Apparatus and methods for stitching vehicle interior components and components formed from the methods

A method of applying stitching to an interior component, comprising only a single substrate layer, the method comprising:

• a) penetrating the substrate layer with an awl of a sewing head to form a piercing therethrough;
• b) retracting the awl from the substrate layer;
• c) inserting a needle of the sewing head through the piercing through the substrate layer to grasp a thread positioned on a show surface of the substrate layer;
• d) pulling the thread through the substrate layer;
• e) looping the thread with a previous stitch passed through the substrate layer;
• f) advancing the sewing head to another position with respect to the interior component, wherein a backside of the substrate layer is free of obstructions;
• and
• g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

A method of applying stitching to an interior component, comprising only a single substrate layer, the method comprising:

• a) penetrating the substrate layer with an awl to form a piercing therethrough;
• b) retracting the awl from the substrate layer;
• c) inserting a needle of a stationary sewing head through the piercing through the substrate layer to grasp a thread positioned on a show surface of the substrate;
• d) advancing the interior component with respect to the stationary sewing head via motion of the needle while the needle is engaged in the piercing of the interior component;
• e) pulling the thread through the substrate layer;
• f) looping the thread with a previous stitch passed through the substrate layer;
• g) repeating steps a-f at different locations of the interior component until a predetermined amount of stitches are applied to the interior component.

A method of applying stitching to an interior component having an outer skin layer, a substrate layer and an intermediary layer located between the outer skin layer and the substrate layer, comprising:

• a) penetrating the outer skin layer, the substrate layer and the intermediary layer with an awl of a robotic sewing head to form a piercing therethrough;
• b) retracting the awl from the outer skin layer, the substrate layer and the intermediary layer;
• c) inserting a needle of the robotic sewing head through the piercing through the substrate layer, the intermediary layer and the outer skin layer to grasp a thread positioned on the outer skin layer;
• d) pulling the thread through the outer skin layer, the intermediary layer and the substrate layer;
• e) looping the thread with a previous stitch passed through the outer skin layer, the intermediary layer and the substrate layer;
• f) advancing the robotic sewing head to another position with respect to the interior component, wherein a backside of the substrate layer is free of obstructions;
• and
• g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

A method of applying stitching to an interior component having an outer skin layer, a substrate layer and an intermediary layer located between the outer skin layer and the substrate layer, the method comprising:

• a) penetrating the outer skin layer, the substrate layer and the intermediary layer with an awl of a sewing head to form a piercing therethrough;
• b) retracting the awl from the outer skin layer, the substrate layer and the intermediary layer;
• c) inserting a needle of the sewing head through the piercing through the substrate layer, the intermediary layer and the outer skin layer to grasp a thread positioned on the outer skin layer;
• d) pulling the thread through the outer skin layer, the intermediary layer and the substrate layer;
• e) looping the thread with a previous stitch passed through the outer skin layer, the intermediary layer and the substrate layer;
• f) advancing the sewing head to another position with respect to the interior component, wherein a backside of the substrate layer is free of obstructions;
• and
• g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

A method of applying stitching to an interior component having an outer skin layer, a substrate layer and an intermediary layer located between the outer skin layer and the substrate layer, the method comprising:

• a) penetrating the outer skin layer, the substrate layer and the intermediary layer with an awl to form a piercing therethrough;
• b) retracting the awl from the outer skin layer, the substrate layer and the intermediary layer;
• c) inserting a needle of a stationary sewing head through the piercing through the substrate layer, the intermediary layer and the outer skin layer to grasp a thread positioned on the outer skin layer;
• d) advancing the interior component with respect to the stationary sewing head via motion of the needle while needle is engaged with the piercing of the interior component;
• e) pulling the thread through the outer skin layer, the intermediary layer and the substrate layer;
• f) looping the thread with a previous stitch passed through the outer skin layer, the intermediary layer and the substrate layer;
• g) repeating steps a-f at different locations of the interior component until a predetermined amount of stitches are applied to the interior component.