Seamless Vehicle Seat Cover With Lining Flaps
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Solution Overview
Problem
Existing vehicle seat cover manufacturing methods result in aesthetically inferior products with visible seams, limiting design continuity and increasing complexity, cost, and compromising comfort due to multiple layers.
Innovation Solution
A vehicle seat element with a seamless cover is achieved by using a lining with joining portions and connecting flaps that are directly connected to the support body, reducing the number of components and manufacturing steps, and allowing for a continuous design without visible seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastening methods are used to attach the cover to the support body, then the cover can be securely fastened, but visible seams appear on the surface deteriorating aesthetic appearance
Solution Approach 1:
The invention extracts the fastening function from the visible surface area and relocates it to the interior lining layer. The connecting flaps are positioned on the lining's second surface facing away from the cover, so that fastening operations occur hidden from view. This allows the cover surface to remain seamless while the support body is securely attached through the lining's connecting flaps.
2Shape
If multiple layers (cover, lining, molding) are used to achieve seamless appearance, then aesthetic appearance improves, but the number of components and manufacturing steps increases
Solution Approach 1:
The invention merges the lining and cover into a closely integrated structure where the lining's second surface directly faces away from the cover. By positioning the connecting flaps on the lining's second surface, the invention combines the aesthetic function of the cover with the fastening function of the lining, reducing the need for separate molding components and simplifying the overall structure.
3Shape
If multiple layers are used to achieve seamless cover, then aesthetic appearance improves, but elasticity and flexibility of the cover decrease
Solution Approach 1:
The invention extracts the fastening and structural support functions from the cover layer itself and relocates them to the lining layer. This allows the cover to remain a thin, flexible, and elastic aesthetic layer without being burdened by additional structural components, while the lining provides the necessary support and connectivity to the support body.
4Reliability
If traditional multi-step manufacturing process is used, then secure fastening is achieved, but manufacturing time and cost increase
Solution Approach 1:
The invention incorporates connecting flaps directly into the lining during its formation, so that the fastening elements are already in place before assembly. This preliminary integration of fastening components into the lining structure eliminates the need for separate fastening operations, reducing manufacturing steps and improving production efficiency while maintaining secure attachment.
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 provides an aesthetically pleasing, cost-effective, and comfortable vehicle seat with a seamless cover that maintains elasticity and flexibility, enhancing user perception of space.
Implementation Method 1
at least one connecting flap, which is provided on a portion of the perimeter of said joining portion and folded towards the support body
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a vehicle seat element (1) provided with a cover (5), and to a method for manufacturing such a vehicle seat element (1). The vehicle seat element (1) comprises a support body (3) and a cover (5) provided with a lining (7), wherein the lining comprises one or more lining elements (7a, 7b, 7c; 107), and wherein at least one of said lining elements includes a joining portion (9a, 9b, 9c; 109a, 109b, 109c), to be attached to the cover, and a connecting flap (11a, 11b, 11c, 11d; 111a, 111b), through which flap(s) the lining is connected to the support body. According to the invention, a vehicle seat element (1) provided with a cover can be manufactured in an easy and cost-effective way. The invention can be advantageously applied to the manufacturing of a vehicle seat element provided with a seamless cover.