin materials 20 becomes thinner. Therefore, they can be fed out at a uniform speed, and the occurrence of deviation during sewing can be suppressed.

[0051] In addition, since the release paper 27 does not intervene in the product 10 with the skin to be manufactured, it is possible to avoid the influence of the rough feeling caused by the intervention of the release paper 27 on the appearance and the touch. Here, when a product with a skin with the release paper 27 intervened is attached to a vehicle, there is a risk of mold growth on the release paper 27 due to environmental changes and temperature fluctuations. However, since the release paper 27 does not intervene in the product 10 with the skin of the present embodiment, mold or the like does not occur on the release paper 27 even after the product 10 with the skin is attached to the vehicle and a long period of time has passed, improving the reliability of the product.

[0052] Also, as described above, in the tape sticking step S42, it is preferable to stick one side of the adhesive tape 14 on the surface of the skin layer 21 of the polymerized portion 28 facing the base material 50. Thereby, since the polymerized portion 28 is fixed to the base material 50, the positional accuracy of the double stitch can be maintained. In addition, it is possible to avoid the possibility that the polymerized portion 28 moves or deforms due to vibration or impact, and the risk of shape change and deterioration due to long-term use can be reduced, so that the reliability of the product can be improved.

[0053] As described above, various embodiments have been described with reference to the drawings. Needless to say, the present invention is not limited to such examples. It is obvious that those skilled in the art can conceive of various modification examples or correction examples within the scope described in the claims, and it is naturally understood that they also belong to the technical scope of the present invention. Further, within the scope not departing from the gist of the invention, the components in the above embodiments may be arbitrarily combined.

[0054] For example, as the skin layer 21, genuine leather may be used instead of synthetic leather. Further, the manufacturing method of the present embodiment is not limited to the interior parts of an automobile, and can be widely applied to products with a skin having stitches on the surface of the skin layer 21.

[0055] At least the following matters are described in this specification. Although the corresponding components and the like in the above-described embodiments are shown in parentheses, the present invention is not limited thereto.

[0056] (1) A method for manufacturing a product with a skin (product with skin 10), a skin layer (skin layer 21), a cushion layer (cushion layer 23) having cushioning properties adhered to the back surface of the skin layer, and an adhesive layer (adhesive layer 25) having one surface adhered to the cushion layer and a release paper (release paper 27) peelable from the other surface adhered thereto, a first half-cutting step (first half-cutting step S30) of cutting the release paper at a first position (first position P1) separated from one end (first end 20A) of the skin material (skin material 20) by a first distance (first distance L1), a second half-cutting step (second half-cutting step S32) of cutting the release paper at a second position (second position P2) separated from the one end of the skin material by a second distance (second distance L2) greater than the first distance, an arranging step (arranging step S33) of arranging two sheets of the skin material so that the skin layers thereof are in contact with each other and the first positions are aligned, after the arranging step, a first sewing step (first sewing step S34) of sewing together the two sheets of the skin material at the first position to form a first stitch (first stitch 11) and integrating the two sheets of the skin material with the first stitch, after the first sewing step, for each of the two sheets of the skin material, a first peeling step (first peeling step S36) of peeling the release paper provided from the one end to the first position and the release paper provided from the first position to the second position, after the first peeling step, for each of the two sheets of the skin material, a folding step (folding step S38) of folding back with the first stitch as a fulcrum and pasting and overlapping the other surface of the adhesive layer between the one end and the first position and the other surface of the adhesive layer between the first position and the second position, after the folding step, a second sewing step (second sewing step S40) of sewing together a polymerized portion (polymerized portion 28) between the first position and the second position for each of the two sheets of the skin material to form a second stitch (second stitch 12), For each of the two skin materials, a second peeling step (second peeling step S44) of peeling the release paper provided from the second position to the other end (first end) of the skin material, After the second peeling step, a pasting step (pasting step S48) of pasting the other surfaces of the adhesive layers of the two skin materials to a base material (base material 50), A method for manufacturing a product with a skin.

[0057] (1) According to (1), in the first stitching step of forming the first stitch, since the two skin materials are stitched at the first position where the release paper was cut in the first half-cut step, the needle basically penetrates through the two layers of the skin layer and the adhesive layer of each skin material. Therefore, compared with the case where the needle penetrates through the three layers of the skin layer, the adhesive layer, and the release paper as in the conventional case, it is possible to suppress the deterioration of productivity due to a decrease in the sewing speed or a deterioration in the sewing accuracy.

[0058] Also, after peeling the release paper provided from one end of the skin material to the first position and the release paper provided from the first position to the second position of the skin material in the first peeling step, since the second stitch is formed in the second stitching step, there is no need to sew a skin material having a three-layer structure as in the conventional case. Therefore, it is possible to avoid the occurrence of problems such as paper dust generated when the needle penetrates the release paper from mixing into or adhering to the sewing part.

[0059] Furthermore, since no release paper is interposed in the manufactured product with a skin, it is possible to avoid the influence of the rough feeling caused by the interposition of the release paper on the appearance and touch. Furthermore, no mold or the like is generated on the release paper, and the reliability of the product is improved.

[0060] (2) A method for manufacturing a product with a skin according to (1), In the first stitching step, at the first position, the two skin materials are stitched together along the cutting line between the release paper provided from the one end to the first position and the release paper provided from the first position to the second position. A method for manufacturing a product with a skin.

