Suspender manufacturing method and suspender manufacturing device
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- YKK CORP
- Filing Date
- 2025-01-22
- Publication Date
- 2026-07-30
Smart Images
Figure JP2025001962_30072026_PF_FP_ABST
Abstract
Description
Method for manufacturing a suspender and manufacturing apparatus for a suspender
[0001] The present invention relates to a method for manufacturing a suspender and a manufacturing apparatus for a suspender. More specifically, the present invention relates to a method for manufacturing a suspender for stretching a skin material covering the surface of a chair, a seat, or the like over the seat or the like and fixing the edge of the skin material at a predetermined position, and a manufacturing apparatus for the suspender.
[0002] Conventionally, in chairs used indoors, seats of vehicles, and the like, cushion materials or flexible pads (foams) are installed on parts that come into contact with the human body, such as the seat surface and the backrest, and many of them are covered with a skin material on the surface. Various structures are adopted for covering and fixing such a skin material. In particular, a skin material fastener having a structure that can easily and neatly fix the skin material and conceal the edge of the skin material externally is used.
[0003] As an attachment structure of the skin material fastener, a structure has been proposed in which a suspender is attached to an end portion of the skin material, while a clip engageable with the suspender is embedded in a skin material fixing groove of a cushion material. In particular, in the suspender, a resin-made engaged member is integrally provided along the longitudinal direction at one edge portion of a belt-like member fixed to the edge of the skin material.
[0004] As the suspender, for example, as described in Patent Document 1, and as a method for manufacturing the suspender, a pair of molding rolls are used for molding the engaged member, and a resin for the engaged member is injected into a cavity formed on the surface of the molding roll to mold the engaged member on the surface of the belt-like member (see, for example, Patent Document 2). In Patent Document 2, a step of filling a resin for forming the engaged member into each cavity of a pair of rotating molding rolls, and a pressing step of passing the belt-like member between the pair of molding rolls in accordance with the rotation of the pair of rolls and pressing the resin for forming the engaged member with the pair of molding rolls to continuously press-bond the engaged member to both surfaces of the belt-like member are described, and it is described that the bonding strength between the belt-like member and the engaged member is increased.
[0005] Furthermore, Patent Document 3 describes a method for manufacturing hook-and-loop fasteners, in which the cavities for forming the male and female snaps have undercut forming portions, and the male and female snaps are formed in a continuous manner.
[0006] International Publication WO2013 / 069114 Pamphlet Japanese Patent No. 7509574 US Patent No. 7462313 Specification
[0007] Incidentally, in order to improve the engagement force between the suspenders and the clips, it is conceivable to provide an undercut on the surface of the suspender's locking member that the clip's locking piece is locked onto.
[0008] On the other hand, when an undercut is required in a product, injection molding offers two methods: a slide method, which involves dividing the mold to remove the molded product, and a forced demolding method, which utilizes the bending deformation within the elastic deformation range of the molded product to demold it. When continuously molding fastening components such as suspenders, the slide method is difficult to apply, so the forced demolding method must be adopted. However, when the forced demolding method is used in continuous molding, deformation remains in the molded product, which may necessitate shape correction through secondary molding. In such cases, secondary molding equipment is required, leading to increased costs and other challenges.
[0009] The manufacturing method described in Patent Document 2 does not assume the molding of a locking member having an undercut. Furthermore, although the manufacturing method described in Patent Document 3 has a shape with an undercut, it is for manufacturing a low-height snap, and therefore cannot be applied to a manufacturing method for providing an undercut to a locking member of a continuously molded suspender.
[0010] The present invention has been made in view of the above-mentioned problems, and its purpose is to provide a method for manufacturing suspenders and a suspender manufacturing apparatus that does not require secondary molding, allows for easy continuous molding of a locking member having an undercut portion, and enables high engagement force with the clip.
[0011] To solve the above problems, the present invention is achieved by the following configuration: (1) A method for manufacturing a suspender (10) to be attached to the edge of a surface material (18) and to attach and fix the surface material (18) so as to cover the surface of a seat, wherein a resin locking member (14) is formed integrally on one edge portion (12a) of a strip-shaped member (12) fixed to the edge of the surface material (18) along the longitudinal direction, wherein the strip-shaped member (12) is provided with a pair of rolls (52, 53) for forming the resin locking member (14), and a cavity (54) for forming the locking member (14) is formed on the surface of the pair of rolls (52, 53), and the cavity (54) is provided with an undercut portion (76c1) for forming an undercut-shaped portion (26c1) in the locking member (14), A nozzle member (60) is provided facing the cavity (54) of the pair of rolls (52, 53) for filling the cavity (54) with the resin that forms the locking member (14). The manufacturing method comprises: a molding step of filling the cavities (54) of each of the rotating pair of rolls (52, 53) with resin to form the locking member (14) via the nozzle member (60); a pressing step of passing the strip-shaped member (12) between the pair of rolls (52, 53) in accordance with the rotation of the pair of rolls (52, 53) and pressing the resin to form the locking member (14) with the pair of rolls (52, 53) to continuously press the locking member (14) onto both sides of the strip-shaped member (12); and a peeling step of peeling the locking member (14), including the undercut-shaped portion (26c1) formed by the cavity (54), from the cavity (54) after passing through the pair of rolls (52, 53). A method for manufacturing suspenders (10), wherein the temperature of the locking member (14) in the peeling step is below the melting point of the resin, and the locking member (14) is in an elastically deformable region having rigidity that allows it to be peeled while maintaining the shape of the undercut portion (26c1) against peeling stress.