Blind Stitching Contoured Automotive Trim via Curved Needle
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for applying decorative stitching on 3D preformed automotive trim components are labor-intensive and limited in placement options, especially on complex surfaces, as they require access to both sides of the part, making it difficult to achieve a realistic 'stitched' look on a wider range of vehicles without increasing costs.
Innovation Solution
A method using a curved needle to penetrate and exit the outer skin layer from one side, with a hook engaging the thread to form stitches, allowing for the creation of a live, non-functional stitch on decorative trim components without needing access to the backside, enabling stitching on previously inaccessible areas like sharp corners and contoured surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional stitching methods are used that require access to both front and backside of the part, then stitching can be applied to simple surfaces, but stitching cannot be applied to complex surfaces such as brows, sharp corners, and highly contoured surfaces
Solution Approach 1:
The patent inverts the traditional stitching approach by making the needle travel through the material from the decorative side and exit through the same side, rather than entering from one side and exiting from the other. This allows the hook to engage the thread on the decorative surface, enabling stitching on complex geometries without backside access
Solution Approach 2:
The patent introduces a new dimensional approach by having the needle traverse through the thickness of the material and return to the same surface, creating a loop that can be engaged by the hook. This dimensional change enables stitching on three-dimensional surfaces that were previously inaccessible
2Manufacturing precision
If functional stitching is used on decorative components, then a realistic stitched look is achieved, but labor intensity and cost increase
Solution Approach 1:
The patent implements a self-service mechanism where the hook automatically engages the thread loop created by the needle without requiring manual intervention. The system uses the thread itself as the engagement medium, eliminating the need for complex threading operations and reducing labor intensity while maintaining realistic stitch appearance
Solution Approach 2:
The patent creates a simulated functional stitch that copies the appearance and feel of traditional cut-n-sew stitching without requiring the actual cutting and sewing of separate pieces. The live stitch mechanism produces a realistic look that replicates functional stitching at lower cost and with reduced labor
3Ease of manufacture
If access to both sides of the part is required for stitching, then stitching can be applied to flat surfaces, but stitching placement is limited on 3D preformed components
Solution Approach 1:
The patent reverses the conventional stitching geometry by having both the needle entry and exit points on the same decorative surface. This inversion allows the stitching mechanism to operate on the exterior of 3D components without requiring backside access, significantly expanding surface coverage
Data Source
AI summary
A method of applying stitching to an outer skin layer of an interior component is provided herein, the outer skin layer having a contoured surface. The method including the steps of: a) penetrating the contoured surface of the outer skin layer at an entry point on a first surface of the contoured surface of the outer skin layer with a curved needle; b) exiting the contoured surface of the outer skin layer at an exit point on the first surface with the curved needle, wherein the steps of penetrating and exiting cause a first thread to pass through the entry point and the exit point on the contoured surface of the outer skin layer; c) grabbing the first thread with a hook located proximate to the exit point; d) retracting the needle through the exit point and the entry point while pulling a second thread through the exit point via the first thread to form a stitch; e) advancing the contoured surface of the outer skin layer to a new location with respect to the needle and hook; and f) repeating steps a-e until a predetermined amount of stitches are applied to the contoured surface of the outer skin layer.