Epidermis Sewing Pattern Planning for Vacuum-Formed Cover Bonding

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Solution Overview

Problem

Conventional methods for producing epidermis-bonded products require skilled operators for manual sewing, are slow, costly, and prone to sewing hole enlargement or breakage due to vacuum molding, especially on curved surfaces, and involve complex steps.

Innovation Solution

A method involving simulation analysis to determine sewing patterns on epidermis before vacuum molding, ensuring expansion rates of 130% or less, and using automated sewing to integrate epidermis with base materials, reducing sewing hole enlargement and deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vacuum molding is performed after sewing is performed, then the epidermis can be bonded to the base material, but the sewing hole is enlarged or sometimes broken in portions having high expansion rate

Engineering Contradiction:

Improvesewing hole integrityVSAvoidsewing hole size control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The sewing pattern is determined and sewn on the epidermis before vacuum molding is performed. By performing the sewing action in advance on the flat epidermis, the sewing holes are created before the high-expansion regions are formed during molding, preventing hole enlargement and breakage that would occur if sewing were performed after molding.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The expansion rate of the epidermis is analyzed and measured during vacuum molding to identify high-expansion portions. This parameter measurement allows for determining the sewing pattern in advance, avoiding sewing in regions that will later experience excessive expansion and hole damage.

Inventive Principle:

Principle #35Parameter changes

2Shape

If the epidermis is molded before sewing, then the epidermis conforms to the base material form, but manual sewing is required which slows production speed and increases cost

Engineering Contradiction:

Improveepidermis conformity to base materialVSAvoidproduction speed

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The sewing pattern is determined on the flat epidermis before vacuum molding, allowing automated sewing machines to perform the sewing operation on the easily accessible flat surface. This preliminary sewing action eliminates the need for slow manual sewing on curved surfaces while still achieving the desired final product with proper epidermis conformity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Manual sewing operations are replaced with automated sewing machines. By determining the sewing pattern in advance on the flat epidermis, automated machines can efficiently perform the sewing operation, replacing the need for skilled manual operators and significantly increasing production speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Shape

If the epidermis is molded before sewing, then the base material form is achieved, but the number of production steps increases

Engineering Contradiction:

Improvebase material formVSAvoidnumber of production steps

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The determination of the sewing pattern is integrated into the vacuum molding process by analyzing the expansion rate during molding. This allows the sewing pattern to be determined as part of the molding operation itself, merging what would otherwise be separate steps and reducing overall process complexity.

Inventive Principle:

Principle #5Merging (Combining)

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

Enables efficient, automated sewing on flat surfaces, reducing sewing hole expansion and breakage, allowing complex patterns on curved surfaces, and simplifying the production process with fewer steps and lower costs.

Implementation Method 1

an analysis step of measuring and analyzing the expansion rate of the epidermis when the epidermis is vacuum-molded on the base material by simulation analysis using a computer

Methodology Applied

Scientific EffectSimulation analysis:

Implementation Method 2

an epidermis to be bonded is molded by vacuum molding or the like so as to be adjusted to the form of the base material

Methodology Applied

Scientific EffectVacuum molding: Vacuum

Data Source

PatentUS20250353285A1Method of determining sewing pattern of epidermis-bonded product and production method

Publication Date: 2025.11.20 JAPAN PLASTICS TECH CO LTD

AI summary

[Problem] To provide a cover bonding product fabrication method with which it is possible to perform complex sewing such as zigzag stitching, double stitching, and embroidery with a pattern sewing machine via automated operation, regardless of the size of a curved surface of the cover bonding product. [Solution] According to the present invention, a method for determining a sewing pattern on a base material includes: (1) an analysis step for measuring and analyzing an expansion rate of a cover when the cover is vacuum-formed on the base material; (2) a specifying step for specifying, on the basis of the measured expansion rate, a range where the expansion rate is 130% or lower; and (3) a sewing pattern determination step for determining a sewing pattern in the range where the expansion rate is 130% or lower.