JP2010188710A - Method for manufacturing member with stitch pattern - Google Patents

Abstract

A method of manufacturing a member having a stitch pattern of a color different from the surface is provided on the surface.
Laser light is irradiated toward the surface of a synthetic resin base material 10 that has been molded into a required shape in the previous step to discolor a surface 12 of the base material 10 to form a thread portion 20 of a stitch pattern ST. At the same time, a needle hole portion 22 carved in a concave shape from the surface 12 is formed at the end of the thread portion 20. Note that an additive that changes color or develops color when irradiated with laser light is added to the resin material for forming the substrate 10.
[Selection] Figure 5

Description

  The present invention relates to a method of manufacturing a synthetic resin member having a stitch pattern on the surface.

  For example, vehicle interior members (instrument panels, floor consoles, etc.) placed in the passenger compartment of automobiles are mainly composed of a rigid base material injection-molded from a resin material such as polyethylene or polypropylene (single layer type) In addition, a material in which a soft skin material formed from a resin material such as vinyl chloride or polyurethane is disposed on the surface of the base material (multi-layer type) has been put into practical use. In the single-layer type vehicle interior member, the base material is exposed to the outside, and the surface of the base material constitutes the design surface of the vehicle interior member. In the multilayer vehicle interior member, the skin material is exposed to the outside, and the surface of the skin material constitutes the design surface of the vehicle interior member.

  Some of the vehicle interior members have a genuine leather skin obtained by sewing a plurality of skin pieces made of genuine leather with a thread on the surface of a base material to improve the texture. However, since the genuine leather skin is expensive and the number of materials is limited, the genuine leather skin is actually used only in some luxury automobiles. Therefore, in most vehicle interior parts, the surface exposed to the passenger compartment of the base material or skin material is provided with a textured pattern that resembles the surface pattern of genuine leather, thereby improving the texture of the leather. Yes.

  Moreover, the base material and skin material which formed the stitch pattern which reproduces the said thread | yarn used for sewing on the surface are also implemented. In addition, in order to provide a stitch pattern on the surface of the base material or the surface of the skin material, the stitch pattern is reversed on the molding surface of the molding die for base material molding or the molding die for skin material molding in the same manner as the texture pattern. By providing the uneven portions of the shape, the stitch pattern is reversed and formed on the surface of the formed base material or skin material. A method for manufacturing a member (skin material) provided with a stitch pattern is disclosed in Patent Document 1, for example. Further, Patent Document 2 discloses a method for manufacturing a member (skin material) provided with a stitch pattern made of real yarn.

JP 2005-125845 A JP 2008-49835 A

  In the method of manufacturing a member provided with a stitch pattern disclosed in Patent Document 1, a thread portion of the stitch pattern is formed from a part of a resin material for molding a base material or a skin material. For this reason, since a thread part becomes the same color as the surface of a base material or a skin material, a stitch pattern does not stand out easily, and there exists a subject that this stitch pattern does not look like a real stitch. Moreover, in the manufacturing method of the member which provided the stitch pattern disclosed by patent document 2, there exists a subject which cannot provide a stitch pattern in a thick and hard base material.

  Accordingly, an object of the present invention is to provide a method for manufacturing a member having a surface provided with a stitch pattern having a color different from that of the surface.

In order to solve the problem and achieve the intended purpose, the invention according to claim 1
A method for producing a synthetic resin member having a stitch pattern on the surface,
By irradiating the surface of a synthetic resin member that changes color by irradiation with laser light, laser light is applied to discolor the surface to form a thread portion of the stitch pattern, corresponding to the end of the yarn portion, A needle hole portion of the stitch pattern is formed by carving a concave shape from the surface with a laser beam.

  Therefore, according to the first aspect of the present invention, a stitch pattern having a color different from the color of the surface is provided by irradiating the surface with laser light and changing the irradiated portion of the racer light to a color different from the surface. Can be manufactured. In addition, since the needle hole portion is formed in a concave shape corresponding to the end portion of the thread portion by the laser beam, the thread portion of the stitch pattern appears to bite into the surface of the member, and the texture of the member is improved. obtain.

