Leather Steering Wheel Covering via High-Frequency Welding
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Solution Overview
Problem
Manual labor is required for sewing leather onto vehicle interior parts like steering wheels, making the process time-consuming and costly.
Innovation Solution
Applying a thermoplastic layer to the leather and using high-frequency welding to attach it to the vehicle interior part, allowing for fully automated assembly and eliminating the need for manual sewing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual sewing is used to attach leather to vehicle interior parts, then the attachment can be achieved, but the production time and labor costs increase significantly
Solution Approach 1:
The patent replaces the mechanical sewing process with a thermal welding process. A thermoplastic layer is applied to the leather piece, and high-frequency welding is used to attach it to the vehicle interior part. This substitution eliminates the need for manual needle and thread work, enabling automated production while maintaining secure attachment.
Solution Approach 2:
The patent changes the material parameter of the leather piece by adding a thermoplastic layer. This modification enables the leather to be welded using high-frequency welding technology, transforming it from a material that requires mechanical sewing to one that can be attached through thermal fusion, thereby enabling automation.
2Extent of automation
If a thermoplastic layer is applied to the leather piece, then automated welding becomes possible, but the material complexity and processing steps increase
Solution Approach 1:
The thermoplastic layer is applied to the leather piece in advance, before the welding process. This preliminary preparation enables the subsequent automated high-frequency welding to proceed efficiently without requiring complex real-time material modification, simplifying the overall automation system.
3Reliability
If the entire leather piece is covered with thermoplastic layer, then welding reliability improves, but the tactile feel and aesthetic quality deteriorate
Solution Approach 1:
Instead of covering the entire leather piece with thermoplastic layer, the patent applies the layer only in localized regions where welding is required. This selective application maintains the natural tactile feel and aesthetic quality of the leather in non-welding areas while providing sufficient thermoplastic material for reliable welding connections at the attachment points.
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 method reduces production time and costs by enabling automated assembly of leather-covered vehicle interior parts, ensuring a reliable and aesthetically pleasing attachment without visible seams.
Implementation Method 1
The leather piece is fastened on the vehicle interior part by a high frequency welding process in a region of the thermoplastic layer
Implementation Method 2
The application of the thermoplastic layer can preferably take place by means of laminating
Data Source
AI summary
A method for covering a vehicle interior part with leather, particularly a vehicle steering wheel, includes the following steps: A leather piece being cut to size and having a front side, a rear side, and edges is provided with a thermoplastic layer on the rear side. The leather piece is fastened on the vehicle interior part by a high frequency welding process in a region of the thermoplastic layer.