Interior Component Production Apparatus with Welding and Sewing Heads
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Solution Overview
Problem
Existing methods for producing interior components for vehicles, particularly in large-area cockpit regions, do not allow for separable and customizable surface materials, leading to difficulties in recycling and maintenance, as well as inconsistent manufacturing tolerances.
Innovation Solution
An apparatus combining sewing and welding processes, controlled by a handling device and a component support adapted to the material properties of the top layer, ensures reliable and reproducible connection of the top layer to the carrier element, enabling separable and customizable interior components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If surfaces are firmly laminated to carrier parts by means of laminating adhesive, then the connection strength is improved, but the separability at end of life cycle deteriorates
Solution Approach 1:
The patent divides the connection system into separate functional elements: a reusable carrier element and exchangeable top layers. The connection is achieved through localized connection elements (adhesive patches, mechanical fasteners) rather than full-surface lamination, enabling separation while maintaining connection strength during use.
Solution Approach 2:
The patent introduces adjustable and reversible connection mechanisms. The connection strength can be dynamically adjusted based on the top layer material properties, and the connection can be reversed for separation. The system adapts between firmly connected state during use and easily separable state for maintenance or end-of-life processing.
2Adaptability or versatility
If exchangeable surface materials are used, then the customization ability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent creates a universal carrier element that can accommodate multiple different top layer materials and designs. The standardized interface and connection system allow the same carrier to work with various top layers, enabling customization without requiring separate manufacturing systems for each material type.
Solution Approach 2:
The patent adjusts connection parameters (adhesive type, fastening method, connection strength) based on the specific top layer material properties. The system selects appropriate connection parameters for each material type to ensure proper bonding while maintaining the ability to exchange layers, thus managing manufacturing complexity through parameter optimization.
3Reliability
If different fastening methods are used for different top layer materials, then the connection reliability is improved, but the production time increases
Solution Approach 1:
The patent prepares the carrier element in advance with pre-applied adhesive patches or pre-installed connection elements in specific patterns. This preliminary preparation allows for rapid attachment of different top layer materials without requiring complex real-time decision-making or multiple different fastening systems, thus maintaining both reliability and productivity.
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
The solution allows for the production of interior components with separable top layers, facilitating customization and recycling, while ensuring consistent manufacturing quality across different material types.
Implementation Method 1
a welding head, in particular an ultrasonic welding head
Implementation Method 2
these are welded by means of the welding head
Implementation Method 3
a sewing head with a sewing apparatus... these are sewn by means of the sewing head
Data Source
AI summary
An apparatus for producing an interior component from a carrier element and a top layer includes a handling device, a component support for receiving the carrier element and the top layer, where the component support has a fixing device for temporarily fixing the carrier element and the top layer on the component support, a welding head, and a sewing head. A control unit controls the handling device where a data set for controlling at least the handling device in a manner dependent on a material of the top layer is stored in the control unit and where the handling device is controllable depending on the material of the top layer by the control unit such that, to connect the top layer to the carrier element, the top layer and the carrier element are welded by the welding head or sewn by the sewing head.