Method for stitching vehicle interior components and components formed from the method

Patent metadata

Field	Value
Publication number	US-9809176-B2
Application number	US-201414450609-A
Country	US
Kind code	B2
Filing date	Aug 4, 2014
Priority date	Jul 8, 2011
Publication date	Nov 7, 2017
Grant date	Nov 7, 2017

Abstract

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 is provided herein. The method including the steps of: a) penetrating the interior component to form a piercing therethrough; b) retracting the awl from the interior component; c) inserting a needle of a robotic sewing head through the piercing to grasp a thread; d) pulling the thread through the interior component; e) looping the thread with a previous stitch passed through the component; 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.

First claim

What is claimed is:

1. A method of applying stitching to an interior component, comprising 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 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.

2. The method as in claim 1 , wherein outer skin layer, is formed from one of the following: vinyl, leather and thermoplastic polyolefin; and the intermediary layer is a foam and the substrate layer is formed from plastic.

3. The method of claim 2 , wherein the interior component is an interior trim piece of a vehicle.

4. The method of claim 3 , wherein the interior trim piece is a portion of an instrument panel of the vehicle.

5. The method of claim 1 , wherein the interior component is an interior trim piece of a vehicle.

6. The method of claim 5 , wherein the interior trim piece is a portion of an instrument panel of the vehicle.

7. The method as in claim 1 , wherein outer skin layer, is formed from leather and the intermediary layer is foam and the substrate layer is formed from plastic.

8. The method of claim 1 , wherein the backside of the substrate layer is free of obstructions along the entire stitch length.

9. The method of claim 8 , wherein the interior component is an interior trim piece of a vehicle.

10. The method of claim 9 , wherein the interior trim piece is a portion of an instrument panel of the vehicle.

11. The method of claim 1 , wherein the backside of the substrate layer is configured to have a separate component attached thereto, the separate component being free of any obstructions.

12. The method of claim 11 , wherein the interior component is an interior trim piece of a vehicle.

13. The method of claim 12 , wherein the interior trim piece is a portion of an instrument panel of the vehicle.

14. The method of claim 13 , wherein outer skin layer is formed from leather and the intermediary layer is foam and the substrate layer is formed from plastic.

15. The method as in claim 14 , wherein outer skin layer, is formed from one of the following: vinyl, leather and thermoplastic polyolefin; and the intermediary layer is a foam and the substrate layer is formed from plastic.

16. The method of claim 15 , wherein the interior component is an interior trim piece of a vehicle.

17. The method of claim 16 , wherein the interior trim piece is a portion of an instrument panel of the vehicle.

Assignees

• Inteva Products Llc

Inventors

• Wenzel Edward J
• Massetti Joseph A

Classifications

• B60R13/0256 Primary

  Dashboard liners · CPC title

• B60R2013/0293

  Connection or positioning of adjacent panels · CPC title

• D05C7/04

  for boring or jogging · CPC title

• B60R13/02

  {Internal} Trim mouldings {; Internal} Ledges; Wall liners {for passenger compartments}; Roof liners (B60R13/01 takes precedence {; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18}) · CPC title

• D05B1/06 Primary

  Single chain-stitch seams · CPC title