Vehicle Interior Stitch Seam with Preformed Acceptance Holes
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Solution Overview
Problem
Existing methods for forming stitch seams in vehicle interior components often result in inefficient processes due to the need for additional equipment, potential overheating of components, and the creation of undesirably shaped holes during the stitching process, which can lead to debris and increased manufacturing costs.
Innovation Solution
The method involves preforming hollow stitch acceptance holes in the component substrate before attaching a decorative covering, allowing for stitching through these holes to create a seamless seam that extends through the covering and substrate, eliminating the need for additional thermoforming tools and improving manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If holes are formed during the stitching process using a needle or awl, then the stitching can be completed, but it creates drag in the stitching process and can overheat components
Solution Approach 1:
The patent applies preliminary action by pre-forming hollow stitch acceptance holes in the component substrate before the stitching process. These pre-formed holes eliminate the need for the stitching needle or awl to penetrate the substrate during stitching, thereby reducing drag and preventing overheating of the stitching components while maintaining production efficiency
2Productivity
If holes are formed during the stitching process, then stitching can be completed, but additional forming equipment is required
Solution Approach 1:
The patent eliminates additional forming equipment by pre-forming hollow stitch acceptance holes in the component substrate before stitching. This preliminary action integrates hole formation into the substrate manufacturing process itself, removing the need for separate hole-forming equipment during stitching while ensuring complete stitching operation
Solution Approach 2:
The patent inverts the conventional sequence by forming holes before stitching rather than during stitching. This reversal eliminates the need for specialized forming equipment during the stitching process, as the holes are already present in the substrate from a previous manufacturing step
3Productivity
If holes are formed during stitching, then the stitching process can proceed, but undesirably shaped holes are created leading to debris
Solution Approach 1:
The patent applies preliminary action by pre-forming hollow stitch acceptance holes with precise, desirable shapes in the component substrate before stitching. These pre-formed holes have controlled geometry that prevents debris generation during stitching, while maintaining continuous stitching process operation
Solution Approach 2:
The patent inverts the conventional approach by forming holes before stitching rather than during stitching. This reversal allows for precise control of hole shape and size using appropriate forming methods, eliminating the creation of undesirably shaped holes and associated debris while ensuring stitching process continuity
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 approach reduces manufacturing costs, improves product quality by avoiding debris and overheating issues, and streamlines the process by allowing for more precise hole placement and alignment, resulting in higher-quality vehicle interior components with reduced cycle time and capital expenses.
Implementation Method 1
The hollow stitch acceptance holes are advantageously molded into the component substrate or laser scored into the substrate before a decorative covering is laminated
Implementation Method 2
the attaching step includes laminating the decorative covering to the component substrate in a thermo-covering process
Implementation Method 3
the attaching step includes laminating the decorative covering to the component substrate in a thermo-covering process
Implementation Method 4
the thermo-covering process is an in-mold grain lamination process that imparts a surface texture on an outer surface of the decorative covering
Implementation Method 5
stitching through the decorative covering and at least some of the hollow stitch acceptance holes of the plurality of hollow stitch acceptance holes to form a stitch seam
Data Source
AI summary
A vehicle interior component and method of making a vehicle interior component where a plurality of hollow stitch acceptance holes are formed in a component substrate to accommodate a stitch seam in a decorative covering that is attached to the component substrate. The stitch seam extends through the decorative covering to create filled stitch acceptance holes from the hollow stitch acceptance holes. The stitch seam can be created after an in-mold grain process in which the component substrate and decorative covering are laminated together.