The invention described in claim 2
The gist of the invention is to form a thread pattern on the yarn portion by irradiation with the laser beam.
Therefore, according to the second aspect of the present invention, since the thread portion looks like a real thread, the stitch pattern can more closely resemble a real stitch.

The invention according to claim 3
A gist of the invention is that the needle hole portion is formed in a contour shape that is equal to or smaller than the yarn width dimension of the yarn portion.
Therefore, according to the invention which concerns on Claim 3, the edge part of the thread part in a stitch pattern can be made to seem to bite into the surface of a member, and the texture of a member can be improved.

The invention according to claim 4
The gist is that the member is molded by adding an additive that changes color or develops color when irradiated with laser light.
Therefore, according to the invention which concerns on Claim 4, the choice degree of the color of a thread | yarn part improves by changing the kind of additive added to a resin material.

The invention described in claim 5
The gist is to form the yarn portion by moving and irradiating laser light obliquely with respect to the longitudinal direction of the yarn portion.
Therefore, according to the fifth aspect of the present invention, it is possible to easily form a twist pattern (yarn pattern) like a real thread in each thread portion, and to make the stitch pattern more resemble a real stitch.

  According to the method for manufacturing a member provided with a stitch pattern according to the present invention, the surface is irradiated with laser light, and the irradiated portion of the racer light is changed to a color different from that of the surface. It is possible to manufacture a member provided with a stitch pattern consisting of the yarn portion. Further, since the needle hole portion is formed in a concave shape corresponding to both ends of the thread portion by the laser beam, the thread portion of the stitch pattern appears to bite into the surface of the member, and the texture of the member can be improved.

It is process drawing which shows schematically the manufacturing method of the base material which is the member made from a synthetic resin which provided the stitch pattern of the Example. (a) is a partial cross-sectional view showing a state in which a base material is injection-molded from a resin material to which an additive that changes color or develops color upon irradiation with laser light, and (b) is a portion of the molded base material. It is a perspective view. It is a schematic block diagram of the laser marking apparatus used for the manufacturing method of an Example. (a) is a perspective view showing a state in which the first thread portion of the stitch pattern is formed by laser light, and (b) shows the needle hole portion subsequent to the formation of the first thread portion. It is a perspective view which shows the state currently formed. (a) is a perspective view which shows the state which forms the 2nd thread part following formation of the 1st needle hole part, (b) is an alternating thread part and needle hole part. It is a perspective view which shows the state currently formed in order. (a) is a perspective view which partially shows the surface of the base material in which formation of the stitch pattern was completed, and (b) is a sectional view taken along the line VI-VI of (a). It is a fragmentary perspective view which shows the 1st modification of the manufacturing method of the member which provided the stitch pattern, Comprising: (a) shows forming each thread part sequentially along the stitch formation plan part first, (b) Indicates that needle hole portions are sequentially formed between the formed yarn portions. It is a fragmentary perspective view which shows the 2nd modification of the manufacturing method of the member which provided the stitch pattern, Comprising: (a) shows forming each needle hole part sequentially along the stitch formation plan part first, (b) ) Indicates that thread portions are sequentially formed between the formed needle hole portions. (a) is a fragmentary perspective view which shows the skin material which is a synthetic resin member which provided the stitch pattern on the surface, (b) is the IX-IX sectional view taken on the line of (a).

  Next, a method for manufacturing a member provided with a stitch pattern according to the present invention will be described below with reference to the accompanying drawings by giving a preferred embodiment.

