Seat assembly trim panel
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Solution Overview
Problem
Existing leather trim panels in vehicle seat assemblies face challenges in maintaining an even thickness and three-dimensional appearance due to the concentration of stitching, which can lead to a discontinuous look and uneven thickness between laminated and non-laminated portions.
Innovation Solution
The trim panel is designed with a first leather portion laminated with a stabilization material and a second portion without stabilization material, both having equal thickness, where the first portion includes a foam layer and adhesive layer for bonding, and the second portion has a silicon layer without adhesive, allowing it to maintain equal thickness and provide a three-dimensional appearance through varying stitching patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a stabilization material is laminated to one portion of the trim panel, then that portion maintains structural stability, but the thickness becomes uneven and the three-dimensional appearance is compromised
Solution Approach 1:
The trim panel is divided into two distinct portions: a first portion with laminated stabilization material and a second portion without stabilization material. This segmentation allows each portion to have different structural properties while maintaining overall aesthetic consistency through equal thickness design.
Solution Approach 2:
Different regions of the trim panel are given different local qualities - the first portion receives stabilization material for structural support, while the second portion remains unstabilized to maintain flexibility and equal thickness, creating local optimization for different functional requirements.
2Ease of manufacture
If stitching is concentrated in certain areas to provide ornamentation, then decorative effect is enhanced, but thickness uniformity is disrupted and discontinuity appears
Solution Approach 1:
Different stitching patterns are applied to different portions of the trim panel. The first portion has one stitching pattern while the second portion has another, allowing each area to be optimized for its specific decorative requirements without compromising overall thickness uniformity.
Solution Approach 2:
Both portions of the trim panel are designed to have equal thickness despite having different stitching patterns and stabilization material applications, creating a visually continuous surface where no single area dominates or disrupts the overall aesthetic balance.
3Strength
If adhesive is applied to bond the stabilization material, then bonding strength is achieved, but the additional layer increases thickness and affects three-dimensional appearance
Solution Approach 1:
The design parameters of the adhesive layer are optimized to provide sufficient bonding strength while minimizing thickness addition. The adhesive layer is applied in controlled amounts and with specific properties that balance bonding requirements with aesthetic thickness requirements.
Solution Approach 2:
The trim panel utilizes composite material construction where the stabilization material, adhesive layer, and leather portions work together as an integrated structure. The composite design allows the adhesive to serve dual purposes: strong bonding and minimal thickness contribution to the overall assembly.
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 design ensures an even thickness and three-dimensional appearance across the trim panel, preventing the discontinuity caused by stitching concentration and maintaining aesthetic consistency.
Implementation Method 1
the adhesive layer is thermally laminated to the first portion and the foam layer
Data Source
AI summary
A trim panel is provided with a first leather portion laminated with a stabilization material, wherein the first portion has a thickness. The trim panel is provided with a second leather portion adjacent to the first leather portion without a laminated stabilization material. The second portion has thickness that is equal to the thickness of the first portion.