T-Member Guide for French Seam Alignment on Curved Armrests
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Solution Overview
Problem
Existing automotive interior seam technologies face challenges in creating aesthetically pleasing French seams on curved and small surfaces like armrests, leading to alignment issues and reduced visual appeal, while also being time-consuming and costly to manufacture.
Innovation Solution
A French seam solution using a T-member extruded from a durable material, secured to the upholstery panels, and aligned with a guide member on a sewing machine to ensure precise and efficient installation, allowing for a more robust and visually appealing seam on armrests and other interior components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional French seam methods are used with laminated foam materials, then the seam can be created on flat surfaces, but the alignment and appearance become problematic on curved surfaces and small components like armrests
Solution Approach 1:
The T-member is pre-formed with a specific T-shaped cross-section and attached to the foam material before the upholstery process. This preliminary preparation of the seam structure enables precise alignment on curved surfaces and small components like armrests, eliminating the alignment problems that occur when traditional French seam methods are applied to non-flat surfaces
Solution Approach 2:
The T-member provides a localized structural element with a specific T-shaped cross-section that creates a consistent seam profile at the joint location. This local structural enhancement allows the seam to maintain proper appearance and alignment precisely where needed, while adapting to the overall curved geometry of components like armrests
2Manufacturing precision
If traditional French seam methods are used, then seams can be created on simple surfaces, but the process becomes time-consuming and costly
Solution Approach 1:
The T-member is pre-formed and attached to the foam material in advance, consolidating multiple operations into a single preparatory step. This preliminary action eliminates time-consuming post-assembly adjustments and ensures consistent seam appearance quality while improving overall manufacturing efficiency
Solution Approach 2:
The invention changes the structural parameter of the seam by introducing a T-shaped cross-section member instead of traditional folded fabric construction. This parameter change simplifies the manufacturing process, reduces production time and cost, while maintaining or improving seam appearance quality through the standardized T-member geometry
3Ease of manufacture
If seams are avoided on armrests to prevent alignment issues, then manufacturing is simpler, but the visual appeal and design flexibility are reduced
Solution Approach 1:
The T-member provides a localized structural solution at the seam location that maintains manufacturing simplicity while dramatically improving design aesthetic. The pre-formed T-member ensures consistent appearance quality without requiring complex assembly procedures, allowing seams to be confidently used for design purposes on armrests and other interior components
Data Source
AI summary
A seam for use in a vehicle armrest or other interior component. The seam includes a first material and a second material joined to the first material. The seam also includes a T-member connected to the first material and the second material to form a French seam appearance on the outer surface of the material. The T-member is then used to align with a groove in a foam of an armrest or other interior component to create an exterior seam on an armrest or interior component of a vehicle. The seam is created using a guide member attached to a sewing machine that will allow for sewing of the first material and second material to the T-member in a simultaneous process at a predetermined speed thus increasing efficiency of manufacturing the upholstery panel and reducing costs to the manufacturer.