(2) The locking member (14) has a central plate-like portion (20) formed along the longitudinal direction on the edge portion (12a) of the strip-shaped member (12), and a plurality of protrusions (26) having a predetermined length in the longitudinal direction that protrude from the side surface of the central plate-like portion (20) at predetermined intervals in the longitudinal direction, and the cavity (54) is provided on the surface of the pair of rolls (52, 53), and the rotation of the pair of rolls (52, 53) forms the central plate-like portion (20) on both sides of the strip-shaped member (12) and the protrusions (26) on at least one surface of the strip-shaped member (12), and the undercut-shaped portion (26c1) is formed on the protrusions (26) along the longitudinal direction, the method for manufacturing the suspenders (10) according to (1). (3) The method for manufacturing the suspenders (10) according to (2), wherein the rotation of the pair of rolls (52, 53) forms the central plate-like portion (20) and the convex portion (26) on both sides of the strip-shaped member (12) at symmetrical positions and / or shapes. (4) The method for manufacturing the suspenders (10) according to (2), wherein the undercut-shaped portion (26c1) is formed in a curved shape. (5) The method for manufacturing the suspenders (10) according to (2), wherein the convex portion (26) is formed by a slope (26b) that moves away from the side surface (20a) of the central plate-like portion (20) as it moves from the tip side to the base side of the central plate-like portion (20), and a return surface (26c) that is located on the opposite side of the slope (26b) in the width direction of the strip-shaped member (12) and forms the undercut-shaped portion (26c1), thereby forming a tapered shape toward the top (26a). (6) The longitudinal ends (26d1, 26a1) of the base (26d) and top (26a) of the protrusion (26) are formed in a curved shape, as described in (2). (7) The edge (12a) of the strip-shaped member (12) overlaps with the plurality of protrusions (26) when viewed from the thickness direction of the suspender (10), as described in (2). (8) The locking member (14) has a plurality of flange portions (21) that protrude from the side surface of the central plate-shaped portion (20) at predetermined intervals in the longitudinal direction and are formed on the surface material side of the plurality of protrusions (26), as described in (2).(9) A manufacturing apparatus for suspenders (10) to be attached to the edge of a surface material (18) and to attach and fix the surface material (18) so as to cover the surface of a seat, wherein a resin locking member (14) is formed integrally on one edge portion (12a) of a strip-shaped member (12) fixed to the edge of the surface material (18) along the longitudinal direction, the strip-shaped member (12) is provided with a pair of rolls (52, 53) for forming the resin locking member (14), the surface of the pair of rolls (52, 53) has a cavity (54) for forming the locking member (14), and the cavity (54) is provided with an undercut portion (76c1) for forming an undercut-shaped portion (26c1) in the locking member (14), A suspender manufacturing apparatus (50) is provided, facing the cavity (54) of the pair of rolls (52, 53), for filling the cavity (54) with resin to form the locking member (14); the resin injected from the nozzle member (60) into the cavity (54) is provided so as to be continuously integrally molded onto both sides of the strip member (12) by passing the strip member (12) between the rotating pair of rolls (52, 53); and the temperature of the pair of rolls (52, 53) is controlled such that the temperature of the locking member (14) when the locking member (14) is peeled off is below the melting point of the resin, and the locking member (14) becomes an elastically deformable region having rigidity that allows it to be peeled off while maintaining the shape of the undercut portion (26c1) against peeling stress. (10) The suspender manufacturing apparatus (50) according to (9), wherein the cavity (54) comprises forming parts (70d, 76a) for forming the central plate-shaped portion (20) of the locking member (14) and a plurality of protrusions (26) having a predetermined length in the longitudinal direction that protrude from the side surface of the central plate-shaped portion (20) at predetermined intervals in the longitudinal direction, and the undercut portion (76c1) is provided in the forming parts (70d, 76a) for forming the protrusions (26). (11) The suspender manufacturing apparatus (50) according to (10), wherein the forming parts (70d, 76a) of the cavity (54) are such that the protrusions (26) are in symmetrical positions and / or shapes on both sides of the locking member (14).(12) The undercut portion (76c1) is formed in a curved shape, the suspender manufacturing apparatus (50) according to (10). (13) The forming portion (70d, 76a) is formed such that the convex portion (26) is formed to taper toward the top portion (26a) by a slope (26b) formed so that it moves away from the side surface (20a) of the central plate-like portion (20) as it moves from the tip side toward the base end side of the central plate-like portion (20), and a return surface (26c) located on the opposite side of the slope (26b) in the width direction of the strip-like member (12) and on which the undercut-shaped portion (26c1) is formed, the suspender manufacturing apparatus (50) according to (10). (14) The forming portion (70d, 76a) is configured such that the longitudinal ends (26d1, 26a1) of the base (26d) and top (26a) of the convex portion (26) are formed in a curved shape, the apparatus for manufacturing suspenders (10) according to (10). (15) The edge portion (12a) of the strip-shaped member (12) overlaps with the plurality of convex portions (26) when viewed from the thickness direction of the suspenders (10), the apparatus for manufacturing suspenders (50) according to (10). (16) The locking member (14) has a plurality of flange portions (21) that protrude from the side surface of the central plate-shaped portion (20) at predetermined intervals in the longitudinal direction and are formed on the surface material side of the plurality of convex portions (26), the apparatus for manufacturing suspenders (50) according to (10).
[0012] According to the present invention, it is possible to easily perform continuous molding of a locking member having an undercut shape without requiring secondary molding, and the engagement force with the clip can be increased.
[0013] Figure 1 is a perspective view of a skin material fastener having suspenders manufactured by a suspender manufacturing method and manufacturing apparatus according to one embodiment of the present invention. Figure 2 is an exploded perspective view of the skin material fastening part. Figure 3 is a front view of the skin material fastener. Figure 4(a) is a front view of the suspenders, Figure 4(b) is a partial side view of the suspenders, and Figure 4(c) is a view of a part of the suspenders seen from the tip side. Figure 5 is a front view showing the molding roll of the suspender manufacturing apparatus according to one embodiment of the present invention. Figure 6 is a right side view showing the molding roll of the suspender manufacturing apparatus according to one embodiment. Figure 7 is a perspective view showing the molding roll of the suspender manufacturing apparatus according to one embodiment. Figure 8 is a cross-sectional view taken along line A-A in Figure 5. Figure 9 is an enlarged cross-sectional view of section B in Figure 8.
[0014] Hereinafter, an embodiment of the manufacturing method and apparatus for suspenders of this invention will be described with reference to the drawings. First, the suspenders 10 and the outer material fastener 100 having clips 30, manufactured by the manufacturing method and apparatus of this embodiment, will be described with reference to Figures 1 to 4.
[0015] As shown in Figures 1 to 4, the upholstery fastener 100 is used to fasten the upholstery material 18 of a seat to the cushion material 16 of a seat in a vehicle or the like, and comprises a suspender 10 and a clip 30 for securing the suspender 10.