[0061] (2) According to this, since it is sewn along the cutting line of the cut release paper, it is possible to suppress the needle from penetrating the release paper. Even if the needle penetrates the release paper partially, since the distance between the end of the release paper and the penetration part is extremely small, the release paper does not remain inside by peeling the release paper in the first peeling step.

[0062] (3) A method for manufacturing a product with a skin according to (1) or (2), In the folding step, for each of the two skin materials, it is folded so that one end overlaps or is close to the second position. A method for manufacturing a product with a skin.

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

[0064] (4) A method for manufacturing a product with a skin according to (1) or (2), Before the pasting step, a tape pasting step (tape pasting step S42) of pasting one side of an adhesive tape (adhesive tape 14) on the surface of the skin layer of the polymerization part facing the base material is further provided, In the tape pasting step, the other side of the adhesive tape is pasted on the base material. A method for manufacturing a product with a skin.

[0065] (4) According to this, by pasting an adhesive tape on the surface of the skin layer of the polymerization part and pasting it on the base material via the adhesive tape, it is possible to avoid the polymerization part provided with the first stitch and the second stitch from moving or deforming due to vibration or impact. In addition, since the influence of shape change and aging deterioration due to long-term use can be suppressed, the reliability of the product can be improved.

[0066] (5) A method for manufacturing a product with a skin according to (4), In the tape pasting step, a peelable release paper (release paper 15) is adhered to the other side of the adhesive tape. Before the pasting step, a third peeling step (third peeling step S46) of peeling the release paper from the other surface of the adhesive tape is provided. Method for manufacturing a product with a skin.

[0067] According to (5), by holding the release paper of the adhesive tape until immediately before pasting it on the base material, problems due to unintentional adhesion and deterioration of productivity can be suppressed.

[0068] (6) The method for manufacturing a product with a skin according to (1) or (2), In the first half-cut step, the release paper and the adhesive layer are cut. Method for manufacturing a product with a skin.

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

[0070] (7) The method for manufacturing a product with a skin according to (1) or (2), The product with a skin is an interior part of an automobile. Method for manufacturing a product with a skin.

[0071] According to (7), highly reliable interior parts of an automobile can be manufactured.

Explanation of symbols

[0072] 11 First stitch 12 Second stitch 14 Adhesive tape 15 Release paper 20 Skin material 20A First end (one end) 21 Skin layer 23 Cushion layer 25 Adhesive layer 27 Release paper 28 Polymerized part 50 Base material L1 First distance L2 Second Distance P1 First Position P2 Second Position S30 First Half-Cut Process S32 Second Half-Cut Process S34 First Stitching Process S36 First Peeling Process S38 Folding Process S40 Second Stitching Process S42 Tape Attachment Process S44 Second Peeling Process S46 Third Peeling Process S48 Attachment Process

Claims

1. A method for producing a product with a skin, comprising the steps of: a first half-cutting step of cutting the release paper at a first position a first distance away from one end of a skin material comprising a skin layer, a cushion layer having cushioning properties bonded to a back surface of the skin layer, and an adhesive layer having one surface bonded to the cushion layer and another surface bonded to a peelable release paper; a second half-cutting step of cutting the release paper at a second position a second distance away from the one end of the skin material that is greater than the first distance; a positioning step of overlapping two of the skin materials so that the skin layers of the skin materials are in contact with each other and aligning the first positions; a first sewing step of sewing together the two sheets of the skin material at the first position after the positioning step to form a first stitch and integrating the two sheets of the skin material with the first stitch; a first peeling step of peeling off the release paper provided from the one end to the first position and the release paper provided from the first position to the second position for each of the two skin materials after the first sewing step; a folding step of folding back each of the two skin materials using the first stitch as a fulcrum after the first peeling step, so that the other surface of the adhesive layer between the one end and the first position and the other surface of the adhesive layer between the first position and the second position are attached and overlapped with each other; a second sewing step of sewing together the overlapping portions of each of the two skin materials between the first position and the second position to form a second stitch after the folding step; a second peeling step of peeling off the release paper provided from the second position to the other end of each of the two skins; and a bonding step of bonding the other surfaces of the pressure-sensitive adhesive layers of the two skin materials to a base material after the second peeling step. A method for manufacturing a product with a skin.

2. A method for producing a skinned product according to claim 1, comprising the steps of: In the first sewing step, the two sheets of the skin material are sewn together at the first position along a cutting line between the release paper provided from the one end to the first position and the release paper provided from the first position to the second position. A method for manufacturing a product with a skin.

3. A method for producing a skinned product according to claim 1 or 2, comprising the steps of: In the folding step, each of the two skin materials is folded back so that the one end overlaps or is adjacent to the second position. A method for manufacturing a product with a skin.

4. A method for producing a skinned product according to claim 1 or 2, comprising the steps of: The method further includes a tape application step of applying a surface of an adhesive tape to a surface of the skin layer of the polymerized portion facing the base material prior to the application step; In the tape application step, the other surface of the adhesive tape is applied to the base material. A method for manufacturing a product with a skin.

5. A method for producing a skinned product according to claim 4, comprising the steps of: In the tape application step, a removable release paper is adhered to the other surface of the adhesive tape, and a third peeling step of peeling the release paper from the other surface of the adhesive tape prior to the attaching step. A method for manufacturing a product with a skin.

6. A method for producing a skinned product according to claim 1 or 2, comprising the steps of: In the first half-cutting step, the release paper and the adhesive layer are cut. A method for manufacturing a product with a skin.

7. A method for producing a skinned product according to claim 1 or 2, comprising the steps of: The skinned product is an interior part of an automobile. A method for manufacturing a product with a skin.

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