Clip bushing, foam molded body and manufacturing process for a foam molded body

Abstract

Foam body (20) with a clip socket (10; 10a) and a cover fastening groove (30) in which the clip socket (10; 10a) is embedded, wherein the clip socket (10; 10a) can be engaged with a clip plug part (50; 50a) which is connected to at least one cover (40a, 40b) which covers at least a part of an outer surface of the foam body (20), wherein the clip socket (10; 10a) comprises: a bottom wall (11); a pair of right and left side walls (12; 12a) which extend from the bottom wall (11) to the right and left and upwards; and a pair of right and left engaging sections (13) extending from the upper sides of the right and left side walls (12; 12a) towards a midpoint between the right and left side walls (12; 12a), wherein the right and left engaging sections (13) can be engaged with the clip plug part (50; 50a), and wherein the clip socket (10;10a) comprises, between the right and left side walls (12; 12a): a clip insertion part receiving chamber (14) which can receive the clip insertion part (50; 50a) between the right and left engaging sections (13), and insertion chambers (15) for foam material on the right and left side of the clip insertion part receiving chamber (14) for introducing a material of the foam molded body (20), wherein the foam molded body (20) comprises inner shaped sections (22) of the clip socket (10, 10a) which are formed in the insertion chambers (15) for foam material, characterized in that the bottom wall (11) has an upwardly projecting extension (16).

Description

FIELD OF THE INVENTIONThe present invention relates to a clip jack, a molded foam body, and a manufacturing method of a molded foam body. More specifically, the present invention relates to a method for manufacturing a clip bush embedded in a molded body such as a seat for an automobile to be engaged with a clip fitting connected to a cover covering the foam molded body; a foam molded body in which the clip bush is embedded; and a method for manufacturing such a foam molded body.BACKGROUND OF THE INVENTIONSeats for automobiles, trains, buses, and the like, sofas, massage chairs, and the like basically include a foam molded body (a cushion body) formed by molding a foaming resin, and at least one trim covering an outer surface of the foam molded body. The covers are usually made of natural leather, artificial leather or the like. As a means for fixing an edge of the trim cover covering the outer surface of the molded foam body, Patent Document 1 (U.S. Patent No. No. 7,517,577 B1) that a clip plug is connected to an edge of the trim cover, while a clip socket engageable with the clip plug is embedded in a trim cover attachment groove of the molded foam body. However, in the means in Patent Document 1, although a plate-like base of the clip bush is embedded in the molded foam body, a main body of the clip bush is entirely exposed from the molded foam body. Accordingly, there is a problem that the peeling strength of the clip bush is low.PRIOR ART DOCUMENTSPatent LiteraturePatent Document 1: U.S. Pat. No. 7,517,577 B1SUMMARY OF THE INVENTIONTechnical ProblemAn object of the invention is to provide a clip bush having high peel strength with respect to a molded foam body, a molded foam body in which such a clip bush is embedded, and a method for producing the molded foam body.Solution of the ProblemIn one aspect, the present invention provides a clip jack engageable with a clip plug that is engageable with at least one trim covering at least a part of an outer surface of a molded foam body and that is embedded in a trim mounting groove of the molded foam body, the clip jack comprising: a bottom wall; a pair of right and left side walls extending rightward and leftward and upward from the bottom wall, respectively; and a pair of right and left engaging portions extending from upper sides of the right and left side walls toward a center between the right and left side walls, wherein the right and left engaging portions are engageable with the clip fitting part, and wherein the clip jack includes, between the right and left side walls: a clip fitting part receiving space capable of receiving the clip fitting part between the right and left engaging portions, and foam material inserting spaces at the right and left sides of the clip fitting part receiving space to insert a material of the foam molded body.The clip bush according to the present invention is embedded in the cover fixing groove formed when the molded foam body is molded. By inserting the clip fitting attached to an edge or the like of the trim covering the outer surface of the molded foam body into the clip fitting receiving space between the pair of right and left engaging portions of the clip bush through the trim attachment groove, the clip fitting is engaged with the clip bush so that the trim is firmly disposed on and covers the molded foam body. The cover fixing groove may be divided into the clip fitting part accommodating space among the right and left engaging portions of the clip socket and a space among the right and left engaging portions of the clip socket. The latter space is open upward to the outer surface of the molded foam body. By detaching the clip plug from the clip socket, the cover can be removed for washing or replacement. The clip jack includes the right and left foam insertion spaces between the right and left side walls. By inserting a foaming material into the foaming material insertion spaces while the molded foam body is being molded, the clip bush can be securely embedded in the molded foam body. This can increase the peel strength of the clip socket with respect to the molded foam