[0016] The surface material 18 is leather, cloth, synthetic leather sheet, etc., that covers the surface of the cushion material 16, and the suspenders 10 can be attached to the surface material 18. The cushion material 16 is a synthetic resin foam material such as foamed polyurethane molded into the shape of a seat, and grooves 16a for fastening the surface material are formed in the cushion material 16, and the clips 30 can be installed in the grooves 16a of the cushion material 16. Therefore, when the suspenders 10 are fastened to the clips 30, the surface material 18 is stretched to a predetermined position on the surface of the cushion material 16.
[0017] In the following description of the skin material fastener 100, Figures 1 to 4 will be used to explain the directions based on the mutually orthogonal XYZ axis directions. The X-axis direction coincides with the longitudinal direction of the suspender 10 (strip-shaped member 12) and the clip 30, and coincides with the direction in which the edge of the skin material 18 and the wire member 15 extend. The Z-axis direction, which is orthogonal to the X-axis direction, coincides with the width direction of the strip-shaped member 12, the depth direction of the groove 16a of the cushioning material 16 and the holding portion 33 of the clip 30 described later, and is called the vertical direction. Furthermore, the direction orthogonal to the X-axis direction and the Z-axis direction is called the Y-axis direction, and is called the left-right direction. The direction parallel to this left-right direction is also called the lateral direction.
[0018] As shown in Figures 1 to 3, the suspenders 10 consist of a long, strip-shaped member 12 made of woven fabric or the like, and a locking member 14 provided along the longitudinal direction of the strip-shaped member 12. The locking member 14 is molded from a thermoplastic resin such as polypropylene, polyethylene, polyvinyl chloride, polystyrene, or polybutylene terephthalate, and is integrally insert-molded along the longitudinal direction at the edge 12a of the strip-shaped member 12 opposite to the edge 12b to which the outer material 18 is fixed. The locking member 14 is used to attach clips 30, etc., which will be described later. The edge 18a of the outer material 18 is sewn and fixed to the edge 12b of the strip-shaped member 12 with sewing thread.
[0019] The strip-shaped member 12 is a long, strip-shaped member with a constant width in the vertical direction (Z-axis direction) and a long length in the longitudinal direction (X-axis direction). It is formed from a woven fabric, nonwoven fabric, knitted fabric, synthetic leather, or a laminate of synthetic leather and fabric, etc., having a strength comparable to that of the surface material 18. The material constituting the strip-shaped member 12 can be selected from appropriate materials such as nylon, polyester, or acrylic.
[0020] The locking member 14, which is integrally provided along the edge 12a of the strip-shaped member 12, is formed by insert molding a thermoplastic resin so as to sandwich the edge 12a of the strip-shaped member 12, and is provided along the longitudinal direction of the strip-shaped member 12 and is formed to the same length as the strip-shaped member 12.
[0021] The locking member 14 has a surface parallel to the surface of the strip-shaped member 12 and includes a central plate-like portion 20 that is provided in an elongated shape with a constant width along the longitudinal direction on the edge portion 12a of the strip-shaped member 12. The central plate-like portion 20 is formed to continuously cover both the left and right sides and the lower end surface of the strip-shaped member 12 so as to clamp the strip-shaped member 12, and the lower end is formed in a curved shape.
[0022] Furthermore, the locking member 14 includes a plurality of protrusions 26 that project from the left and right sides of the central plate-like portion 20 in the left-right direction at predetermined intervals P1 in the longitudinal direction (see Figure 4(b)), and a plurality of flange portions 21 that project from the left and right sides of the central plate-like portion 20 in the left-right direction at the same predetermined intervals as the protrusions 26 in the longitudinal direction, closer to the surface material than the plurality of protrusions 26. The protrusions 26 and flange portions 21 are arranged symmetrically on both the left and right sides of the strip-like member 12, with symmetrical positions and shapes.
[0023] The protrusion 26 extends from the side surface of the central plate-like portion 20 to the top 26a on the left-right outer side, and is formed such that it moves away from the side surface 20a of the central plate-like portion 20 as it moves from the tip side to the base end, and has a return surface 26c on the opposite side of the inclined surface 26b in the width direction of the strip-shaped member 12, extending from the side surface 20a of the central plate-like portion 20 to the top 26a, and is formed such that it moves away from the side surface 20a of the central plate-like portion 20 as it moves from the tip side to the base end, and has a predetermined length W1 in the longitudinal direction.
[0024] The inclination angle θ2 of the straight portion of the return surface 26c with respect to the vertical direction (Z direction) is greater than the inclination angle θ1 of the inclined surface 26b with respect to the vertical direction (see Figure 4(a)). Therefore, the convex portion 26, with the inclined surface 26b and the return surface 26c, forms a tapered shape toward the apex 26a, and the return surface 26c of the convex portion 26c forms an undercut shape portion 26c1, which is a curved shape, between its straight portion and the side surface 20a of the central plate-like portion 20. The straight portion of the return surface 26c also constitutes the undercut shape portion 26c1. As a result, the undercut shape portion 26c1 is also formed on the convex portion 26 along its longitudinal direction. The predetermined length W1 of the convex portion 26 on which the undercut shape portion 26c1 is formed is shorter than the predetermined interval P1 on which the convex portions 26 are formed.
[0025] Furthermore, the pair of left and right protrusions 26, which are provided symmetrically on both the left and right sides of the strip-shaped member 12, together with the lower end of the central plate-shaped portion 20, form an arrowhead-shaped locking portion 25 when viewed from the longitudinal direction. In other words, multiple locking portions 25 are intermittently formed on the locking member 14 at predetermined intervals in the longitudinal direction.
[0026] As shown in Figure 4(a), when viewed from the thickness direction of the suspender 10, the multiple protrusions 26 overlap with the edge portion 12a of the strip-shaped member 12. Also, as shown in Figure 4(c), the longitudinal ends 26d1 and 26a1 of the base portion 26d and top portion 26a of the protrusion 26 are formed by chamfering into a curved shape.
[0027] Multiple flange portions 21 are also formed intermittently at predetermined intervals P1 along the longitudinal direction of the suspender 10. Note that the flange portions 21 may be formed only on one side of the suspender 10 in the left-right direction, or they may be provided continuously in the longitudinal direction.