  FIG. 1 is a process diagram schematically showing a method of manufacturing a member provided with a stitch pattern according to an embodiment. In the embodiment, the surface 12 of the hard base material 10 injection-molded from a resin material such as polyethylene or polypropylene is irradiated with the laser beam LB by the laser marking device LM, so that the stitch pattern ST having a color different from that of the surface 12 is obtained. 3 shows a method of manufacturing the base material 10 provided with the material. That is, an additive that changes color or develops color when irradiated with the laser beam LB is added to the resin material that forms the substrate 10, and the substrate 10 itself is discolored when irradiated with the laser beam LB. A stitch pattern ST having a color different from that of the surface 12 is provided on the base material 10. In addition, the additive which changes color by irradiation of the laser beam LB may be compounded into a resin material, or may be dry blended into the resin material before the base material 10 is molded.

  As the additive, a marking material that changes color or develops color upon irradiation with laser light, a mica pigment, an iron oxide pigment such as Bengala or Tetsuguro, carbon black, or the like can be used. In particular, the color former component in the pigment contains metal ions, and when irradiated with a laser, the crystal structure of the ions changes or the amount of hydration in the crystals changes, and the composition of the components changes chemically. In this case, it is preferable that the color developing agent develops a phenomenon by increasing the concentration of the color developing agent.

  As shown in FIG. 3, the laser marking device LM used to form the stitch pattern of the embodiment includes a laser generation unit 40 that generates Nd: YAG laser light, a first galvanometer mirror 44, and a second galvanometer mirror. 46 and a laser marking head 42 incorporating a planarizing lens 48, a control unit, a controller (not shown), and the like. The first galvanometer mirror 44 and the second galvanometer mirror 46 can be displaced in the two axial directions (X-axis and Y-axis) under the control of the control unit. That is, the laser beam LB generated by the laser generation unit 40 is adjusted in the direction of irradiation by controlling the posture of the first galvanometer mirror 44 and the second galvanometer mirror 46, and the focal length is adjusted by the planarizing lens 48. Under adjustment, irradiation is performed toward the stitch forming scheduled portion 14 provided on the surface 12 of the base material (synthetic resin member) 10. Since the laser marking device LM is a known device that has been put into practical use, a detailed description of a specific configuration, function, and the like is omitted. Further, as the laser marking device, it is possible to use a device that generates CO2 laser light or a device that generates YVO4 laser light.

  Next, the manufacturing method of the base material 10 provided with the stitch pattern ST of the embodiment will be described with reference to FIGS.

  First, as shown in FIG. 1, a pigment that changes color or develops color when irradiated with the laser beam LB is added to a resin material (polyethylene, polypropylene, or the like) that forms the substrate 10. In addition, the kind and addition amount of the pigment are determined by the color of the base material 10 and the color of the yarn portion 20 of the stitch pattern ST. In Examples, as the pigment, a mixture of Bengala, ultramarine blue (pigment), carbon black and titanium dioxide in a required ratio was used.

  Next, as shown in FIG. 2, the resin material to which the pigment is added is injected into a cavity 52 of a base material molding die (injection molding die) 50, and the base material 10 having a required shape is injection molded. As a result, the pigment is contained in the molded base material 10, and a stitch forming scheduled portion 14 that is flat overall is formed at a required position on the surface 12 of the base material 10.

  Next, as shown in FIG. 3, the molded base material 10 is set on the installation base 49 of the laser marking device LM so that the stitch forming scheduled portion 14 is located in the laser light irradiation region. In addition, the control unit of the laser marking device LM is preliminarily stored with an operation program based on the shape and size of the thread portion 20 and the needle hole portion 22 of the stitch pattern ST, the extension length, the extension shape, and the like of the stitch pattern ST. Enter it.

  By the operation of the laser marking device LM based on the operation program, the laser beam LB output from the laser generation unit 40 is reflected by the first galvanometer mirror 44 and the second galvanometer mirror 46 which are displaced in posture, and then the planarized lens 48 is moved. Then, it is irradiated in a predetermined irradiation pattern toward the stitch forming scheduled portion 14. In the embodiment, when the stitch pattern ST is formed, the thread portions 20 and the needle hole portions 22 are alternately provided sequentially by the movement of the installation base 49 or the movement of the laser marking head 42. That is, in the embodiment, as shown in FIGS. 4A and 5A, a “thread part forming operation” in which the pigment part is discolored or colored by irradiation with the laser light LB to form the thread part 20, and the laser light. The stitch pattern ST is formed while alternately repeating the “needle hole portion forming operation” for forming the concave needle hole portion 22 by LB irradiation.

