Wadded Seat Trim Cover Double-Layer Wadding Structure
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Solution Overview
Problem
Existing vehicle seat trim cover designs require multiple components and complex manufacturing processes, leading to uneven seams and inconsistent cushioning, which compromise the luxurious feel and comfort of the seat.
Innovation Solution
A double-layered wadding structure is achieved by sewing two types of wadding members together under the trim cover pieces, eliminating the need for additional core pieces and simplifying the manufacturing process by avoiding grooves and claws, ensuring even cushioning and a luxurious feel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a core piece is used to secure the trim cover to the seat pad, then the trim cover can be firmly attached, but the number of components increases and the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the core piece and wadding member into a single integrated component. The wadding member is placed inside the trim cover piece, eliminating the need for a separate core piece to provide structural support and attachment functionality, thereby reducing component count while maintaining attachment firmness
Solution Approach 2:
The wadding member serves multiple functions: it provides cushioning, maintains the shape of the trim cover, and enables attachment to the seat pad through the protruding end. This multi-functional design replaces the need for separate core pieces and wadding members, simplifying the overall structure
2Reliability
If a core piece with claws is used to attach the trim cover, then the attachment is secure, but the single-stitch seam becomes uneven and the outer appearance is lowered
Solution Approach 1:
The patent combines the attachment function into the seam itself by making the wadding member protrude through the trim cover at the seam location. This allows the seam to serve both as a joining element and an attachment element, eliminating the need for separate claws and producing a more uniform appearance
Solution Approach 2:
The protruding end of the wadding member acts as an intermediary element that connects the trim cover to the seat pad through the groove. This mediator enables secure attachment while allowing the seam to remain smooth and uniform on the visible surface
3Reliability
If grooves and claws are used to attach the trim cover, then the attachment is firm, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges multiple manufacturing steps into fewer operations. Instead of separately creating grooves, claws, and attachment mechanisms, the design uses the seam allowance and wadding member protrusion to achieve attachment, simplifying the manufacturing process
Solution Approach 2:
The patent extracts and eliminates unnecessary components from the manufacturing process. By removing the need for separate core pieces, grooves, and claws, and instead using the existing seam structure with a protruding wadding member, the manufacturing process is significantly simplified
Data Source
AI summary
A surface structure of wadded seat, with a trim cover having a plurality of trim cover pieces backed with wadding members and sewed together at ends, further includes: first sewed portions, each formed by sewing two adjacent trim cover pieces at one end of each trim cover piece, while serving as seam allowance, the portions not backed with the wadding members; second sewed portions, each formed first by forming a continuous trim cover piece, then by laying a long wadding member on the backs of the wadding members, and finally by sewing, at both ends of the continuous trim cover piece, the wadding members on the backs of the trim cover pieces and the long wadding member; and third sewed portions, each formed by sewing, at both ends of each first sewed portion, the long wadding member to the end of each trim cover piece.