Abstract:
A method for manufacturing a covered string-like object, the method comprising a placement step of placing a string-like object on a sheet-like flexible backing, a sewing step of sewing the string-like object to the backing with an embroidery material, and a separation step of separating the backing from the string-like object. According to the method for manufacturing a string-like object, a string-like object can be easily and reliably covered with an embroidery material.

Description:
TECHNICAL FIELD 
     The present invention relates to a method for manufacturing a covered string-like object, and more specifically, relates to a method for manufacturing a covered string-like object obtained by covering a string-like object such as an electrical cord with an embroidery material. 
     BACKGROUND ART 
     Research has been conducted on enhancing the aesthetic characteristics of electrical cords such as earphone cords, power cords, and extension cords by covering such cords with cloth, thread, or the like (for example, Patent Literatures 1 and 2). A method in which cloth, string, or the like is adhered to an electrical cord, a method in which thread, leather string, or the like is wound around or sewn to an electrical cord, and like methods are known examples of specific methods for covering electrical cords. 
     CITATION LIST 
     Patent Literature 
     Patent Literature 1: JP 2011-155623A 
     Patent Literature 2: JP 2012-20416A 
     SUMMARY OF INVENTION 
     Technical Problem 
     However, in the case where the target of covering is a string-like object such as an electrical cord or a power cable that is repeatedly bent during use, covering methods that utilize adhesion or winding pose durability problems. On the other hand, although methods in which thread is sewn to a string-like object can enhance the aesthetic characteristics by using an embroidery thread, there is a possibility of a needle accidentally penetrating the string-like object during sewing work. Therefore, problems such as insufficient electrical conduction resulting from damaging the conductive wire of an electrical cord are likely to occur, and such methods are thus problematic in that the sewing work is likely to be troublesome. 
     Accordingly, an objective of the present invention is to provide a method for manufacturing a covered string-like object, capable of easily and reliably covering the string-like object with an embroidery material. 
     Solution Problem 
     The foregoing object of the present invention is achieved by a method for manufacturing a covered string-like object, comprising: 
     a placement step of placing a string-like object on a sheet-like flexible backing; 
     a sewing step of sewing the string-like object to the backing with an embroidery material; and 
     a separation step of separating the backing from the string-like object. 
     In this method for manufacturing a covered string-like object, it is preferable that the backing is attached to one surface of a template having a cut-out hole formed in accordance with a shape of the string-like object, and it is preferable that the placement step comprises placing the string-like object on the backing via the cut-out hole. 
     It is preferable that the embroidery material comprises an upper thread and a lower thread, and it is preferable that the sewing step comprises performing zigzag stitching while entwining the upper thread and the lower thread on both sides of the string-like object that has been linearly placed. 
     The placement step may comprise placing a decoration on the backing so as to be adjacent to the string-like object; the sewing step may comprise sewing the decoration to the backing during a course of sewing the string-like object to the backing in a lengthwise direction; and the separation step may comprise separating the string-like object and the decoration from the backing. 
     It is preferable that the backing is composed of an easily tearable stretched film. 
     Advantageous Effects of Invention 
     The present invention can provide a method for manufacturing a covered string-like object, capable of easily and reliably covering the string-like object with an embroidery material. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a plan view of a template used for a method for manufacturing a covered string-like object according to one embodiment of the present invention. 
         FIGS. 2( a ) to 2( c )  are diagrams showing principal steps of one example of a method for manufacturing a covered string-like object in which the template shown in  FIG. 1  is used. 
         FIG. 3  is an enlarged view of principal parts, showing a state during the process of manufacturing a covered string-like object. 
         FIG. 4( a )  is a cross-sectional view showing a state during the process of manufacturing a covered string-like object, and  FIG. 4( b )  is a cross-sectional view of a manufactured covered string-like object. 
         FIG. 5  is a plan view of a template used for a method for producing a covered string-like object according to another embodiment of the present invention. 