[0028] In particular, as shown in Figures 3 and 4(a), the flange portion 21 is formed with a greater width in the left-right direction from the side surface 20a of the central plate-like portion 20 than the convex portion 26. The flange portion 21 extends to the top 21a in the left-right direction of the flange portion 21 and has an upper surface 21b which is a plane facing approximately upward in the vertical direction and a lower surface 21c which faces approximately downward in the vertical direction.
[0029] The lower surface 21c of the flange portion 21 is inclined away from the tip side of the suspender 10 (the tip side of the central plate-like portion 20) as it approaches the top 21a side of the flange portion 21. Also, the vertical width of the flange portion 21 decreases as it approaches the top 21a side of the flange portion 21 from the base connected to the central plate-like portion 20. As shown in Figure 4(c), the base 21d and top 21a of the flange portion 21 are also formed with chamfered edges at both ends 21d1 and 21a1 in the longitudinal direction, creating a curved shape.
[0030] Furthermore, as shown in Figures 1 to 3, the clip 30 has a plurality of clip portions 31 that engage with the locked portion 25, and a plurality of connecting portions 32 that connect the plurality of clip portions 31 in the longitudinal direction so that the plurality of clip portions 31 are aligned in the front-to-back direction.
[0031] The clip 30 is formed by extrusion molding with a metal wire member 15 inserted, and the wire member 15 extends longitudinally across a plurality of clip portions 31 and a plurality of connecting portions 32.
[0032] The clip portion 31 includes a holding portion 33 that can hold a part of the suspender 10 (in this embodiment, the locked portion 25), a pair of left and right locking pieces 37 that extend from the upper part of the holding portion 33 toward each other and can engage with the locked portion 25 of the suspender 10, and a plate-shaped clip base portion 38 that extends toward the outer surface of the holding portion 33 and can be fixed to the cushioning material 16.
[0033] In particular, as shown in Figure 3, the holding portion 33 has a bottom wall 34 located on the lower side in the vertical direction and a pair of left and right side walls 35 extending from the bottom wall 34 to the left and right and upward, and is open in the front-rear direction, and the cross-sectional shape of the plane perpendicular to the longitudinal direction is U-shaped. The outer surfaces of the bottom wall 34 and the side walls 35 can come into contact with the inner surface of the groove 16a of the cushioning material 16.
[0034] As shown in Figures 1 to 3, the pair of locking pieces 37 are provided projecting from the upper parts of the left and right side walls 35, with the tips moving downward in the vertical direction and approaching each other. The pair of locking pieces 37 are formed across the entire longitudinal width of the holding portion 33 and are longer than the pitch of the multiple engaged portions 25 of the suspender 10. The gap in the left-right direction at the tips of the pair of locking pieces 37 is smaller than the left-right width of the engaged portion 25, that is, the distance from the top 26a of one protrusion 26 to the top 26a of the other protrusion 26 in the left-right direction.
[0035] The clip base 38 extends from the upper parts of the left and right side walls 35 in the left-right and longitudinal directions. The clip base 38 is formed in a plate shape with a constant thickness in the vertical direction. The clip base 38 has an elongated hole 38a formed in it, into which the cushioning material 16 is filled by insert molding.
[0036] The connecting portion 32 connects the longitudinal ends of the bottom walls 34 of adjacent clip portions 31 in the longitudinal direction, and a wire member 15 is insert-molded inside. Therefore, the wire member 15 is inserted across the bottom walls 34 of the multiple clip portions 31 and the multiple connecting portions 32, and when the cushioning material 16 is molded, it is coupled to a magnet of a mold (not shown) to position the clip 30 relative to the mold.
[0037] Next, a suspender manufacturing apparatus 50 and its manufacturing method for insert molding a locking member 14 into a long, strip-shaped member 12 of this embodiment will be described. As shown in Figures 5 to 9, the suspender manufacturing apparatus 50 includes a pair of rolls 52 and 53 that form a resin locking member 14 on the end edge 12a of the strip-shaped member 12. Cavities 54 for forming the locking member 14 are formed on the surfaces of the pair of rolls 52 and 53, and the outer circumferential surfaces of the pair of rolls 52 and 53 face each other and are rotatably mounted by rotating shafts 56 and 57.
[0038] The cavity 54 is formed around the outer circumferential surface of a pair of rolls 52 and 53 at a predetermined pitch, and is formed to be filled with resin that forms the locking member 14. As shown in Figures 6 to 9, the shape of the cavity 54 is formed in a spatial shape corresponding to the side shape of half of the locking member 14 in the Y-axis direction, with the strip-shaped member 12 at the center, and is provided in a shape that continuously forms parts such as the forming portion 70d of the intermediate plate-shaped portion 20 of the locking member 14, the forming portion 71a of the flange portion 21, and the forming portion 76a of the convex portion 26 at a predetermined pitch.
[0039] The cavities 54 of the pair of rolls 52 and 53 are formed in a symmetrical shape with respect to the center between the pair of rolls 52 and 53, at positions facing each other. The cavities 54 of the pair of rolls 52 and 53 are aligned in phase and facing each other so that the locking member 14 to be formed is formed symmetrically with respect to the center line in the thickness direction of the strip-shaped member 12. As described above, an undercut shape portion 26c1 is formed on the return surface 26c of the convex portion 26, so as shown in Figure 9, an undercut portion 76c1 is formed in the forming portion 76a of the cavity 54 to form the undercut shape portion 26c1.
[0040] In other words, the cavity 54 forming portion 76a is configured to taper towards the bottom in accordance with the shape of the convex portion 26, and the undercut portion 76c1 is formed to have a convex curved shape and a linear shape corresponding to the undercut shaped portion 26c1.
[0041] The lateral portions of the outer surfaces of the pair of rolls 52 and 53, where the cavities 54 are formed, are opposing sides 52a and 53a where the outer surfaces are close to each other, preventing resin from leaking to the outside. Furthermore, the opposing sides 52a and 53a on one axial side of the rolls 52 and 53 sandwich the strip-shaped member 12.
