Embossed Notch Alignment for Motor Vehicle Seat Cap Assembly
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Solution Overview
Problem
Existing methods for forming seams in motor vehicle seat caps, particularly those with a foam layer on the reverse side of textile, skin, or synthetic material, face challenges in ensuring proper alignment and simplifying the assembly process, as they often rely on visible cuts which complicate the assembly and are not suitable for foam-covered surfaces.
Innovation Solution
The introduction of embossed notches or strips on the edges of the cover element, formed through cold molding, serve as alignment marks for sewing, allowing for correct positioning and assembly of pieces without visible cuts, using a mold to create these embossed features which can be recessed or raised, facilitating the sewing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cuts are made in the edges of cap pieces to form alignment marks, then alignment during sewing is improved, but the assembly process becomes more complex and cuts are visible on the rear surface
Solution Approach 1:
The invention extracts the alignment mark formation from the cap pieces themselves and relocates it to the foam support block. By forming embossed notches directly on the foam block, the alignment marks are separated from the cap pieces, eliminating the need for cuts in the cap piece edges and simplifying the assembly process while maintaining alignment precision
Solution Approach 2:
Instead of creating alignment marks by removing material (cuts) from the cap pieces, the invention inverts the approach by creating embossed notches (adding material form) on the foam support block. This inversion eliminates visible cuts on the cap pieces while providing the same alignment function
2Manufacturing precision
If visible cuts are used as alignment marks, then alignment during sewing is achieved, but the aesthetic appearance is degraded due to visible marks
Solution Approach 1:
The alignment mark function is extracted from the visible cap pieces and relocated to the foam support block. The embossed notches on the foam block serve as alignment marks during sewing but remain hidden from view once the cap is assembled, preserving the aesthetic appearance of the final product
Solution Approach 2:
The foam support block acts as an intermediary that carries the alignment marks (embossed notches) during the assembly process. This intermediary allows alignment to be achieved without creating visible marks on the final cap product, as the marks are temporarily present on the foam block rather than the cap pieces themselves
3Ease of operation
If traditional seam forming methods are used for foam-covered surfaces, then assembly is simplified, but proper alignment of pieces cannot be ensured
Solution Approach 1:
The invention performs preliminary action by forming the embossed notches on the foam support block before the assembly process begins. This pre-formed alignment system is integrated into the foam block itself, providing both the alignment function and the simplified assembly interface in one preparation step
Solution Approach 2:
The invention merges the alignment mark function with the foam support block structure. The embossed notches are formed directly on the foam block, combining the support function and alignment function into a single integrated element, eliminating the need for separate alignment marks on the cap pieces
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 solution simplifies the assembly of motor vehicle seat caps by providing visible alignment marks during sewing, ensuring accurate alignment and reducing complexity, applicable to various seat elements and materials, enhancing the efficiency of the sewing process.
Implementation Method 1
the cover element is obtained by cold forming of a foam sprayed on a substrate
Data Source
AI summary
A cover element for a motor vehicle seat element lining, including: a foam on the reverse side of a textile, skin, or synthetic material; and in edges, intended to be assembled by sewing to at least one piece of textile, skin, or synthetic material, one or a plurality of embossed notches forming alignment marks to perform the sewing.