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 layer. 【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, and a second sewing step S40 of forming a second stitch 12 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 layer.

Background Art

[0002] As a product with a skin layer in which the surface of a base material is covered with a skin material, there are, for example, 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 attached to the surface of the base material in a state where the cushion layer is 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 attaching 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 the back surface thereof and the skin material wound in a state having a certain width is sequentially fed out to have 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 in a state where their surface sides are aligned with each other, leaving a region where stitches can be formed between the half-cut position and the end of each skin material, so as to be integrated, With the stitches sewn for integrating the pair of the 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, comprising peeling off the release paper of the region with a larger area from the adhesive layer adhered to the pair of skin materials with the position of the half cut as a boundary, and adhering so as to cover the base material with the skin material integrated via the adhesive layer of the double-sided adhesive sheet.

[0005] The invention described in Patent Document 1 forms a double stitch by sewing and integrating two skin materials with the 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 the 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 part, 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 a release layer.

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 layer at a first position that is separated from one end of a skin material by a first distance, the skin material including a skin layer and an adhesive layer provided on the back side of the skin layer and having a release layer that can be peeled off adhered to the other surface opposite to one surface on the skin layer side; a second half-cut step of cutting the release layer at a second position that is separated from the one end of the skin material by a second distance greater than the first distance; an arrangement step 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; a first stitching step of stitching the two sheets of the skin material at the first position after the arrangement 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 the release layer provided from the one end to the first position and the release layer provided from the first position to the second position for each of the two sheets of the skin material after the first stitching step; a folding step of folding each of the two sheets 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; a second stitching step of stitching a polymerized portion between the first position and the second position for each of the two sheets of the skin material after the folding step to form a second stitch.

Advantages of the Invention

[0012] According to the present invention, it is possible to suppress defects caused by sewing a release layer during the manufacture of a product with a skin layer.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

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 the present embodiment will be described with reference to FIGS. 1 and 2.

[0015] The target of the skin-attached product is typically interior and exterior automotive parts such as an automotive instrument panel, console, door trim, glove box, pillar garnish, etc., but is not limited thereto, and may be, for example, interior and exterior building parts. In the following description, a glove box of an automobile will be described as an example of the skin-attached product.

[0016] As shown in FIG. 1, a skin-attached product 10 is used for a glove box 1 disposed in a vehicle compartment 2 of an automobile. As shown in FIGS. 2(A) and 2(B), the skin-attached product 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 in the example shown in FIG. 2, two skin materials 20 are integrated with one first stitch 11, but 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 forming the skeletal part of the skin-attached product 10 and ensures the rigidity of the skin-attached 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 skin material 20 is a member that forms the outer shell (surface layer) portion 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, easily adhering with light pressure, and leaving no adhesive residue on the surface of the adherend after peeling." In other words, it is "a substance that fastens multiple materials by wetting and anchoring properties 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 cross-linking the components to form a solid." Thus, although they are originally different, they are common in that they fasten multiple materials, and generally, they may not be clearly distinguished in some cases. 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 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 knitted 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 tactile sensation 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, 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 two skin materials 20 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 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 various designs can be adopted not limited to being arranged in a straight line.

[0026] Unlike the first stitch 11, the second stitch 12 is exposed outside the epidermal 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 product 10 with an epidermis 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 epidermal material 20 with a predetermined die (for example, a Thomson die) in order to cut the epidermal 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 this 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 with one side adhered to the cushion layer 23 and a peelable release paper 27 adhered to the other side. 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 with one side adhered to the cushion layer 23 and a peelable release paper 27 adhered to the other side. The release paper 27 is composed of a paper serving as a base material and a release layer in contact with the other side 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 when manufacturing the product 10 with skin, it is supplied from the roller and cut to a predetermined length. 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 the first position P1 that is separated from the first end 20A of the skin material 20 by the 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 the folding described later while considering the design.

[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. However, as shown in FIG. 4(B), it is preferable that all of the adhesive layer 25 is cut. This can prevent the needle from passing through the adhesive layer 25 and passing between the cut adhesive layers 25 when sewing together the two skin materials 20 in the first sewing step S34 described later, thus suppressing the adhesion of the adhesive layer to the needle.

[0035] (Second half-cutting step) In the second half-cutting step S32, the release paper 27 is cut at a second position P2 that is farther than a first distance L1 from the first end 20A of the skin material 20 by a second distance L2 that is greater than the first distance L1. The second distance L2 is approximately twice the first distance L1 or a distance longer than twice 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. However, as shown in FIG. 4(B), it is preferable that all of the adhesive layer 25 is cut. This allows the depth of the half-cut in the first half-cutting step S30 to be aligned, making it easier to adjust the half-cut.

[0036] The first half-cutting step S30 and the second half-cutting 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 that have been half-cut at the first position P1 and the second position P2 through the first half-cutting step S30 and the second half-cutting step S32 are overlapped so that the skin layers 21 are in contact with each other, and are arranged 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 it is held so that the two skin materials 20 do not shift during sewing.