body.In the present invention, the molded foam body may be, for example, seats for automobiles, trains, buses, and the like, sofas, massage chairs, and the like, but is not limited thereto. The clip jack according to the present invention may be formed of, for example, thermoplastic resins such as polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl acetate, polyurethane, Teflon® ABS resin, AS resin, acrylic resins and the like, but is not limited to these materials. Further examples of the material of the molded foam article include, but are not limited to, polyurethane, polystyrene, polyolefins, phenolic resins, polyvinyl chloride, urea resins, silicones, polyimides, melamine resins, and the like.In an embodiment of the present invention, the right and left engaging portions or the right and left side walls are flexible. Accordingly, the right and left engaging portions can be respectively bent rightward and leftward when the male member is inserted between the right and left engaging portions of the clip jack.In an embodiment of the present invention, right and left side walls extend in a curved manner from the bottom wall rightward and leftward and upward, respectively; and the pair of right and left engaging portions extend diagonally downward from the upper end of the right and left side walls, respectively, toward a center between the right and left side walls. By extending the right and left side walls in a curved manner to the right and left and upward, respectively, the right and left side walls become flexible to the right and left, respectively, and a sufficient clearance for the foam material introduction spaces on the right and left sides is obtained between the right and left side walls. Further, by extending the pair of right and left engaging portions from the upper end of each of the right and left side walls diagonally downward toward a center between the right and left side walls, the clip fitting can be smoothly inserted into the clip fitting receiving space between the right and left engaging portions, and once the clip fitting is inserted into the clip fitting receiving space, it cannot be easily pulled out again between the right and left engaging portions because the clip fitting is locked by the edges or tips of the right and left engaging portions.In one embodiment of the present invention, the bottom wall has an upwardly projecting extension. The extension can be effectively utilized in the following cases: (i) with the extension, an insertion piece of a clip holding member as mentioned below can be easily disposed at a predetermined position in the clip insertion part receiving space of the clip socket by inserting the insertion piece into the clip insertion part receiving space when the molded foam body is molded; and ii) the clip insertion part can be held at a predetermined optimum position in the clip insertion part receiving space of the clip socket when the clip insertion part is received in the clip insertion part receiving space. In either of the cases i) and ii), for example, a recess or a recess into which the projection fits may be provided in the insertion piece of the clip holding member or the clip fitting part.In another aspect, the present invention provides a group of clip jacks comprising a plurality of clip jacks as described above, the plurality of clip jacks being interconnected by at least one link. In the group of clip sleeves, two adjacent clip sleeves are spaced apart from each other by a predetermined gap. Through this gap, the foaming material can flow into the foam material introduction spaces inside each of the clip bushes while the molded foam body is being molded. As the connecting member, for example, flexible metal wires, twisted string-like members such as twist strings, monofilaments, and the like may be used, but are not limited thereto. When using a group of a plurality of the clip bushes connected to each other by connecting members in forming the molded foam body, it is easier to align the clip bushes in a molding die compared to using individual clip bushes independent from each other. Furthermore, when using flexible connectors, it is possible to flexibly arrange a group of clip bushes in a curved reference fastening groove.In yet another aspect, the present invention provides a foam molded body including the trim attachment groove in which the clip socket is embedded. By inserting the clip fitting attached to an edge or the like of the trim covering the outer surface of the molded foam body into the clip fitting receiving space between the pair of right and left engaging portions of the clip bush through the trim attachment groove, the clip fitting is engaged with the clip bush so that the trim is firmly disposed on and covers the molded foam body.In another aspect, the present invention provides a method of manufacturing a molded foam article having at least one clip socket embedded in a trim cover attachment groove, the clip socket engageable with at least one clip plug connected to at least one trim cover, the trim cover covering at least a part of an outer surface of the molded foam article, the clip socket comprising: a bottom wall; a pair of right and left side walls respectively extending rightward and leftward and upward from the bottom wall; and a pair of right and left engaging portions extending from upper sides of the right and left side walls toward a center between the right and left side walls, the right and left engaging portions engageable with the clip plug, and the clip socket comprising:, between the right and left side walls: a clip insertion part accommodating space capable of accommodating the clip insertion part between the