Vehicle Interior Leather Lining With Folded Insert Edges
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Solution Overview
Problem
Existing methods for producing decorative coverings for vehicle interior elements often result in an unaesthetic appearance, visible joints, poorly controlled grain shine, and a lack of differentiation, failing to achieve a high-end quality perception.
Innovation Solution
A process involving thinning and folding edges of leather pieces to form embankments, with a decorative insert placed between the edges, allowing for secure coupling to the vehicle element, enhancing the perceived quality and offering customization options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to attach decorative inserts to vehicle interior elements, then the production process is simple, but the appearance quality deteriorates with visible joint lines and poor grain control
Solution Approach 1:
The leather piece is segmented into multiple zones with different thicknesses: a first portion with standard thickness and a second portion (edge) with reduced thickness. This segmentation allows the edge to be folded over without creating excessive bulk, thereby eliminating visible joint lines and improving appearance quality while maintaining a manageable process
Solution Approach 2:
The solution transitions from a two-dimensional attachment (flat leather piece bonded to surface) to a three-dimensional structure by folding the thinned edge over the decorative insert. This creates a recessed configuration where the folded edge forms a rim around the insert, hiding joint lines and improving grain control through the vertical dimension
2Manufacturing precision
If leather is bonded to interior trim to improve quality, then perceived quality improves, but diversity and personalization options are lost
Solution Approach 1:
The leather piece is treated differently in different regions: the first portion maintains standard thickness for structural integrity and quality appearance, while the second portion (edge) is thinned to enable folding. This local differentiation allows the same leather piece to provide both high perceived quality in the main area and versatility through various folding configurations and decorative insert options
3Area of stationary object
If decorative inserts are attached with overlapping trim panels, then coverage is improved, but visible joint lines and unaesthetic appearance result
Solution Approach 1:
The thinned edge of the leather piece is folded over the decorative insert, creating a nested configuration where the folded edge forms a rim that encloses the insert. This nesting approach provides complete coverage of the insert edges while hiding joint lines within the folded structure, achieving both full coverage and high aesthetic quality
Data Source
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AI summary
A method for manufacturing a decorative lining (HD) for a vehicle interior element (EH) is disclosed. Said method involves: - step (i) wherein the size of at least one edge (B11, B12) of two leather parts (PC1, PC2) is reduced on an inner face (FI1) and each reduced-size edge is folded over to form a fold (R1, R2) on each leather part (PC1, PC2); and - step (ii) wherein the leather parts (PC1, PC2) as well as a decorative insert (ID) that is inserted between the two leather parts (PC1, PC2) are coupled to the vehicle interior element (EH) by placing two edges (B21, B22) underneath the folds (R1, R2).