[0042] Returning to Figure 5, the nozzle members 60 are positioned facing the pair of rolls 52 and 53 at a position 3 / 2 π in the opposite direction to the rotation direction of the pair of rolls 52 and 53 (3 / 4 of a turn in the opposite direction to the rotation direction of the pair of rolls 52 and 53 from the position where the pair of rolls 52 and 53 are facing each other and clamping the strip-shaped member 12). Each nozzle member 60 is in contact with the outer circumferential surface of the pair of rolls 52 and 53, and the pair of rolls 52 and 53 are rotatably arranged. The surface of the nozzle member 60 that contacts the pair of rolls 52 and 53 is formed as a curved surface 60a equal to the outer circumferential surface of the pair of rolls 52 and 53. As shown in Figures 8 and 9, the gate portion 62 of the nozzle member 60 is formed as a flat shape that is long in the axial direction of the rotation axes 56 and 57 of the pair of rolls 52 and 53, and is connected to an injection molding machine (not shown). The casting portion 64, which communicates with the gate portion 62 of the nozzle member 60 and faces the cavity 54, is formed to be longer and flatter in the axial direction of the rotation axes 56 and 57 and the Z-axis direction of the locked member 14.
[0043] Next, a method for manufacturing the suspender 10 of this embodiment will be described. The manufacturing method of the suspender 10 of this embodiment is to integrally form the engaged member 14 along the longitudinal direction on one edge portion 12a of the belt-like member 12 fixed to the edge 18a of the skin material 18. The molten resin for forming the engaged member 14 is injected into the cavity 54 of the pair of rolls 52 and 53 for forming the engaged member 14 through the nozzle member 60 (molding step). Further, with the belt-like member 12 sandwiched between the opposing side surfaces 52a and 53a of the rolls 52 and 53, the rolls 52 and 53 are opposed to each other and rotated at the same speed in opposite directions. At this time, the cavities 54 of the rolls 52 and 53 are rotated synchronously with symmetric positions and shapes with respect to each other.
[0044] The injection position of the molten resin is at a position of 3 / 2π on the upstream side in the rotation direction of the rolls 52 and 53 from the opposing positions on the surfaces of the rolls 52 and 53 for forming the engaged member 14 on the belt-like member 12. This position is appropriately set according to the rotation speed of the pair of rolls 52 and 53, the amount of molten resin, the cooling condition of the molten resin, etc., and is appropriately set between positions of 1 / 2π to 3 / 2π on the upstream side in the rotation direction of the pair of rolls 52 and 53 according to the adhesion of the molten resin to the belt-like member 12 described later.
[0045] After the molding step of the engaged member 14, as shown in FIG. 1, with the belt-like member 12 sandwiched between the opposing side surfaces 52a and 53a of the rolls 52 and 53, when the pair of rolls 52 and 53 rotate, the molten resin injected from the nozzle member 60 at a position 3 / 2π upstream rotates to the opposing positions of the rolls 52 and 53 in a state where the cavity 54 is filled. The belt-like member 12 is sandwiched between the opposing side surfaces 52a and 53a of the pair of rolls 52 and 53, and the molten resin filled in the cavity 54 is pressure-bonded to both surfaces of the belt-like member 12, and the molten resin in the cavity 54 is integrally joined to the belt-like member 12 (pressure-bonding step). Thereby, due to the rotation of the pair of rolls 52 and 53, the central plate-like portion 20, the flange portion 21, and the convex portion 26 are integrally formed symmetrically on both side surfaces of one edge portion 12a of the belt-like member 12.
[0046] The resin forming the locking member 14 is supplied to the pressing process in a state where the pressing surface is partially or entirely molten, and pressed onto the strip-shaped member 12. This is because the rolls 52 and 53 are made of metal, and the metal surface on the rolls 52 and 53 cools more easily than the surface exposed to air. Also, because cooling water circulates inside the rolls 52 and 53, the molten resin takes shape on the inside while the surface remains molten, making it easier to press.
[0047] Then, after passing through the pair of rolls 52 and 53, the multiple protrusions 26 of the locked member 14, including the undercut-shaped portion 26c1 formed by the cavity 54, are continuously peeled from the cavity 54 (peeling step). The temperature of the locked member 14 in this peeling step is below the melting point of the resin, and is in an elastically deformable region where the locked member 14 has the rigidity to maintain the shape of the undercut-shaped portion 26c1 and peel off against peeling stress. Specifically, when polypropylene is used as the resin, the temperature of the locked member 14 in the peeling step of the cavity 54 of the pair of rolls 52 and 53 is set to a temperature below the melting point of polypropylene, approximately 165°C, and above a temperature that is in an elastically deformable region with the rigidity to maintain the shape of the undercut-shaped portion 26c1 and peel off. Specifically, in a prototype in which the undercut-shaped portion 26c1 was formed without problems, the surface temperature of the locked member 14 immediately after the peeling step was measured with a non-contact sensor and was approximately 100°C. If the temperature of the locked member 14 is above the melting point of the resin, the rigidity of the undercut portion 26c1 is insufficient, making it impossible to forcibly remove it. On the other hand, if the temperature of the locked member 14 is below the temperature in the region where elastic deformation is possible, the rigidity of the undercut portion 26c1 is too high, resulting in a large forcible removal stress, and if the strength is insufficient, plastic deformation will occur.
[0048] Specifically, by adjusting the cooling power of the rolls 52 and 53 by the cooling water circulating inside the pair of rolls 52 and 53, the position of the nozzle member 60, the resin temperature inside the nozzle member 60, the cooling time based on the rotational speeds of the rolls 52 and 53, etc., the above temperature is applied in the peeling process. Thereby, the convex portion 26 having the undercut-shaped portion 26c1 can be easily peeled from the cavity 54 without deformation. After that, the resin forming the locked member 14 decreases in temperature from the temperature in the elastically deformable region and solidifies after being peeled from the cavity 54.
[0049] Also, as shown in FIG. 4(c), since both longitudinal ends 26d1 and 26a1 of the base portion 26d and the top portion 26a of the convex portion 26 are formed in a curved surface shape, in the above temperature range, the convex portion 26 having the undercut-shaped portion 26c1 can be more easily peeled from the cavity 54 without deformation.
[0050] Furthermore, since the nozzle member 60 includes a casting portion 64 for injecting resin, the belt-like member 12 is sandwiched between the opposing side surfaces 52a and 53a, and sufficient resin filled in the cavity 54 is applied to both surfaces of the belt-like member 12. Then, by the rotation of the pair of rolls 52 and 53, the resin filled in the cavity 54 is pressure-bonded to the belt-like member 12, and the resin is surely joined to the belt-like member 12.
