Trim cover assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional trim cover assemblies for vehicle seats often require adhesives that are non-recyclable and result in visible deformations when under tension, limiting recyclability and aesthetic appeal.
Innovation Solution
A multi-layer trim cover assembly using thermal lamination to secure layers without adhesives, featuring a non-woven base layer, foam or fleece intermediate layer, and a textile or leather top layer, secured with tie-downs and retainers that distribute tension evenly, minimizing visible deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives are used to secure trim cover layers, then the layers are securely attached, but the adhesives are non-recyclable and cause visible deformations under tension
Solution Approach 1:
The trim cover assembly is divided into multiple independent layers (first layer, second layer, third layer) that can be separately attached and detached. Each layer is secured independently through tie-downs and retainers rather than being bonded together with adhesives, allowing individual layers to be removed and recycled without causing deformation to other layers.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesives) with a mechanical fastening system consisting of tie-downs and retainers. This mechanical system provides secure attachment while allowing for easy removal and recycling, and crucially does not cause visible deformations when tension is applied, as the mechanical fasteners can accommodate movement without creating permanent distortion.
2Device complexity
If a single-layer trim cover is used, then the structure is simple, but it cannot provide both aesthetic appearance and secure attachment without deformation
Solution Approach 1:
The patent transitions from a single-layer two-dimensional structure to a multi-layer three-dimensional structure. The multiple layers (first layer, second layer, third layer) are stacked and independently secured, creating a volumetric assembly that distributes mechanical stresses across multiple planes. This dimensional expansion allows each layer to maintain its shape independently while collectively providing both aesthetic appearance and secure attachment.
3Strength
If adhesives are used to attach trim covers, then attachment is secure, but recyclability is compromised
Solution Approach 1:
The trim cover layers are designed with pre-attached tie-downs and retainers during manufacturing, creating a modular assembly that can be easily detached and reattached. This preliminary configuration of mechanical fasteners allows the entire trim cover assembly to be removed as a unit for recycling and then quickly reinstalled, maintaining secure attachment while enabling full recyclability without requiring adhesive removal or special processing.
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 enhances recyclability and maintains a smooth appearance by eliminating non-recyclable adhesives and distributing tensile loads, allowing for secure attachment without visible deformation.
Implementation Method 1
A multi-layer trim cover assembly using thermal lamination to secure layers without adhesives
Data Source
AI summary
An assembly is provided with a first layer sized to be displaced over a seat component. A tie down is connected to the first layer to extend at least partially along or at least partially through a cushion of the seat component. A retainer is connected to the tie down, and is sized to retain the tie down and the first layer to the seat component. A second layer is stacked upon and secured to the first layer. A third layer is stacked upon and secured to the second layer.