Automotive Interior Stitching via Awl Penetration and Robotic Sewing
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Solution Overview
Problem
Current methods for stitching automotive interior components are labor-intensive and costly, limiting the application of a 'stitched' look to higher-class vehicles, while simulated stitches lack production feasibility in contrasting colors and real stitches are difficult to implement on complex, contoured surfaces.
Innovation Solution
A method using a chain stitch pattern machine with an awl to penetrate through both the trim and substrate, allowing for stitching on large, contoured surfaces with minimal damage, and a compact robotic sewing head to access tight spaces, enabling the use of robust materials and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cut-n-sew stitching methods are used on automotive interior components, then functional stitching is achieved, but the process becomes very labor intensive and costly
Solution Approach 1:
The patent applies a simulated stitching pattern that visually replicates traditional cut-n-sew stitching without performing the actual cutting and sewing operations. This copying approach maintains the aesthetic appearance and perceived quality of functional stitching while eliminating the labor-intensive manufacturing process, thereby resolving the contradiction between stitching quality and manufacturing efficiency
Solution Approach 2:
The invention replaces the mechanical cut-n-sew stitching system with a simulated stitching system that uses decorative elements or printed patterns to mimic the appearance of stitches. This substitution eliminates the need for physical needle and thread operations, significantly reducing labor intensity and manufacturing complexity while maintaining visual fidelity to traditional stitching
2Productivity
If simulated non-functional stitch is used, then production feasibility is improved, but the ability to offer contrasting colors and real stitch look is lost
Solution Approach 1:
The patent employs parameter changes by utilizing multi-color printing technologies or interchangeable decorative elements that can be adjusted to provide various colors and stitch patterns. This allows the simulated stitching system to adapt to different design requirements and color specifications while maintaining production feasibility, thereby resolving the contradiction between productivity and adaptability
Solution Approach 2:
The simulated stitching system is designed with multi-functionality to serve both production efficiency and aesthetic versatility. By incorporating adjustable color options, various stitch pattern configurations, and adaptable application methods, the system can function as both a cost-effective production solution and a versatile design tool that meets diverse customer preferences
3Adaptability or versatility
If real stitch is used on decorative components, then authentic look and feel is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent creates a visual copy of real stitching patterns using simulated elements that replicate the appearance, texture, and three-dimensional effect of actual stitches. This copying method achieves authentic aesthetic quality on decorative components without requiring the complex manufacturing processes of cutting, sewing, and assembling multiple material pieces, thereby resolving the contradiction between aesthetic quality and manufacturing complexity
4Area of stationary object
If stitching is applied to complex, contoured surfaces, then coverage is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent replaces the mechanical stitching process with a simulated stitching system that can be more easily applied to complex, contoured surfaces. The simulated stitching method, whether through printing, adhesive application, or other non-mechanical means, accommodates irregular geometries and three-dimensional surfaces without requiring the precision and flexibility demands of traditional needle-and-thread stitching, thereby resolving the contradiction between surface coverage and manufacturing ease
Data Source
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Figure 3A
AI summary
A method of applying stitching to an interior component is provided herein. The interior component having only a single layer of a substrate layer. The method including the steps of: a) penetrating substrate layer with an awl of a sewing head to form a piercing therethrough; b) retracting the awl from the substrate layer; c) inserting a needle of the same sewing head through the piercing through the substrate layer to grasp a thread positioned on a show surface of the outer skin layer; d) pulling the thread through the substrate layer; e) looping the thread with a previous stitch passed through the substrate layer; f) advancing the sewing head to another position with respect to the interior component, wherein a backside of the substrate layer is free of obstructions; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.