[0051] As described above, according to the manufacturing method of the suspender 10 and the manufacturing apparatus 50 of the suspender 10 of the present embodiment, secondary molding after a series of molding steps from the molding step to the peeling step is not required, and continuous molding of the locked member 14 having the undercut-shaped portion 26c1 is easily possible, and a suspender 10 provided with a locked member having an undercut-shaped portion 26c1 and having a high locking force with the clip 30 can be manufactured.
[0052] In particular, by aligning the positions of the protrusions 26 on both sides of the central plate-like portion 20, a region is formed in which the locked member 14 becomes relatively thinner, making it easier for the locked member 14 to bend in the Y-axis direction. Furthermore, it becomes possible to easily accommodate curved sections of the groove 16a for suspending the surface material 18. By aligning the shape of the protrusions 26, the pair of locking pieces 37 of the clip 30 corresponding to the protrusions 26 can be made of the same shape, eliminating the need to match the shapes when engaging the clip 30 with the locked member 14.
[0053] Furthermore, the manufacturing method and apparatus for the suspenders of this invention are not limited to the above-described embodiments, and the shape of the locking member and the shape of the cavity of the pair of rolls that form it can be set as appropriate. In addition, the shape of the nozzle member and the shape of the casting section can also be set as appropriate to match the shape of the locking member to be molded.
[0054] As described above, the following matters are disclosed in this specification: (1) A method for manufacturing a suspender (10) to be attached to the edge of a surface material (18) and to attach and fix the surface material (18) so as to cover the surface of a seat, wherein a resin locking member (14) is formed integrally on one edge portion (12a) of a strip-shaped member (12) fixed to the edge of the surface material (18), the strip-shaped member (12) is provided with a pair of rolls (52, 53) for forming the resin locking member (14), the surface of the pair of rolls (52, 53) has a cavity (54) for forming the locking member (14), and the cavity (54) has an undercut portion (76c1) for forming an undercut-shaped portion (26c1) in the locking member (14), A nozzle member (60) is provided facing the cavity (54) of the pair of rolls (52, 53) for filling the cavity (54) with the resin that forms the locking member (14). The manufacturing method comprises: a molding step of filling the cavities (54) of each of the rotating pair of rolls (52, 53) with resin to form the locking member (14) via the nozzle member (60); a pressing step of passing the strip-shaped member (12) between the pair of rolls (52, 53) in accordance with the rotation of the pair of rolls (52, 53) and pressing the resin to form the locking member (14) with the pair of rolls (52, 53) to continuously press the locking member (14) onto both sides of the strip-shaped member (12); and a peeling step of peeling the locking member (14), including the undercut-shaped portion (26c1) formed by the cavity (54), from the cavity (54) after passing through the pair of rolls (52, 53). A method for manufacturing suspenders (10), wherein the temperature of the locking member (14) in the peeling step is below the melting point of the resin, and the locking member (14) is in an elastically deformable region having rigidity that allows it to be peeled while maintaining the shape of the undercut portion (26c1) against peeling stress. With this configuration, secondary molding is not required, continuous molding of the locking member having the undercut portion is easily possible, and the engagement force with the clip can be increased.
[0055] (2) The locking member (14) has a central plate-like portion (20) formed along the longitudinal direction on the edge portion (12a) of the strip-shaped member (12), and a plurality of protrusions (26) having a predetermined length in the longitudinal direction that protrude from the side surface of the central plate-like portion (20) at predetermined intervals in the longitudinal direction, and the cavity (54) is provided on the surface of the pair of rolls (52, 53), and the rotation of the pair of rolls (52, 53) forms the central plate-like portion (20) on both sides of the strip-shaped member (12) and the protrusions (26) on at least one surface of the strip-shaped member (12), and the undercut-shaped portion (26c1) is formed on the protrusions (26) along the longitudinal direction, the method for manufacturing the suspenders (10) according to (1). This configuration allows for easy continuous molding of a locking member having multiple protrusions, each with an undercut shape, thereby increasing the engagement force with the clip.
[0056] (3) The method for manufacturing the suspenders (10) according to (2), wherein the rotation of the pair of rolls (52, 53) forms the central plate-like portion (20) and the convex portion (26) on both sides of the strip-shaped member (12) at symmetrical positions and / or shapes. With this configuration, forming the central plate-like portion and the convex portion at symmetrical positions on both sides of the strip-shaped member makes it easier for the member to be locked to bend, and forming the central plate-like portion and the convex portion on both sides of the strip-shaped member in symmetrical shapes makes it easier to engage the member to be locked with the clip.
[0057] (4) The method for manufacturing the suspenders (10) according to (2), wherein the undercut-shaped portion (26c1) is formed in a curved shape. With this configuration, the convex portion having the undercut-shaped portion is easier to remove from the cavity, and continuous molding of the locking member becomes easier.
[0058] (5) The method for manufacturing the suspenders (10) according to (2), wherein the convex portion (26) is formed to taper toward the top portion (26a) by a slope (26b) which is formed so as it moves away from the side surface (20a) of the central plate-like portion (20) from the tip side toward the base end side of the central plate-like portion (20), and a return surface (26c) which is located on the opposite side of the slope (26b) in the width direction of the strip-like member (12) and on which the undercut-shaped portion (26c1) is formed. With this configuration, it becomes easier to continuously form a locking member having a tapered convex portion with an undercut-shaped portion on the return surface.
[0059] (6) The longitudinal ends (26d1, 26a1) of the base (26d) and top (26a) of the convex portion (26) are formed in a curved shape, as described in (2) for the method of manufacturing the suspender (10). With this configuration, it becomes easier to remove the convex portion from the cavity and easier to continuously form the locking member.
[0060] (7) The end edge (12a) of the strip-shaped member (12) overlaps with the plurality of protrusions (26) when viewed from the thickness direction of the suspender (10), as described in (2). The method for manufacturing the suspender (10). With this configuration, the bonding strength between the strip-shaped member and the locking member can be increased.