right and left engaging portions, and foam material introducing spaces at the right and left sides of the clip insertion part accommodating space for introducing a material of the foam molded body, the method comprising: a step A of providing a mold for molding the foam molded body, the mold comprising a clip holding member capable of holding the clip bush at a position corresponding to the reference fixing groove in a cavity surface of the mold, the clip holding member comprising a groove forming portion for forming a portion other than the clip insertion part accommodating space of the clip bush in the reference fixing groove; and an insertion piece protruding from the groove forming portion and inserted into the clip insertion part receiving space between the right and left engaging portions of the clip socket therethrough; a step B of fixing the clip socket to the insertion piece of the clip holding member by inserting the insertion piece into the clip insertion part receiving space between the right and left engaging portions of the clip socket so that the clip holding member holds the clip socket; and a step C of filling the mold with a material to form the molded foam body, the material being inserted into the foam material insertion spaces in the clip socket.In the step A of the present invention, the casting mold for forming the molded foam body is provided. The inside of the mold includes a clip holding member that can firmly arrange and hold the clip bushing at a position corresponding to the cover fixing groove in a cavity surface of the mold. The clip holding member includes a groove forming portion for forming a portion other than the clip insertion part accommodating space of the clip socket in the reference fixing groove, more specifically, a portion of portions of the clip socket engaging between the right and left to the outer surface of the molded foam body; and an insertion piece protruding from the groove forming portion. The insertion piece is inserted into the clip insertion part receiving space between the right and left engaging portions of the clip socket. The groove forming portion of the clip holding member extends over the entire length in the longitudinal direction of the cover fixing groove. On the other hand, the insertion piece of the clip holding member may be provided over the entire length of the trim attachment groove as in the groove forming portion, or may be provided only in a part corresponding to each clip socket (only in a part for inserting the clip fitting part) in a discontinuous manner in the longitudinal direction of the trim attachment groove.In step B of the present invention, the insertion piece is received in the clip insertion part receiving space between the right and left engaging portions of the clip bushes to fix the clip insertion piece to the insertion piece of the clip holding member. As a result, the clip bushing is held by the clip holding element. The clip socket held by the clip holding element is placed upside down so that the bottom wall is located at the top side. When using a group of a plurality of the clip bushes connected to each other by the connecting members, it is easier to fasten the clip bushes to the clip holding member compared to using individual clip bushes independent of each other.In step C of the present invention, the casting mold is filled with the material of the molded foam body, and the material is foam-cast. Thereby, in the molded foam body by the groove forming portion of the clip holding member, the portion other than the clip fitting part accommodating space of the clip socket is formed in the reference fixing groove, more specifically, the portion of portions engaging between the right and left is formed to the outer surface of the molded foam body. Moreover, the clip plug-in part receiving space of the clip socket is formed by the insertion piece of the clip holding element. Further, by flowing the foaming material into the foam insertion spaces on the right and left sides of the clip bush, the space between the right and left side walls of the clip bush is filled with the foamed molded body, leaving the clip fitting part receiving space. This can increase the peel strength of the clip socket with respect to the molded foam body.In an embodiment of the present invention, in the step B, the insertion piece of the clip holding member and the bottom wall of the clip socket are attracted to each other by magnetic force. To achieve this, for example, at least one tip of the insertion piece of the clip holding element can be made of a magnet or a magnetic body, while metallic media or magnetized media which attract the magnet or the magnetic body of the insertion piece are embedded in the bottom wall of the clip socket. Since the insertion piece of the clip holding member and the bottom wall of the clip socket can magnetically attract each other, it would be possible to improve workability in setting the clip socket to the clip holding member.In an embodiment of the present invention, the clip socket has an extension projecting upward from the bottom wall, and the insertion piece of the clip holding member may have a recess matching the extension. By engaging the extension of the clip socket with the recess of the insertion piece of the clip holding element, it would be easy to arrange the clip socket at a predetermined position in the clip holding element.In an embodiment of the present invention, a plurality of clip sleeves are connected to each other by at least one connecting member. By using a group of clip bushes connected to each other by the connecting members, it would be easier to fasten the clip bushes to the clip holding element