  Each thread portion 20 is formed in a different color from the surface 12 of the base material 10 by the color change or coloration of the pigment contained in the portion irradiated with the laser beam LB of the stitch forming scheduled portion 14. Each thread portion 20 can be given a stitch pattern or the like like a real thread by program-controlling the irradiation mode of the laser beam LB. For example, when the yarn portion 20 is formed by moving and irradiating laser light obliquely with respect to the longitudinal direction of the yarn portion 20, a twisted pattern (yarn pattern) like a real yarn can be formed realistically and easily.

  Further, each needle hole portion 22 is formed in a concave shape on the surface 12 of the substrate 10 by gradually engraving and excising the portion irradiated with the laser beam LB of the stitch forming scheduled portion 14 into a dot shape by laser beam irradiation. Formed. The needle hole portion 22 provided corresponding to the end portion of the thread portion 20 is orthogonal to the longitudinal direction of the thread portion 20 (the direction connecting the needle hole portions 22 and 22 provided corresponding to both ends of the thread portion 20). The width dimension W2 of the needle hole portion 22 in the direction (thread width direction) is formed in a circular contour shape smaller than the thread width dimension W1 in the thread width direction of the thread portion 20 (FIG. 4B). As a result, both ends of the thread portion 20 can appear to have bite into the surface 12 of the base material 10, and the texture of the base material 10 can be improved. In addition, the width dimension W2 of the needle hole part 22 should just be below the thread width dimension W1 of the thread part 20. FIG.

  Then, a predetermined number of thread portions 20 are intermittently formed on the surface 12, and needle hole portions 22 are formed in a recessed manner corresponding to both ends of each thread portion 20, and each thread portion 20 and each needle hole portion are formed. When the forming operation 22 is completed, the operation of the laser generating unit 40 is stopped and the irradiation of the laser beam LB is stopped, whereby the forming operation of the stitch pattern ST on the substrate 10 is completed (FIG. 6).

  Therefore, according to the manufacturing method of the base material 10 provided with the stitch pattern ST of the embodiment, the laser beam LB is irradiated with the laser beam LB in a predetermined irradiation pattern toward the stitch forming scheduled portion 14 on the surface 12. The base material 10 in which the stitch pattern ST of a color different from the color of the surface 12 is provided on the surface 12 can be manufactured by changing the color of the portion. Thereby, since the stitch pattern ST appears conspicuously on the surface 12 of the base material 10, the base material 10 with improved texture can be manufactured. Further, since the needle hole portions 22 having a width dimension W2 equal to or smaller than the thread width dimension W1 of the thread portion 20 are formed in a concave shape on both sides of each thread portion 20 by irradiation with the laser beam LB, each thread of the stitch pattern ST The stitch pattern ST can be made to resemble a real stitch by making the portion 20 appear to bite into the surface 12 of the substrate 10.

  The marking speed by the laser marking device LM can be increased to about 5000 mm / second. Therefore, since each thread part 20 and each needle hole part 22 of the stitch pattern ST can be formed in a short time, the manufacturing cost of the base material 10 can be suppressed. Furthermore, the shape and size of the thread portion 20 and the needle hole portion 22 can be changed quickly and flexibly by changing the operation program input to the control unit of the laser marking device LM, so that various stitch patterns ST can be easily obtained. Can be formed. In addition, by changing the type of additive added to the resin material, the color of the thread portion 20 can be easily changed, and even if there are a plurality of types of base materials 10 having different colors, each base material 10 Each time, a stitch pattern ST having a different color from the surface 12 can be formed on the surface 12.

