Vehicle Composite Skin with Play Structure for Wrinkle-Free Stitching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing composite materials for vehicles face challenges in preventing wrinkles when stitched into three-dimensional shapes due to the lack of consideration for ease stitching, which affects their appearance and durability.
Innovation Solution
A composite material comprising a skin material with a play structure, preferably a woven fabric with warp and weft yarns of different total finenesses, and a polyurethane foam sheet, which accommodates distortion during stitching, maintaining a smooth surface and preventing wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional backing process is applied to woven fabric, then fraying is prevented and durability is improved, but weight increases
Solution Approach 1:
The invention extracts and eliminates the conventional backing process from the composite material structure. By using a woven fabric with specifically designed yarn arrangements and interlacing patterns, the fabric achieves self-sufficiency in preventing fraying without requiring additional backing layers, thus reducing weight while maintaining durability
Solution Approach 2:
The woven fabric is designed to be self-sufficient through its internal structure. The combination of different yarn types, their interlacing patterns, and the play structure create a self-supporting system that prevents fraying and maintains integrity without external backing, making the material self-service in terms of durability protection
2Shape
If ease stitching with high easing ratio is performed to achieve round three-dimensional shape, then shape quality is improved, but skin material distorts and wrinkles
Solution Approach 1:
The invention introduces dynamic characteristics to the woven fabric through the play structure, which allows the material to adapt and move during the ease stitching process. The fabric can dynamically adjust to the deformation caused by high easing ratio stitching, following the shape changes without developing wrinkles, thus maintaining surface smoothness while achieving round three-dimensional forms
Solution Approach 2:
The invention changes the structural parameters of the woven fabric by incorporating yarns with different total finenesses and varying interlacing patterns. This creates regions with different stiffness and flexibility characteristics, allowing the fabric to accommodate the localized deformation and stress distribution during ease stitching, preventing wrinkle formation while maintaining the desired three-dimensional shape
3Reliability
If yarns with different total finenesses are used to create play structure, then wrinkle resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The invention applies local quality by using yarns with different total finenesses in specific locations within the woven fabric structure. Rather than uniformly changing the entire fabric, the variation in yarn fineness is strategically placed to create the necessary play structure in areas most susceptible to wrinkling during ease stitching, optimizing wrinkle resistance while controlling manufacturing complexity
Data Source
AI summary
Provided is a composite material for vehicles capable of substantially preventing the occurrence of wrinkles caused by ease stitching. This composite material for vehicles is a layered product of a skin material and a polyurethane foam sheet. The skin material has a play structure which, when the composite material for vehicles is stitched, allows the skin material to follow deformation caused by the stitching with a smooth state of a surface of the skin material maintained. The skin material is a woven fabric including warp yarns and weft yarns. The warp yarns and/or the weft yarns include two or more types of yarns having different total finenesses, and form the play structure.