compared to using individual clip bushes independent of each other.Advantageous Effects of the InventionIn the present invention, by inserting a foam material into the foam material insertion spaces between the right and left sides of the clip insertion part accommodation space of the clip insertion part while the foam molded body is being molded, the clip socket can be securely embedded in the foam molded body. This can increase the peel strength of the clip socket with respect to the molded foam body.BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is a perspective view illustrating a group of clip jacks including five clip jacks connected to each other as an example. FIG. 2 is a side view of the clip jack assembly in FIG. 1. FIG. 3 is a front view illustrating one of the clip bushes of the group in FIG. 1. FIG. 4 is a plan view of the clip jack in FIG. 3. FIG. 5 is a partial cross-sectional explanatory view illustrating a clip socket embedded in a reference fixing groove of a molded foam body. FIG. 6 is an explanatory view showing a state in which a clip connector connected to an edge of a trim cover is engaged with the clip socket of FIG. 5. FIG. 7 is an explanatory view showing a state in which a clip holding member firmly aligned with a cavity surface of a mold for molding a molded foam body holds a clip bush. FIG. 8 is a partial cross-sectional view illustrating another example of a clip jack and a clip plug. FIG. 9 is an explanatory view illustrating a clip holding member having a recess.DESCRIPTION OF THE EMBODIMENTSHereinafter, preferred embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to such embodiments, and the embodiments may be modified or changed within the scope of the claims or the range of equivalents. FIGS. 1 and 2 are respectively a perspective view and a side view of a group 10G of clip bushes (clip bush group 10G) in which five clip bushes 10 are connected to each other by way of example. Each of the clip sleeves 10 is according to an embodiment of the present invention. Each of the clip bushes 10 of the clip bush group 10G is connected to each other by a flexible metal wire 18 as a connecting member. Adjacent clip bushes 10 are each spaced apart from one another by a gap 19. The distance of each gap 19 may be about 1 / 3 of the length in the longitudinal direction (the right-left direction in FIG. 2 ) of each clip bush 10. As will be described in detail below, a foam material is partially introduced into each clip socket 10 through the gaps 19 while a foam molded body 20 (partially illustrated in FIGS. 5 and 6, etc.) is being molded, and thereby the clip socket group 10G is embedded in the foam molded body 20. In this embodiment, the molded foam body 20 is a cushion body for seats of automobiles, but the present invention is not limited thereto. The molded foam body may also be a molded foam body obtained with covers for seats for other vehicles, sofas, massage chairs, and the like. For example, the wire 18 may be integrally embedded in the clip bushes 10 at the center of each bottom wall 11 as described below while the clip bush group 10G is formed of a thermoplastic resin. The clip bush group 10G is embedded in a reference fixing groove (hereinafter referred to simply as "fixing groove") 30 of the molded foam body (see FIGS. 5 and 6, etc.). By engaging each clip bush 10 with a clip fitting part 50 connected to each edge or each end of first and second covers 40 a, 40 b, the first and second covers 40 a, 40 bcover at least a part of an outer surface of the molded foam body 20. When a clip jack group 10G consisting of five clip jacks 10 is used as one unit, plural units can be used over the entire length in the longitudinal direction of the fixing groove 30. Alternatively, one or more groups having more or less than five clip bushings may be used over the entire length in the longitudinal direction of the attachment groove 30. When the attachment groove 30 is linear, the link (wire 18 in this embodiment) does not need to have flexibility. However, by providing a link member having flexibility, it is possible to flexibly align the clip jack group 10G in a curved mounting groove 30.FIG. 3 is a front view of one of the clip bushes 10 of the clip bush group 10G, and FIG. 4 is a plan view of the clip bush 10. Further, the direction in which the wire 18 extends refers to a front-rear direction. The clip bush 10 may be formed by, for example, injection molding a thermoplastic resin. The clip jack 10 includes a bottom wall 11; a pair of right and left side walls 12 extending from the bottom wall 11 rightward and leftward and upward, respectively, in a curved manner; and a pair of right and left engaging portions 13 extending obliquely downward from the upper end of the right and left side walls 12, respectively, toward a center between the right and left side walls 12. In other words, the left side wall 12 extends upward from the left side of the bottom wall 11 in a curved manner, while the left engaging portion 13 extends obliquely downward from the upper end of the left side wall 12 toward the right side wall 12, and the right side wall 12 extends upward from the right side of the bottom wall 11 in a curved manner, while the right engaging portion 13 extends obliquely downward from the upper end of the right side wall 12 toward the left side wall 12. The engaging portion 13 extends from the upper end of the side walls 12 toward the other side wall 12 and the bottom wall 11 and accordingly, the distal ends of the right and left engaging portions 13 are arranged lower than the upper ends of the right and left side walls and are arranged higher than the level corresponding to half or the midpoint of