         FIG. 6  is an enlarged view of principal parts, showing one example of a method for producing a covered string-like object in which the template shown in  FIG. 5  is used. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Below, embodiments of the present invention will now be described with reference to the appended drawings.  FIG. 1  is a plan view of a template used for a method for manufacturing a covered string-like object according to one embodiment of the present invention. A template  1  shown in  FIG. 1  is used for an earphone cord as a string-like object to be covered. The template  1  is configured such that a plate body  2  having a rectangular shape is provided within a frame  4 , and the plate body  2  has two cut-out holes  6  and  8  formed in accordance with the shape of the string-like object to be covered. As indicated by the dashed lines in  FIG. 1 , the cut-out holes  6  and  8  are respectively covered with backings  10  and  12  attached to one surface (the back-surface side) of the plate body  2  using an easily removable adhesive or the like, and the string-like object (not shown) can be placed on the backings  10  and  12  via the cut-out holes  6  and  8 . 
     It is preferable that the plate body  2  has such a rigidity that the plate body  2  does not deform due to the attachment of the backings  10  and  12 . The plate body  2  can be formed from, for example, cardboard, a synthetic-resin plate, or a metal plate. In accordance with the overall shape of the earphone to be covered, the cut-out holes  6  and  8  are each formed so as to be able to accommodate roughly half of the earphone cord. The cut-out hole  6  can accommodate roughly a plug-side half of the earphone cord in a straightened state. The cut-out hole  8  can accommodate the bifurcated portions of the earphone cord both in a straightened state. 
     The cut-out hole  6  comprises a narrow holding part  6   a  and a slot-like insertion part  6   b  on the respective sides in the lengthwise direction. The distal part of the earphone cord is held by the holding part  6   a , and, on the other hand, an insert (not shown) is inserted into the insertion part  6   b  to latch the mid part of the earphone cord, and it is thus possible to fix the earphone cord within the cut-out hole  6 . As with the cut-out hole  6 , the cut-out hole  8  also comprises holding parts  8   a  and an insertion part  8   b . As long as the earphone cord can be reliably fixed within the cut-out holes  6  and  8 , fixing means other than the holding parts  6   a  and  6   b  and the insertion parts  8   a  and  8   b  may be used. 
     The backings  10  and  12  are sheet-like components that a sewing-machine needle can penetrate, and it is preferable that the backings  10  and  12  are flexible so as to conform to the earphone cord during sewing. Examples of the material of the backings  10  and  12  include synthetic resin film, metal foil, thin paper, and the like. Since the backings  10  and  12  are eventually separated from the earphone cord, it is preferable that the backings  10  and  12  have excellent tearability, and, for example, a stretched polyethylene film or the like that is easily torn in the direction of stretch can be suitably used. 
     Next, a method for manufacturing a covered string-like object using the above-described template  1  will now be described with reference to  FIG. 2 .  FIG. 2  shows partially enlarged views of the cut-out hole  6  of the template shown in  FIG. 1 . First, as shown in  FIG. 2( a ) , the plug  20   a  side of the earphone cord  20  in a straightened state is accommodated inside the cut-out hole  6 , the proximal part of the plug  20   a  is held by the holding part  6   a , and also the side of the earphone cord  20  at the center is fixed at the insertion part  8   b  shown in  FIG. 1 . In this way, the earphone cord  20  is positioned on the backing  10  via the cut-out hole  6 . 
     Subsequently, this template  1  is placed on an automatic sewing machine (not shown), and as shown in  FIG. 2( b ) , a section of the earphone cord  20  from the plug  20   a  side to near the center is sewn to the backing  10  with a sewing material  22 . As shown in the enlarged view of  FIG. 3 , the sewing material  22  is composed of an upper thread  22   a  and a lower thread  22   b , and a sewing-machine needle is caused to penetrate the backing  10  on both sides of the earphone cord  20  to entwine the upper thread  22   a  and the lower thread  22   b  by way of zigzag lockstitching, and thus the upper thread  22   a  is disposed in a zigzag manner so as to cover the earphone cord  20  on the front-surface side of the backing  10 . On the back-surface side of the backing  10 , the lower thread  22   b  is disposed in a zigzag manner. A pitch p of the zigzag pattern of the upper thread  22   a  is emphasized in  FIG. 3  so as to appear large, but, practically, it is preferable that the upper thread  22   a  is sewn at such a small pitch p that the earphone cord  20  is not exposed. It is also possible to entwine the upper thread  22   a  and the lower thread  22   b  in such a way that one thread forms a zigzag pattern, and the other thread linearly extends along the earphone cord  20 . 