[0061] (8) The method for manufacturing the suspender (10) according to (2), wherein the locking member (14) has a plurality of flange portions (21) that are formed on the surface material side of the plurality of protrusions (26) that protrude from the side of the central plate-like portion (20) at predetermined intervals in the longitudinal direction. With this configuration, continuous molding of the locking member having a plurality of protrusions and a plurality of flange portions becomes easy.
[0062] (9) A manufacturing apparatus for suspenders (10) to be attached to the edge of a surface material (18) and to attach and fix the surface material (18) so as to cover the surface of a seat, wherein a resin locking member (14) is formed integrally on one edge portion (12a) of a strip-shaped member (12) fixed to the edge of the surface material (18) along the longitudinal direction, the strip-shaped member (12) is provided with a pair of rolls (52, 53) for forming the resin locking member (14), the surface of the pair of rolls (52, 53) has a cavity (54) for forming the locking member (14), and the cavity (54) is provided with an undercut portion (76c1) for forming an undercut-shaped portion (26c1) in the locking member (14), A suspender manufacturing apparatus (50) is provided, facing the cavity (54) of the pair of rolls (52, 53), for filling the cavity (54) with resin to form the locking member (14); the resin injected from the nozzle member (60) into the cavity (54) is provided so as to be continuously integrally molded onto both sides of the strip member (12) by passing the strip member (12) between the rotating pair of rolls (52, 53); and the temperature of the pair of rolls (52, 53) is controlled such that the temperature of the locking member (14) when the locking member (14) is peeled off is below the melting point of the resin, and the locking member (14) becomes an elastically deformable region having rigidity that allows it to be peeled off while maintaining the shape of the undercut portion (26c1) against peeling stress. This configuration eliminates the need for secondary molding, making it easy to continuously mold the locking member having an undercut shape, and allowing for a higher engagement force with the clip.
[0063] (10) The manufacturing apparatus (50) for the suspender (10) described in (9), wherein the cavity (54) comprises a forming section (70d, 76a) for forming the central plate-shaped portion (20) of the locking member (14) and a plurality of protrusions (26) having a predetermined length in the longitudinal direction that protrude from the side surface of the central plate-shaped portion (20) at predetermined intervals in the longitudinal direction, and the undercut portion (76c1) is provided in the forming section (70d, 76a) for forming the protrusions (26). With this configuration, continuous molding of the locking member having a plurality of protrusions, each having an undercut shape, is easily possible, and the engagement force with the clip can be increased.
[0064] (11) The suspender manufacturing apparatus (50) according to (10), wherein the forming portion (70d, 76a) of the cavity (54) has the convex portion (26) in a symmetrical position and / or shape on both sides of the locking member (14). With this configuration, the locking member becomes easier to bend by forming the central plate-like portion and the convex portion in symmetrical positions on both sides of the strip-shaped member, and the locking member becomes easier to engage with the clip by forming the central plate-like portion and the convex portion in a symmetrical shape on both sides of the strip-shaped member.
[0065] (12) The undercut portion (76c1) is formed in a curved shape, as described in (10) for the suspender manufacturing apparatus (50). With this configuration, the convex portion having the undercut shape is easier to remove from the cavity, and continuous molding of the locking member becomes easier.
[0066] (13) The forming portion (70d, 76a) is formed such that the convex portion (26) moves away from the side surface (20a) of the central plate-like portion (20) as it moves from the tip side to the base side of the central plate-like portion (20), and the return surface (26c) is located on the opposite side of the slope (26b) in the width direction of the strip-like member (12) and the undercut-shaped portion (26c1) is formed, thereby forming a tapered shape toward the top portion (26a), as described in (10) (50) of the suspender manufacturing apparatus (50). With this configuration, it becomes easier to continuously form a locking member having a tapered convex portion with an undercut-shaped portion on the return surface.
[0067] (14) The forming portion (70d, 76a) is configured such that the longitudinal ends (26d1, 26a1) of the base (26d) and top (26a) of the convex portion (26) are formed in a curved shape, as described in (10) (50) of the suspender manufacturing apparatus. With this configuration, it is easier to remove the convex portion from the cavity and easier to continuously form the locking member.
[0068] (15) The edge portion (12a) of the strip-shaped member (12) overlaps with the plurality of protrusions (26) when viewed from the thickness direction of the suspender (10), as described in (10) (50) suspender manufacturing apparatus. With this configuration, the bonding strength between the strip-shaped member and the locking member can be increased.
[0069] (16) The suspender manufacturing apparatus (50) according to (10), wherein the locking member (14) has a plurality of flange portions (21) formed on the surface material side of the plurality of protrusions (26) that protrude from the side of the central plate-like portion (20) at predetermined intervals in the longitudinal direction. With this configuration, continuous molding of locking members having a plurality of protrusions and a plurality of flange portions becomes easy.
[0070] 10 Suspender 12 Strip-shaped member 12a, 12b Edge portion 14 Locking member 15 Wire member 18 Surface material 20 Central plate-shaped portion 21 Flange portion 25 Locking portion 26 Protrusion 26c1 Undercut-shaped portion 30 Clip 33 Holding portion 34 Bottom wall 35 Side wall 37 Locking piece 38 Clip base portion 40 Recess 50 Suspender manufacturing apparatus 52, 53 Roll 54 Cavity 56, 57 Rotating shaft 60 Nozzle member 62 Gate portion 64 Casting portion 70d, 71a, 76a Forming portion 76c1 Undercut portion 100 Surface material fastener
Claims
1. A method for manufacturing suspenders (10) to be attached to the edge of a surface material (18) and to attach and fix the surface material (18) so as to cover the surface of a seat, wherein a resin locking member (14) is formed integrally on one edge portion (12a) of a strip-shaped member (12) fixed to the edge of the surface material (18) along the longitudinal direction, wherein a pair of rolls (52, 53) for forming the resin locking member (14) is provided on the strip-shaped member (12), a cavity (54) for forming the locking member (14) is formed on the surface of the pair of rolls (52, 53), and the cavity (54) is provided with an undercut portion (76c1) for forming an undercut-shaped portion (26c1) in the locking member (14), A nozzle member (60) is provided facing the cavity (54) of the pair of rolls (52, 53) for filling the cavity (54) with the resin that forms the locking member (14). The manufacturing method comprises: a molding step of filling the cavities (54) of each of the rotating pair of rolls (52, 53) with resin to form the locking member (14) via the nozzle member (60); a pressing step of passing the strip-shaped member (12) between the pair of rolls (52, 53) in accordance with the rotation of the pair of rolls (52, 53) and pressing the resin to form the locking member (14) with the pair of rolls (52, 53) to continuously press the locking member (14) onto both sides of the strip-shaped member (12); and a peeling step of peeling the locking member (14), including the undercut-shaped portion (26c1) formed by the cavity (54), from the cavity (54) after passing through the pair of rolls (52, 53). A method for manufacturing suspenders (10), wherein the temperature of the locking member (14) in the peeling step is below the melting point of the resin, and the locking member (14) is in an elastically deformable region having rigidity that allows it to be peeled while maintaining the shape of the undercut portion (26c1) against peeling stress.