the height of the clip bush 10 in the up and down direction. Thereby, it is possible to obtain a dimension in the up-and-down direction for accommodating the clip fitting 50. Further, the distance between the right and left engaging portions 13 in the right and left direction is less than or equal to half the width of the clip bush 10 in the right and left direction, preferably less than or equal to one third thereof. Thereby, the engaging portions 13 can be easily bent when they are engaged with the clip fitting 50. Moreover, the right and left direction dimension of each engaging portion 13 is less than half the right and left direction dimension of the clip socket 10, and more than one third thereof. Thereby, the engaging portions 13 can be easily engaged with the clip fitting 50. The bottom wall 11 and the respective side walls 12 are smoothly connected to each other. The clip bush 10 is open in the front-rear direction. In the bottom wall 11, the wire 18 is integrally embedded and extends in the front-rear direction when the clip bush 10 is injection molded. The wire 18 serves as a connection between the adjacent clip bushes 10 in the clip bush group 10G. The portion of the bottom wall 11 with the embedded wire 18 is slightly raised to form a bulge 18 aextending in the front and rear direction. The wire 18 is partially exposed from the bulge 18a. As shown in FIG. 3, the wire 18 and the bulge 18 amay be referred to as an extension that protrudes upward from the bottom wall 11. The bottom wall 11 (except for the wire 18 and the bulge 18a) and each side wall 12 have the same thickness, and each engaging portion 13 has a thickness slightly thinner than that of the side walls 12. The space between the right and left side walls 12 of the clip jack 10 is divided into a clip insertion center receiving space 14 capable of receiving the clip insertion 50 between the right and left engaging portions 13, and foam material insertion spaces 15 at the right and left sides of the clip insertion receiving space 14 for receiving a foam material when the foam molded body 20 is molded (see a broken line in FIG. 3 ). Each of the foam material introduction spaces 15 is the space surrounded by an imaginary line extending from the distal end of each engaging portion 13 along the up-and-down direction and each side wall 12 and each engaging portion 13. The foam material introduction spaces 15 are open in the front and rear direction.In the clip receptacle 10, a predetermined interval is provided between the right and left engaging portions 13, and the interval defines a receiving port 14 afor receiving the clip fitting 50 into the clip fitting receiving space 14. the clip fitting receiving space 14 is the interval surrounded by the imaginary lines from the respective distal ends of the right and left engaging portions 13 along the up-and-down direction and the bottom wall 11. the clip fitting receiving space 14 is open in the front-and-rear direction. Referring to FIG. 6, the clip fitting part 50 includes a clip body 51 to which the first and second covers 40 a, 40 bare connected, and right and left engaging portions 52 respectively protruding rightward and leftward from the right and left sides of the clip body 50 in a nearly rectangular shape. The distance between the right and left engaging portions 13, more specifically, the lateral width of the receiving terminal 14a is substantially the same as the lateral width of the clip body 51 of the clip fitting 50, and is slightly narrower than the entire lateral width of the right and left engaging portions 52. Thereby, the engaging portions 52 of the clip fitting 50 are received through the receiving terminal 14 ainto the clip fitting receiving space 14. The right and left side walls 12 are formed in a curved manner so that the right and left engaging portions 13 are bent rightward and leftward upon engagement with the clip fitting 50. The right and left engaging portions 13 themselves also have flexibility.FIG. 5 is a partial cross-sectional explanatory view illustrating a clip socket 10 embedded in a fixing groove 30 of the molded foam body 20. FIG. 6 is an explanatory partial cross-sectional view showing the clip jack 10 of FIG. 5 engaged with the clip fitting 50 to which each edge of the first and second datums 40 a, 40 bis attached. In this embodiment, each edge of the first and second covers 40 a, 40 bis fixed to an upper part of a single plate member 53 by sewing, for example, and a lower part of the plate member 53 is fixedly embedded in the clip body 51 of the clip fitting part 50. The attachment groove 30 includes an upper groove portion 31 over the right and left engaging portions 13 of the clip socket 10, and a clip-fitting-part accommodating space 14 of the clip socket 10 formed continuously downward from the upper groove portion 31. The bottom surface of the mounting groove 30 is defined by the bottom wall 11 of the clip fitting 50. The upper groove portion 31 is open to a surface 21 of the molded foam body 20. The lateral width of the upper groove portion 31 slightly exceeds the maximum lateral width of the clip fitting 50, more specifically, the lateral width of the right and left engaging portions 52. The right and left inner molded portions 22 of the clip jack are molded by the foam material inserted into the foam material insertion spaces 15 inside the clip jack 10, as described below. Since the accommodation space 14 is disposed below the upper groove portion 31, the accommodation space 14 may also be referred to as a lower groove portion 14. The lateral width of the clip-fitting-part accommodating space 14 is the same as that of the accommodation terminal 14 aof the clip-fitting-part