Interchangeable Interior Inserts for Wrinkle-Free Concave Trim
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Solution Overview
Problem
Covering concave surfaces and interior compartment surfaces in vehicles with premium materials is challenging due to the difficulty in maintaining tension to avoid wrinkles and bunching, leading to these surfaces often being left uncovered.
Innovation Solution
A system featuring interchangeable inserts with a wall surface and a gripping member, where the inserts are covered in premium materials and secured through connector elements, allowing seamless coverage of concave surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If premium material is used to cover concave surfaces, then the aesthetic appearance is improved, but the material cannot be maintained in tension leading to wrinkles and bunching
Solution Approach 1:
The insert is divided into multiple segments or panels that can independently conform to the concave surface geometry. This segmentation allows each panel to be tensioned separately, preventing wrinkles and bunching while maintaining the premium material covering on the complex curved surface.
Solution Approach 2:
The insert incorporates flexible or adjustable components that allow the material to dynamically adapt to the concave surface shape. This may include flexible connectors or adjustment mechanisms that enable the material to maintain tension across varying curvatures without wrinkling.
2Shape
If premium material is used to cover interior compartment surfaces, then the aesthetic appearance is improved, but it is difficult to maintain tension to avoid wrinkles
Solution Approach 1:
The premium material is pre-formed or pre-tensioned in a controlled manufacturing environment before installation. This preliminary action ensures that the material is properly tensioned and free of wrinkles before being installed in the vehicle, simplifying the installation process while maintaining aesthetic appearance.
Solution Approach 2:
The insert uses flexible thin film or shell structures that can be easily conform ed to interior compartment surfaces. These flexible materials can be stretched and tensioned during installation to achieve a wrinkle-free appearance, making the manufacturing and installation process more manageable.
3Ease of manufacture
If concave surfaces are left uncovered, then the manufacturing complexity is reduced, but the aesthetic appearance and premium feel are compromised
Solution Approach 1:
The insert design uses universal components and standardized attachment mechanisms that can be applied to various concave surfaces throughout the vehicle interior. This multi-functionality allows the same insert technology to cover different shapes and locations, maintaining aesthetic appearance without significantly increasing overall manufacturing complexity.
Data Source
AI summary
A vehicle feature includes a wall having a wall surface formed from a first material and an opening extending through the wall surface. An insert is mounted to the wall surface. The insert is formed from a second material. The insert includes a wall member having a first side facing the wall surface and a second side facing away from the wall surface. The first side includes at least one connector element that engages with the wall surface through the opening. The insert is covered in a third material that is distinct from the first material and the second material.