Trim Cover Jig for Stitch and Hole Alignment
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Solution Overview
Problem
The existing manufacturing methods for trim cover surface materials face challenges with misalignment of stitches and through hole patterns due to deformation of leather over time, especially when automatic sewing is used, leading to design spoilage.
Innovation Solution
A manufacturing method and apparatus that utilize a jig with a first frame to hold the outer material and a second frame to hold the wadding material, allowing for simultaneous holding and stitching without removing the outer material, ensuring precise positioning and alignment throughout the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the leather is formed with through holes beforehand and then stitched later, then the breathability of the leather is secured, but the leather deforms under temperature and humidity influence causing through hole patterns to deviate and misalignment with stitches
Solution Approach 1:
The through holes are formed in the leather beforehand before stitching, allowing the breathability function to be established early in the process while the leather is still constrained by the jig, preventing deformation during the subsequent stitching operation
Solution Approach 2:
A jig is introduced as an intermediary device that holds both the leather and wadding material in precise alignment during both the through hole formation and stitching operations, preventing deformation and misalignment that would otherwise occur between separate operations
2Measurement precision
If the outer periphery is held by a frame-like jig during automatic sewing, then the positioning is improved, but an error in positioning of the surface material to the jig may still occur when the leather is deformed
Solution Approach 1:
The jig is designed to hold both the leather and wadding material simultaneously in a merged positioning system, ensuring that both layers remain aligned throughout the stitching process without relative movement or positioning errors
3Strength
If the leather and wadding material are bonded at the outer periphery, then the bonding strength is improved, but the positioning becomes further harder when the leather is deformed
Solution Approach 1:
The positioning of both leather and wadding material is established beforehand using the jig before bonding occurs, ensuring that both components are correctly positioned and aligned prior to the bonding process, making subsequent bonding easier and more accurate
Data Source
AI summary
A manufacturing method of a trim cover surface material, includes: providing a jig including a first frame configured to hold an outer periphery of an outer material and a second frame configured to hold an outer periphery of a wadding material by overlapping the wadding material on the outer material which is held by the first frame; holding the outer periphery of the outer material with the first frame of the jig; forming through holes at the outer material which is held by the jig; holding the outer periphery of the wadding material with the second frame of the jig while the outer material is held by the first frame of the jig; and forming stitches at the outer material and the wadding material which are overlapped and held by the jig.