accommodating space 14, but since the right and left inner molded portions 22 of the clip socket on the right and left sides of the clip-fitting-part accommodating space 14 have a cushioning property, the clip-fitting-part accommodating space 14 can accommodate the clip-fitting part 50 having a greater lateral width than that of the clip-fitting-part accommodating space 14 thanks to the engaging portions 52. As shown in FIG. 3, each distal end of the right and left engaging portions 13 of the clip jack 10 forms a downwardly sharp edge 13c formed by a vertical surface 13a extending in the up-and-down direction and an inclined lower surface 13b of each engaging portion 13. Moreover, the lateral width between right and left upper surfaces 13d of the engaging portions 13 gradually decreases from the upper ends of the right and left side walls 12 toward the receiving terminal 14a, whereby the upper surfaces 13d of the engaging portions 13 are inclined. Accordingly, as shown in FIG. 6, when the engaging portions 52 of the clip fitting 50 enter the clip fitting receiving space 14, first hypotenuses 52 aof substantially rectangular triangular portions come into contact with the engaging portions 13 and bend these portions 13. Since the molded foam body 20 including the right and left inner molded portions 22 of the clip bush has a cushioning property, the right and left side walls 12 and the engaging portions 13 of the clip bush 10 embedded in the molded foam body 20 may bend when being engaged with the clip fitting 50. Moreover, after the clip fitting part 50 is inserted into the clip fitting part receiving space 14 of the fixing groove 30 in the molded foam body 20, the clip fitting part 50 can be removed again from the fixing groove 30 including the clip fitting part receiving space 14 by pulling up the first and second covers 40 a, 40 bwith a force larger than a certain level. In this way, the first trim cover 40a or the second trim cover 40b can be detached for washing or replacement.Next, a method of manufacturing the molded foam body 20 in which the clip bush 10 is embedded in the fixing groove 30 will be described. FIG. 7 is an explanatory cross-sectional view illustrating a clip holding member 70 that holds the clip bush 10. Hereinafter, the up and down direction of the clip holding member 70 is based on FIG. 7. the clip holding member 70 is fixedly aligned at a position where the attachment groove 30 is formed on a cavity surface 61 of a mold 60 for molding the molded foam body 20 after foam molding. In this manner, the mold 60 is provided (step A). In order to fix the clip holding element 70 to the casting mold 60, the casting mold 60 can be manufactured with a lower end of the clip holding element 70 embedded in the casting mold 60, for example. The cavity surface 61 coincides with the surface 21 (see FIGS. 5 and 6 ) of the molded foam body 20. The clip holding member 70 includes a center plate 71 extending upward from the cavity surface 61 and a groove forming portion 72 or right and left groove forming plates 72 fixed to the right and left sides of the center plate 71. The center plate 71 protrudes above the groove forming portion 72, and this protruding part of the center plate 71 constitutes an insertion piece 73 to be inserted into the clip insertion part receiving space 14 of the clip socket 10. Although not illustrated, the groove forming portion 72 and the insertion piece 73 extend over the entire length of the attachment groove 30 in the longitudinal direction thereof. However, the insertion piece 73 does not necessarily extend over the entire length in the longitudinal direction of the attachment groove 30, but may be interrupted in the longitudinal direction of the attachment groove 30 as long as the clip fitting part 50 can be engaged with each of the plurality of clip bushes 10 held by the clip holding member 70.The groove forming portion 72 of the clip holding member 70 is a part for forming the upper groove portion 31 of the attachment groove 30, and the insertion piece 73 is a part for forming the clip fitting part accommodating space 14 of the clip socket 10. For this reason, the lateral width of the groove forming portion 72 is equal to the lateral width of the upper groove portion 31, and the lateral width of the insertion piece 73 is equal to the distance between the right and left engaging portions 13 of the clip socket 10. FIG. 7 shows a state in which the clip socket 10 has accommodated the insertion piece 73 of the clip holding member 70 into the clip fitting part accommodating space 14 between the right and left engaging portions 13 until the upper end of the insertion piece 73 has come into contact with the bottom wall 11, where the clip socket 10 has been placed upside down with the bottom wall 11. In this state, the upper surfaces of the right and left groove forming plates 72 are configured to incline rightward and leftward, respectively, so that the upper surfaces are parallel to and close to the upper surfaces 13 d(lower surfaces based on FIG. 7 ) of the right and left engaging portions 13 of the clip bush 10. The upper end of the insertion piece 73 is provided with a recess 73a corresponding to the bulge 18a of the bottom wall 11 of the clip socket 10. When the clip socket 10 is held by the clip holding member 70, the upper end of the insertion piece 73 having the recess 73 aand the bulge 18 ais in contact with the bottom wall 11 of the clip socket 10 without a gap therebetween. In this manner, the insertion piece 73 is received in the clip insertion part receiving space 14 of the clip socket 10, and the clip socket 10 is held by the clip holding member 70 (step B). Actually, a