(Example of change)
The manufacturing method of the member provided with the stitch pattern of the present application relates to the formation of the stitch pattern ST on the surface 12, and the formation order of each thread portion 20 and each needle hole portion 22 is not limited to the above embodiment.
(1) FIG. 7 is an explanatory perspective view showing a first modified example relating to a method of manufacturing a member provided with a stitch pattern. That is, in the manufacturing method of the first modified example, first, only each yarn portion 20 is intermittently provided along the stitch forming scheduled portion 14 (FIG. 7 (a)), and then the longitudinal direction of each yarn portion 20 formed next. By providing each needle hole portion 22 in a portion adjacent to the end portion (between each yarn portion 20) (FIG. 7B), the base material 10 provided with the stitch pattern ST on the surface 12 is manufactured. ing. Thus, even if each thread portion 20 and each needle hole portion 22 are separately formed, the stitch pattern ST can be suitably formed on the surface 12 of the substrate 10.
(2) FIG. 8 is an explanatory perspective view showing a second modified example relating to a method of manufacturing a member provided with a stitch pattern. That is, in the manufacturing method of the second modified example, only the needle hole portions 22 are first provided at the required intervals along the stitch forming scheduled portions 14 (FIG. 8A), and then the formed needle hole portions 22 are formed. By providing each thread portion 20 between them (FIG. 8B), the base material 10 having the surface 12 provided with the stitch pattern ST is manufactured. Thus, even if each needle hole portion 22 and each thread portion 20 are separately formed, the stitch pattern ST can be suitably formed on the surface 12 of the base material 10.

(3) If the width dimension W2 of the needle hole portion 22 is equal to or smaller than the thread width dimension W1 of the thread portion 20, the contour shape is not limited to the circular shape exemplified in the above embodiment, but an elliptical shape, a polygonal shape, or a complicated shape. It may be formed in an annular spline curve shape or the like.

(4) The synthetic resin member targeted by the present application is not limited to the hard base material 10 shown in the embodiment, and is disposed on the surface of the hard base material 10 or the like as shown in FIG. A soft skin material 30 may be used. This skin material 30 is vacuum-molded from a resin sheet material (resin material) such as vinyl chloride by a vacuum molding die, slush-molded from a resin powder (resin material) by a powder slush molding die, or a spray molding die. Those formed by spray molding from urethane (resin material) and those molded by RIM (Reaction Injection Molding) from urethane (resin material) by an injection mold.

(5) The manufacturing method of the member provided with the stitch pattern according to the present invention is not limited to the base material or the skin material in the vehicle interior member, but is a member constituting furniture products such as sofas and chairs, and daily commodities such as shoes and bags. It is possible to form a stitch pattern on a member made of synthetic resin that constitutes various products, such as a member that constitutes.

10 base material (member), 12 surface, 20 thread part, 22 needle hole part, 30 skin material (member)
32 Surface, ST stitch pattern, LB laser beam, W1 Thread width dimension of thread part W2 Width dimension of needle hole part

Claims (5)

A method for producing a synthetic resin member having a stitch pattern on the surface,
By irradiating the surface of a synthetic resin member that changes color by irradiation with laser light, laser light is applied to discolor the surface to form a thread portion of the stitch pattern, corresponding to the end of the yarn portion, A method of manufacturing a member provided with a stitch pattern, wherein the needle hole portion of the stitch pattern is formed by engraving a concave shape from the surface with a laser beam.   The method for manufacturing a member provided with a stitch pattern according to claim 1, wherein a thread pattern is formed on the thread portion by irradiation with the laser beam.   The said needle hole part is a manufacturing method of the member provided with the stitch pattern of Claim 1 or 2 formed in the outline shape used as the thread width dimension or less of the said thread part.   The manufacturing method of the member which provided the stitch pattern as described in any one of Claims 1-3 which adds the additive which discolors or color-forms by irradiating a laser beam to the resin material.   The manufacturing method of the member which provided the stitch pattern as described in any one of Claims 1-4 which forms the said thread part by moving and irradiating a laser beam diagonally with respect to the longitudinal direction of this thread part.

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