[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 sewing step) Subsequently, in the first sewing step S34, as shown in FIG. 4(D), the two skin materials 20 are sewn and integrated at the first position P1 using a sewing device such as a sewing machine. More specifically, the needle of the sewing device is relatively moved along the first position P1 in the boundary extension direction (the front-back direction in FIG. 4), and the two skin materials 20 are sewn 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 sewing 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 developed 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 a 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 extension direction (the front-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 attachment step S42, as shown in FIG. 5(C), an adhesive tape 14 is attached to the back surface of the overlapping portion 28 of the two skin materials 20, that is, the skin layer 21 on the first end portion 20A side of the overlapping portion 28 formed by folding back the first end portion 20A. It is preferable to attach 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 detachably adhered to the surface of the adhesive tape 14 opposite to the surface adhered 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 second end portion (not shown) 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 attached to the back surface of the overlapping portion 28 in the tape attachment 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] (Attachment step) In the attachment 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 attached 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 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 stitched along the cutting line of the cut release paper 27, so the needle basically penetrates only the two layers of the skin layer 21 and the adhesive layer 25 of each skin material 20. Therefore, 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 the sewing speed or deterioration of the 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 stitched 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 such as paper powder generated when the needle penetrates the release paper 27 from mixing 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, so 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 manufactured product 10 with the skin, it is possible to avoid the influence of the rough feeling caused by the intervention of the release paper 27 on the appearance and touch. Here, when a product with a skin in which the release paper 27 is interposed 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 a long period of time when the product 10 with the skin is attached to the vehicle, and the reliability of the product is improved.

[0052] Also, as described above, in the tape sticking step S42, it is preferable to stick one surface 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 it is possible to reduce the risk of shape change and deterioration due to long-term use, 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 to the other surface, 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 of the two sheets of the skin material 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 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 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), and 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 method, 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, it is not necessary to stitch the skin material having a three-layer structure as in the conventional method. Therefore, it is possible to avoid the occurrence of problems caused by the paper powder generated when the needle penetrates the release paper from being mixed 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 the 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 portion of the release paper and the penetration portion 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, it is possible to easily peel the release paper provided from the second position to the other end of the skin material in the second peeling step.

[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 surface 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 surface 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 surface of the adhesive tape. Before the pasting step, there is provided a third peeling step (third peeling step S46) of peeling the release paper from the other surface of the adhesive tape. 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, it is possible to suppress defects due to unintentional adhesion and deterioration of productivity.

[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 it is possible to suppress the adhesion of the adhesive layer to the needle.

[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), it is possible to manufacture highly reliable interior parts of an automobile.

Explanation of reference numerals

[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 manufacturing a product with a skin, comprising: a first half-cut step of cutting the release layer at a first position separated from one end of the skin material by a first distance, the skin material comprising a skin layer and an adhesive layer provided on the back side of the skin layer and having a releasable release layer adhered to the other surface opposite to the one surface on the skin layer side; a second half-cut step of cutting the release layer 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 sheets 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 the two sheets of the skin material at the first position to form a first stitch and integrating the two sheets of the skin material with the first stitch after the arranging step; a first peeling step of peeling the release layer provided from the one end to the first position and the release layer provided from the first position to the second position for each of the two sheets of the skin material after the first sewing step; a folding step of folding each of the two sheets of the skin material about the first stitch 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 the overlapping portions between the first position and the second position for each of the two sheets of the skin material to form a second stitch after the folding step, A method for manufacturing a product with a skin.

2. The method for manufacturing a product with a skin according to claim 1, further comprising: a second peeling step of peeling the release layer provided from the second position to the other end of the skin material for each of the two sheets of the skin material; an attaching step of attaching the other surface of the adhesive layer of the two sheets of the skin material to a substrate after the second peeling step, A method for manufacturing a product with a skin.

3. The method for manufacturing a product with a skin according to claim 1 or 2, wherein: in the first sewing step, the two sheets of the skin material are sewn along the cutting line between the release layer provided from the one end to the first position and the release layer provided from the first position to the second position at the first position. A method for manufacturing a product with a skin.

4. The method for manufacturing a product with a skin according to claim 1 or 2, wherein: In the folding-back step, for each of the two skin materials, the one end is folded back so as to overlap or be close to the second position. Method for manufacturing a product with a skin.

5. The method for manufacturing a product with a skin according to claim 2, further comprising a tape attaching step of attaching one surface of an adhesive tape having a release layer that can be peeled off on the other surface to the surface of the skin layer of the overlapping portion facing the base material. Method for manufacturing a product with a skin.

6. The method for manufacturing a product with a skin according to claim 5, comprising a third peeling step of peeling the release layer from the other surface of the adhesive tape before the attaching step. Method for manufacturing a product with a skin.

7. The method for manufacturing a product with a skin according to claim 1 or 2, wherein in the first half-cut step, the release layer and the adhesive layer are cut. Method for manufacturing a product with a skin.

8. The method for manufacturing a product with a skin according to claim 1 or 2, wherein the product with a skin is an interior part of an automobile. Method for manufacturing a product with a skin.

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