plurality of units in which the clip jack group 10G is integrated with five clip jacks 10 (as mentioned above) are used and fixed to the clip holding member 70 so as to extend over the entire longitudinal direction of the fixing groove 30. This is far more effective than securing the clip sleeves 10 one by one to the clip retaining member 70.As described above, the foam resin for foam molding is filled in the mold 60 (step C) when the clip bush 10 (more specifically, the clip bush group 10G) is held by the clip holding member 70. During the foam molding, the upper groove portion 31 of the attachment groove 30 is formed by the groove forming portion 72 of the clip holding member 70, and the clip plug receiving space 14 of the attachment groove 30 is also formed between the right and left side walls 12 of each clip socket 10 by the insertion piece 73 (described below). That is, during the foam molding, the foam material flows into the foam material insertion spaces 15 on the right and left sides of the insertion piece 73 of the clip holding member 70 in each clip socket 10 through the gaps 19 of the clip socket group 10G. Thereby, the right and left inner molded portions 22 of the clip socket are molded between the right and left side walls 12 of the clip socket 10, and the clip fitting part accommodating space 14 is left between the right and left inner molded portions 22 of the clip socket. In this way, a molded foam body 20 is manufactured, which includes the mounting groove 30 and the clip bush group 10G embedded in the mounting groove 30.In order to further improve workability in the step of holding the clip bush group 10G by the clip holding member 70 in the method of manufacturing the molded foam body 20, for example, the tip of the insertion piece 73 of the clip holding member 70 and the bottom wall 11 of the clip bush 10 may be attracted to each other by magnetic force to successfully locate the insertion piece 73 at the predetermined position in the clip bush 10. To achieve this, for example, at least the tip of the insertion piece 73 may be made of a magnet or a magnetic body, while metallic media or magnetized media that attract the magnet or the magnetic body of the insertion piece 73 are embedded in the bottom wall 11 of the clip socket 10. As shown in FIG. 8, in another embodiment, a protrusion 16 that protrudes further beyond the bulge 18 amay be provided, and a recess 74 matching the protrusion 16 may be provided at the tip portion of the insertion piece 73 (as shown in FIG. 9 ). This would make it easier to adjust the clip socket 10, 10 ato the predetermined position of the clip holding member 70. The above-mentioned method using magnetic attractive force can be combined with the above-mentioned method using the accuracy of fit between the extension 16 and the recess 74. That is, the extension 16 and the recess 74 may have a mutual magnetic attractive force. Since the clip holding member shown in Fig. 9 is the same as the clip holding member 70 (except that the former has the recess 74), the same reference numeral 70 is used for the former, and the same reference numerals are also used for other parts of the former clip holding member.FIG. 8 is a partial cross-sectional view illustrating another example of the clip socket and the clip fitting. The clip bush 10 ain FIG. 8 is different from the clip bush 10 described above as follows: the right and left side walls 12 aof the clip bush 10 aextend more to the right and left than the side walls 12 of the clip bush 10, respectively. Further, the protrusion 16 protruding beyond the bulge 18 aof the bottom wall 11 of the clip bush 10 is provided with the wire 18 embedded therein so as to be continuous in the front and rear direction. Here, too, since the clip bush 10a is the same as the clip bush 10 (except for the side walls 12a and the projection 16), the same reference numerals as the latter are used for the former, and descriptions of the same parts are omitted. The above descriptions of the clip socket 10 may also apply to the clip socket 10 aand the clip socket 10 may be provided with the extension 16. A clip plug 50a is composed of two clips, more specifically a left-hand first clip 51a and a right-hand second clip 51b. An edge of the first trim 40 ais fixed to an upper end of a first plate member 53 a, for example, by sewing, and a lower end of the first plate member 53 ais fixed to the first clip 51 a. An edge of the second trim 40 bis fixed to an upper end of a second plate member 53 b, for example, by sewing, and a lower end of the second plate member 53 bis fixed to the second clip 51 b. The first and second clips 51a, 51b include respective engaging portions 52c projecting leftward and rightward from the left and right sides of the clips 51a, 51b in a nearly rectangular shape. The first clip 51 ato which the first trim cover 40 ais attached and the second clip 51 bto which the second trim cover 40 bis attached are separate from each other, and they can be attached between the engaging portions 13 in a manner in which the first and second clips 51 a, 51 bare connected or in contact with each other, as illustrated in FIG. 8. For this reason, the first cover 40a or the second cover 40b can be removed from the first plate member 53a or the second plate member 53b, so that re-covering of the covers is easily possible. Further, in the state where the first and second clips 51 a, 51 bare in contact with each other, there is a concave portion 55 having an almost triangular cross-sectional shape from the lower end of the clips 51 a, 51 b. The concave portion 55 fits the bulge 18 aand the extension 16 of the clip bushing 10 a. Therefore, when the first and second clips 