Covering material, interior material, and method for producing interior material
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Solution Overview
Problem
Conventional methods for fixing a covering material with a stitching pattern to a base material in automobile interiors face challenges such as difficult alignment of the stitching pattern, requiring visual checking and leading to increased production time and potential misalignment, necessitating re-adhesion.
Innovation Solution
A covering material with a resin-based design surface featuring a stitching pattern and protrusions or recesses along the pattern, which engage with corresponding features on the base material, allowing for precise alignment without visual checking, and adhesive-free fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If visual checking is used to align the stitching pattern with the base material, then positioning accuracy can be achieved, but production time increases and re-adhesion may be necessary
Solution Approach 1:
Positioning protrusions are formed on the covering material and corresponding positioning recesses are formed on the base material in advance, before the actual assembly process. This preliminary preparation of positioning features eliminates the need for visual checking during assembly, as the components self-align through the mechanical engagement of these pre-formed features.
Solution Approach 2:
The visual checking method is replaced with a mechanical positioning system consisting of protrusions and recesses. Instead of relying on human operators to visually align the stitching pattern, the mechanical interlocking features automatically guide and secure the covering material to the base material in the correct position.
2Reliability
If adhesive is applied and visual checking is performed for alignment, then the covering material can be fixed to the base material, but the fixing process becomes time-consuming and complex
Solution Approach 1:
The positioning protrusions and recesses are pre-formed on the covering material and base material respectively, establishing the correct alignment before any fixation action occurs. This preliminary positioning simplifies the subsequent fixation process by eliminating the need for complex alignment procedures or visual checking during adhesion.
Solution Approach 2:
The positioning protrusions and recesses act as intermediary elements that facilitate the connection between the covering material and base material. These mechanical features serve as a mediator that ensures proper alignment and provides a reliable foundation for the fixation process, whether through adhesive or other bonding methods.
Data Source
AI summary
An interior material is composed of: a covering material formed of a resin material and having a front surface which is a design surface and a back surface which is a fixed surface; and a base material to which the fixed surface of the covering material is fixed. An outer stitch is formed on the design surface of the covering material. A protrusion is formed along the outer stitch on the fixed surface. A hole with which the protrusion is engageable is formed at the base material. The covering material is fixed to the base material by engaging the protrusion with the hole.