     As shown in  FIG. 4( a ) , the place where the upper thread  22   a  and the lower thread  22   b  are entwined may be above (on the front-surface side of) the backing  10 , and, also, it may be in the interior of the backing  10  or below (on the back-surface side of) the backing  10  as well. The thread tension can be suitably adjusted. An embroidery thread can be suitably used as the embroidery material  22 , thus making it possible to enhance the aesthetic characteristics by taking advantage of its color, luster, etc. The embroidery material  22  may be a string-like or belt-like embroidery material other than a thread-like material. The embroidery material  22  may be intended primarily for textural, anti-allergic, or like purposes other than aesthetic purposes. 
     After about half of the earphone cord  20  is sewn to the backing  10  with the embroidery material  22  in this way, the rest of the earphone cord  20  is sewn to the backing  10  with the embroidery material  22  in the same manner as above by using the cut-out hole  8  shown in  FIG. 1 . In this way, substantially all the earphone cord  20  can be sewn to the backing  10 . 
     Thereafter, the earphone cord  20  is removed from the template  1  to separate the backing  10  from the earphone cord  20  as shown in  FIG. 4( b ) , and, thereby, the entire outer circumference of the earphone cord  20  is covered with the upper thread  22   a  and the lower thread  22   b , and, as shown in  FIG. 2( c ) , it is thus possible to obtain the covered string-like object  30  in which the earphone cord  20  is covered with the embroidery material  22 . After the backing  10  is separated from the earphone cord  20 , there may be a slight remainder of the backing  10  between the earphone cord  20  and the embroidery material  22  (see  FIG. 4( b ) ). Forming the zigzag pattern of the embroidery material  22  at a small pitch makes it possible to prevent the remaining backing  10  from being exposed to the outside and adversely affecting the appearance. Thereafter, the backing  10  ( 12 ) remaining on the template  1  is removed, then a new backing  10  ( 12 ) is attached, and it is thus possible to used the template  1  again. 
     As described above, according to the method for manufacturing a covered string-like object of the present embodiment, the earphone cord  20  is sewn to the backings  10  and  12  with the embroidery material  22 , and then the backings  10  and  12  are separated from the earphone cord  20 . It is therefore possible to easily and reliably cover the earphone cord  20  with the embroidery material  22  without damaging the earphone cord  20  with a sewing-machine needle or the like, and thus possible to obtain the covered string-like object  30  that has good durability. Moreover, the use of the template  1  on one surface of which the backings  10  and  12  have been attached makes it possible to more easily manufacture the covered string-like object  30 . 
     One embodiment of the present invention has been described in detail above, but the specific aspects of the present invention are not limited to the above embodiment. For example, the above embodiment has been described using an earphone cord as an example of a target to be covered with an embroidery material, but other string-like objects may be used as well, such as power cords, extension cords, and like electrical cords, and cables. 
     Moreover, as shown in  FIG. 5 , one or more decorative parts  14   c  may be formed by making slots that are in communication with a linear cut-out hole  14  formed in a template  1 ′, such that a backing  16  is attached so as to cover the cut-out hole  14  and the decorative parts  14   c . As shown in  FIG. 6 , with this template  1 ′, the string-like object  20  such as an earphone cord is placed in the cut-out hole  14 , a decoration  30  (such as a leaf or a flower of a plant) is placed in the decorative parts  14   c , and the decoration  30  can be sewn to the backing  10  with an embroidery material  32  during the course of sewing the string-like object  20  to the backing  10  with the embroidery material  22  in the lengthwise direction. The embroidery materials  22  and  32  may be the same or may be different. Thereafter, the backing  10  is separated from the string-like object  20  and the decoration  30 , and it is thus possible to obtain a covered string-like object having enhanced aesthetic characteristics. In  FIG. 5 , the same components as in  FIG. 1  are given the same reference numbers. 
     REFERENCE SIGNS LIST 
     
         
         
           
               1  Template 
               2  Plate body 
               4  Frame 
               6 ,  8  Cut-out holes 
               10 ,  12  Backings 
               20  Earphone cord (String-like object)