Robotic Sewing Head for Automotive Interior Stitching

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Solution Overview

Problem

Current automotive interior stitching methods are labor-intensive and costly, limiting their application to higher-class vehicles, and the production of a contrasting simulated stitch is not feasible, making it difficult for original equipment manufacturers to offer a 'stitched' look across various price classes.

Innovation Solution

A method involving a robotic sewing head that penetrates an outer skin layer, a substrate layer, and an intermediary layer to create a live, non-functional stitch, allowing for the application of stitching on decorative components with minimal damage and increased accessibility to complex geometries, using a chain stitch pattern that enables stitching through contoured surfaces and large, soft trim panels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional functional stitching methods are used, then stitching can be applied to vehicle interiors, but the process is labor-intensive and costly

Engineering Contradiction:

Improvemanufacturing complexityVSAvoidlabor intensity

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces manual mechanical stitching operations with an automated robotic system that uses a specialized stitching head to perform the stitching function. This substitution eliminates labor-intensive manual operations while maintaining the stitching capability, directly resolving the contradiction between ease of manufacture and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The stitching system is designed to be self-contained with the stitching head integrating multiple functions (penetrating, stitching, and retracting) into a single automated unit. This self-service capability reduces the need for multiple operators and complex manual procedures, thereby reducing labor intensity while maintaining manufacturing capability.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If traditional stitching methods are used, then stitching can be applied, but it is restricted to higher class vehicles due to cost

Engineering Contradiction:

Improveapplication rangeVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent changes the operational parameters of the stitching process by using an automated robotic system with a specialized stitching head that can operate on various material types and thicknesses. This parameter flexibility allows the same system to be applied across different vehicle classes and price points, expanding adaptability while controlling manufacturing costs through automation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The stitching head is designed as a universal component that can perform stitching operations on various vehicle interior components regardless of the specific application. This multi-functionality allows the system to be adapted across different vehicle classes and price segments, expanding the application range while maintaining cost-effectiveness through a single versatile platform.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If stitching is applied to decorative components, then a stitched look can be achieved, but traditional methods are too costly for widespread use

Engineering Contradiction:

Improveaesthetic capabilityVSAvoidproduction feasibility

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces costly manual stitching operations with an automated robotic system that can efficiently produce aesthetic stitching on decorative components. This substitution maintains the desired aesthetic capability while dramatically improving production feasibility by reducing labor costs and increasing throughput for widespread application.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If stitching penetrates through multiple layers, then a secure stitch can be formed, but surface damage may occur

Engineering Contradiction:

Improvestitch securityVSAvoidsurface damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an intermediary stitching mechanism that penetrates through multiple layers to form secure stitches while minimizing surface damage. The specialized stitching head acts as an intermediary tool that distributes the penetration force and creates cleaner, less damaging openings compared to traditional stitching methods, thereby maintaining stitch security while reducing harmful surface effects.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS9869044B2Apparatus and methods for stitching vehicle interior components and components formed from the methods

Publication Date: 2018.01.16 INTEVA PRODUCTS LLC

AI summary

A method of applying stitching to an interior component is provided herein. The interior component having only a single layer of a substrate layer. The method including the steps of: a) penetrating substrate layer with an awl of a sewing head to form a piercing therethrough; b) retracting the awl from the substrate layer; c) inserting a needle of the same sewing head through the piercing through the substrate layer to grasp a thread positioned on a show surface of the outer skin layer; d) pulling the thread through the substrate layer; e) looping the thread with a previous stitch passed through the substrate layer; f) advancing the sewing head to another position with respect to the interior component, wherein a backside of the substrate layer is free of obstructions; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.