2. The locking member (14) has a central plate-like portion (20) formed along the longitudinal direction on the edge portion (12a) of the strip-shaped member (12), and a plurality of protrusions (26) having a predetermined length in the longitudinal direction that protrude from the side surface of the central plate-like portion (20) at predetermined intervals in the longitudinal direction, and the cavity (54) is provided on the surface of the pair of rolls (52, 53), and the rotation of the pair of rolls (52, 53) forms the central plate-like portion (20) on both sides of the strip-shaped member (12) and the protrusions (26) on at least one surface of the strip-shaped member (12), and the undercut-shaped portion (26c1) is formed on the protrusions (26) over the longitudinal direction, the method for manufacturing a suspender (10) according to claim 1.
3. The method for manufacturing the suspenders (10) according to claim 2, wherein the rotation of the pair of rolls (52, 53) forms the central plate-like portion (20) and the convex portion (26) on both sides of the strip-shaped member (12) at symmetrical positions and / or shapes.
4. The method for manufacturing the suspenders (10) according to claim 2, wherein the undercut-shaped portion (26c1) is formed in a curved shape.
5. The method for manufacturing a suspender (10) according to claim 2, wherein the convex portion (26) is formed to taper toward the top portion (26a) by a slope (26b) which is formed so as it moves away from the side surface (20a) of the central plate-like portion (20) from the tip side toward the base end side of the central plate-like portion (20), and a return surface (26c) which is located on the opposite side of the slope (26b) in the width direction of the strip-like member (12) and on which the undercut-shaped portion (26c1) is formed.
6. The method for manufacturing suspenders (10) according to claim 2, wherein both longitudinal ends (26d1, 26a1) of the base (26d) and top (26a) of the convex portion (26) are formed in a curved shape.
7. The method for manufacturing the suspenders (10) according to claim 2, wherein the edge portion (12a) of the strip-shaped member (12) overlaps with the plurality of protrusions (26) when viewed from the thickness direction of the suspenders (10).
8. The method for manufacturing a suspender (10) according to claim 2, wherein the locking member (14) has a plurality of flange portions (21) formed on the surface material side of the plurality of protrusions (26) that protrude from the side surface of the central plate-like portion (20) at predetermined intervals in the longitudinal direction.
9. A manufacturing apparatus for suspenders (10) to be attached to the edge of a surface material (18) and to attach and fix the surface material (18) so as to cover the surface of a seat, wherein a resin locking member (14) is formed integrally on one edge portion (12a) of a strip-shaped member (12) fixed to the edge of the surface material (18) along the longitudinal direction, the strip-shaped member (12) is provided with a pair of rolls (52, 53) for forming the resin locking member (14), the surface of the pair of rolls (52, 53) has a cavity (54) for forming the locking member (14), and the cavity (54) is provided with an undercut portion (76c1) for forming an undercut-shaped portion (26c1) in the locking member (14), A suspender manufacturing apparatus (50) is provided, facing the cavity (54) of the pair of rolls (52, 53), for filling the cavity (54) with resin to form the locking member (14); the resin injected from the nozzle member (60) into the cavity (54) is provided so as to be continuously integrally molded onto both sides of the strip member (12) by passing the strip member (12) between the rotating pair of rolls (52, 53); and the temperature of the pair of rolls (52, 53) is controlled such that the temperature of the locking member (14) when the locking member (14) is peeled off is below the melting point of the resin, and the locking member (14) becomes an elastically deformable region having rigidity that allows it to be peeled off while maintaining the shape of the undercut portion (26c1) against peeling stress.
10. The suspender manufacturing apparatus (50) according to claim 9, wherein the cavity (54) comprises forming parts (70d, 76a) for forming the central plate-shaped portion (20) of the locking member (14) and a plurality of protrusions (26) having a predetermined length in the longitudinal direction that protrude from the side surface of the central plate-shaped portion (20) at predetermined intervals in the longitudinal direction, and the undercut portion (76c1) is provided in the forming parts (70d, 76a) for forming the protrusions (26).
11. The suspender manufacturing apparatus (50) according to claim 10, wherein the forming portion (70d, 76a) of the cavity (54) has the protrusion (26) in a position and / or shape symmetrical on both sides of the locking member (14).
12. The suspender manufacturing apparatus (50) according to claim 10, wherein the undercut portion (76c1) is formed in a curved shape.
13. The forming portion (70d, 76a) is formed such that the convex portion (26) is formed to taper toward the top portion (26a) by a slope (26b) formed such that the convex portion (26) moves away from the side surface (20a) of the central plate-like portion (20) as it moves from the tip side toward the base end side of the central plate-like portion (20), and a return surface (26c) located on the opposite side of the slope (26b) in the width direction of the strip-like member (12) and on which the undercut-shaped portion (26c1) is formed. The suspender manufacturing apparatus (50) according to claim 10.
14. The forming portion (70d, 76a) is configured such that the longitudinal ends (26d1, 26a1) of the base (26d) and top (26a) of the convex portion (26) are formed in a curved shape, the suspender manufacturing apparatus (50) according to claim 10.
15. The suspender manufacturing apparatus (50) according to claim 10, wherein the edge portion (12a) of the strip-shaped member (12) overlaps with the plurality of protrusions (26) when viewed from the thickness direction of the suspender (10).
16. The suspender manufacturing apparatus (50) according to claim 10, wherein the locking member (14) has a plurality of flange portions (21) formed on the surface material side of the plurality of protrusions (26) that protrude from the side surface of the central plate-shaped portion (20) at predetermined intervals in the longitudinal direction.