Abstract: Disclosed is an ornamental chain stitching head, including: an upper head assembly, the upper head assembly controls movement of a needle bar and a walking foot mechanism; a walking foot eccentric configured to allow adjustment of a foot lift while a stitch length eccentric is configured to allow for adjustment of both a walking foot and a needle bar advancement via regulation of a rock frame the determines a length of a stitch created by the ornamental chain stitching head; a lower head assembly; and a needle bar cam assembly that drives rotation of the needle bar during each stitch cycle of the ornamental chain stitching head to achieve desired stitch patterns, the needle bar cam assembly is driven directly by an upper shaft through a pair of gears that reduce the needle bar cam assembly speed according to a size ratio of the pair of gears.

Abstract: An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. A head for applying stitches to a decorative component having a three dimensional configuration, including: a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to provide a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion, the post assembly being operatively coupled to the head via a cylinder arm assembly and a downshaft assembly; and wherein the cylinder arm assembly is rotated in a synchronized manner with a rock frame through mechanical linkage connecting a rock frame drive shaft to the cylinder arm assembly.

Abstract: A needle bar holder for a sewing machine head, including: a revolver configured to hold a plurality of separate needle bars; a motor operably coupled to the revolver for rotating the revolver; and a means for ensuring alignment and stability of the revolver when one of the plurality of separate needle bars are selected for a sewing process.

Abstract: An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. A head for applying stitches to a decorative component having a three dimensional configuration, including: a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to prove a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion, the post assembly being operatively coupled to the head via a cylinder arm assembly and a downshaft assembly; and wherein the cylinder arm assembly is rotated in a synchronized manner with a rock frame through mechanical linkage connecting a rock frame drive shaft to the cylinder arm assembly.

Abstract: An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. The apparatus having a head with a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to provide a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; and a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion.

Abstract: A method of forming a trim panel is provided. The method including the steps of: placing a non-woven mat of material in a heating press; heating the material to a predetermined temperature; applying a decorative film to a first surface of the heated material to create a bilaminate; placing the bilaminate layer into a cavity of a tool such that the decorative film is facing the cavity; heating the cavity; and injecting a thermoplastic resin into the tool such that the thermoplastic resin is adhered to a second surface of the material, the second surface being opposite to the first surface. Also disclosed is the trip panel formed by the foregoing method.

Abstract: A method of forming a trim panel is provided. The method including the steps of: placing a non-woven mat of material in a heating press; heating the material to a predetermined temperature; applying a decorative film to a first surface of the heated material to create a bilaminate; placing the bilaminate layer into a cavity of a tool such that the decorative film is facing the cavity; heating the cavity; and injecting a thermoplastic resin into the tool such that the thermoplastic resin is adhered to a second surface of the material, the second surface being opposite to the first surface.

Abstract: An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. The apparatus having a head with a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to provide a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; and a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion.

Abstract: An apparatus and method for applying stitches to a decorative component having a three dimensional configuration is provided. The apparatus having a head with a needle bar assembly operatively coupled to the head; a looper configured to cooperate with the needle bar assembly in order to provide a plurality of stitches in the decorative component, the looper rotating in a plane parallel to the decorative component; and a post assembly configured to drive the looper in a reciprocating fashion in the plane, wherein the post assembly is operatively coupled to a motor configured to drive the needle bar assembly in a reciprocating fashion.

Abstract: A method of forming a trim panel is provided. The method includes the steps of: heating a non-woven material to a predetermined temperature; applying a decorative film having perforations to a first surface of the heated material to create a bilaminate; placing the bilaminate layer into a cavity of a tool such that the decorative film is facing the cavity; heating the cavity; and injecting a thermoplastic resin into the tool such that the thermoplastic resin is adhered to a second surface of the material, the second surface being opposite to the first surface.

Abstract: An apparatus for stitching an interior component is disclosed herein. The component having an outer skin layer and the apparatus is a single needle chain stitch machine with a rotary looper and wherein a needle of the apparatus descends through the interior component and a hook of the rotary looper engages a thread loop formed during retraction of the needle after it has descended through the interior component; and wherein the apparatus further includes a mechanism for moving the interior component relative to the needle and looper to establish a stitch length.

Abstract: A method of applying stitching to an outer skin layer of an interior component is provided herein, the outer skin layer having a contoured surface.

Abstract: An apparatus for stitching a component is provided. The apparatus having: an awl bar assembly, the awl bar assembly having an awl configured to be moved from a withdrawn position to an inserted position; a needle bar assembly having a needle, the needle movable between an inserted and a withdrawn position, the needle bar assembly being pivotally mounted to a pivot; and a biasing member coupled to the needle bar assembly, the biasing member being arranged to pivot and align the needle bar assembly in response to the needle being moved to the withdrawn position.

Abstract: A method of applying stitching to an interior component is provided herein. The method including the steps of: 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 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) advancing the interior component to another position, wherein a backside of the substrate layer is free of obstructions; and f) repeating steps a-e until a predetermined amount of stitches are applied to the interior component.

Abstract: A method of forming a trim panel is provided. The method includes the steps of: heating a non-woven material to a predetermined temperature; applying a decorative film having perforations to a first surface of the heated material to create a bilaminate; placing the bilaminate layer into a cavity of a tool such that the decorative film is facing the cavity; heating the cavity; and injecting a thermoplastic resin into the tool such that the thermoplastic resin is adhered to a second surface of the material, the second surface being opposite to the first surface.

Abstract: A method of applying stitching to an interior component is provided herein. The method including the steps of: a) penetrating the outer skin layer, the substrate layer and the intermediary layer with a chain stitch pattern machine to form a piercing therethrough; b) retracting the chain stitch pattern machine from the outer skin layer, the substrate layer and the intermediary layer; c) inserting a needle 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) advancing the interior component to another position, wherein a backside of the substrate layer is free of obstructions; and f) repeating steps a-e until a predetermined amount of stitches are applied to the interior component.

Abstract: A method of applying stitching to an interior component is provided herein. The method including the steps of: 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 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 interior component to another position, 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.

Abstract: A method of applying stitching to an interior component is provided herein. The interior component having only a single layer of a substrate layer. The method including the steps of: a) penetrating 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 same sewing head through the piercing through the substrate layer to grasp a thread positioned on a show surface of the outer skin 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.

Abstract: A method of illuminating a component, having an outer skin layer, the method including the steps of: forming the outer surface layer from at least two separate pieces of an outer skin layer, the outer skin layer having a show surface and an opposite backing surface; forming a seam in the outer surface layer such that the at least two separate pieces are secured to each other; locating an elongated light conducting medium in the seam and behind a stitch securing the at least two separate pieces together; and securing the elongated light conducting medium to the outer surface layer.

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.