Composite Cover Stitching Layout for Uniform Tactile Feel
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Solution Overview
Problem
The existing layered composite components for vehicle interior components face challenges in maintaining consistent tactile sensations between stitched and unstitched sections due to interference from small projections during the sewing process, leading to variations in tactile feedback.
Innovation Solution
A layered composite component design featuring a plate-shaped base member and an elastically deformable cover member with projections only on non-stitched areas, where the cover member includes stitched portions with ridges that extend along the stitching, allowing for uniform tactile sensation and facilitating seamless sewing using a specialized sewing apparatus with rising plates to guide the stitching process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If very small projections are arranged on the rear surface of the cover member to improve tactile sensation, then tactile sensation is improved, but the sewing process is hindered by projection interference
Solution Approach 1:
The cover member is segmented into two distinct zones: a stitched portion where stitching is applied and a non-stitched portion where projections are arranged. This spatial segmentation allows the stitching apparatus to operate on the smooth stitched portion without projection interference, while the projections remain on the non-stitched portion to provide tactile sensation, thereby resolving the contradiction between sewing ease and tactile quality
Solution Approach 2:
Different surface qualities are applied to different locations of the cover member. The stitched portion has a smooth surface suitable for sewing operations, while the non-stitched portion features projections for enhanced tactile sensation. This local differentiation allows each zone to fulfill its specific function without interfering with the other
2Ease of manufacture
If projections are removed from the stitched portion and peripheral section to facilitate sewing, then sewing process is simplified, but tactile sensation varies between stitched and unstitched sections
Solution Approach 1:
A ridge structure is introduced as an intermediary element between the stitched and non-stitched portions. This ridge acts as a transition zone that bridges the two different surface characteristics, allowing the tactile sensation to transition smoothly from the stitched area to the projection area, thereby maintaining tactile consistency across the entire cover member surface
3Shape
If stitching is added to improve ornamentality, then ornamentality is enhanced, but the sewing process becomes complex due to projection interference
Solution Approach 1:
The cover member surface is divided into stitched and non-stitched zones, allowing stitching to be applied only where needed for ornamentality without requiring the entire surface to be free of projections. This selective stitching approach enhances aesthetic appeal while avoiding the complexity of removing projections from the entire surface
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces variations in tactile sensation between stitched and unstitched sections, enhances the ornamentality of vehicle interior components, and simplifies the sewing process by preventing projection interference, resulting in a consistent and improved user experience.
Implementation Method 1
The cover member is formed from a plastic material and is elastically deformable. When the surface of the cover member is pushed toward the base member with a finger or hand, the projections come into contact with the opposing surface of the base member and are bent and deformed. The deformation produces a moderate reaction force
Data Source
AI summary
A layered composite component includes a plate-shaped base member formed from a plastic material, a cover member layered on the base member, and a stitching. The cover member includes a plate-shaped main body extending along the base member such that the main body is spaced apart by a gap from the base member and projections projecting from an opposing surface of the main body opposed to the base member. The cover member is formed from a plastic material and is elastically deformable. The cover member includes a stitched portion linearly extending and including a portion on which the stitching is formed. The projections are not formed on the stitched portion, and the stitched portion includes a ridge extending along the stitching.