51 a, 51 bare inserted into the clip insertion part receiving space 14 of the clip socket 10 a, the concave portion 55 of the first and second clips 51 a, 51 bmay contact the protrusion 16 and the bulge 18 a. As a result, it would be easy to hold the first and second clips 51 a, 51 bin the clip insertion part accommodating space 14. When the clip fitting 50 ais inserted into the clip fitting receiving space 14 of the clip socket 10 a, the engaging portions 52 cof the first and second clips 51 a, 51 bare locked by the engaging portions 13 of the clip socket 10 a, just as the engaging portions 52 of the clip fitting 50, the clip fitting 50 amay be engaged with the clip socket 10, or the clip fitting 50 may be engaged with the clip socket 10 a. A clip fitting is not limited to the illustrated examples as long as it can be engaged with a pair of engaging portions 13, and it may have a cross-sectional, expanded, or circular shape, for example.DESCRIPTION OF THE REFERENCE NUMERALS10, 10a Clip Jack 10G Group of Clip jacks (Clip Jack Group) 11 Bottom wall 12a Side wall 13 Engaging portion 14 Clip plug receiving space 15 Foam material insertion space 16 Projection 18 Wire (connection part) 20 Foam molded body 30 Reference fixing groove 40a, 40b Reference 50, 50a Clip plug 51a First clip 51b Second clip 52, 52c Engaging portion 60 Mold 61 Cavity surface 70 Clip holding member 72 Groove forming portion 73 Insertion piece 74 Recess

Claims

A foam molded body (20) comprising a clip bush (10; 10a) and a cover fixing groove (30) in which the clip bush (10; 10a) is embedded, the clip bush (10; 10a) being engageable with a clip fitting part (50; 50a) connected to at least one cover (40a, 40b) covering at least a part of an outer surface of the foam molded body (20), the clip bush (10; 10a) comprising: a bottom wall (11); a pair of right and left side walls (12; 12a) extending rightward and leftward and upward from the bottom wall (11), respectively; and a pair of right and left engaging portions (13) extending from upper sides of the right and left side walls (12; 12a) extending toward a center between the right and left side walls (12; 12a), wherein the right and left engaging portions (13) are engageable with the clip fitting (50; 50a), and wherein the clip socket (10; 10a) comprises between the right and left side walls (12; 12a): a clip-fitting-part accommodating space (14) capable of accommodating the clip fitting part (50; 50a) between the right and left engaging portions (13) therethrough, and foam material introducing spaces (15) at the right and left sides of the clip-fitting-part accommodating space (14) for introducing a material of the foam molded body (20), the foam molded body (20) comprising inner molded portions (22) of the clip bush (10, 10a) formed in the foam material introducing spaces (15), characterized in that the bottom wall (11) has an upwardly protruding protrusion (16).The molded foam body (20) according to claim 1, wherein the right and left engaging portions (13) or the right and left side walls (12, 12a) are flexible.The molded foam body (20) according to claim 1 or 2, wherein the pair of right and left side walls (12; 12a) extend in a curved manner from the bottom wall (11) rightward and leftward and upward, respectively; and wherein the pair of right and left engaging portions (13) extend diagonally downward from the upper end of the right and left side walls (12; 12a), respectively, toward a center between the right and left side walls (12; 12a).Foam molded body (20) according to one of Claims 1 to 3, having a plurality of clip bushes (10; 10a) which is connected to one another by at least one connecting member (18).A method for producing a molded foam article (20) according to any preceding claim, the method comprising: a step A of providing a mold (60) for molding the molded foam article (20), the mold (60) comprising a clip holding member (70) capable of holding the clip socket (10; 10a) at a position where the cover fixing groove (30) is formed in a cavity surface (61) of the mold (60), the clip holding member (70) comprising a groove forming portion (72) for forming a portion (31) other than the clip fitting receiving space (14) of the clip socket (10; 10a) in the cover fixing groove (30); an insertion piece (73) protruding from the groove forming portion (72) and inserted into the clip insertion part receiving space (14) between the right and left engaging portions (13) of the clip socket (10, 10a); a step B in which the clip socket (10; 10a) is fixed to the insertion piece (73) of the clip holding member (70) by inserting the insertion piece (73) into the clip insertion part receiving space (14) between the right and left engaging portions (13) of the clip socket (10; 10a) so that the clip holding member (70) holds the clip socket (10; 10a); and a step C of filling the mold (60) with a material to form the molded foam body (20), wherein the material is introduced into the foam material introduction spaces (15) in the clip socket (10; 10a).The method for manufacturing a molded foam body according to claim 5, wherein in the step B, the insertion piece (73) of the clip holding member (70) and the bottom wall (11) of the clip socket (10; 10a) are attracted to each other by magnetic force.The method for manufacturing a molded foam body according to claim 5, wherein the clip bush (10a) has an extension (16) protruding upward from the bottom wall (11), and the insertion piece (73) of the clip holding member (70) may have a recess (74) matching the extension (16).The method for manufacturing a molded foam article according to any one of claims 5 to 7, wherein the plurality of clip bushes (10; 10a) are connected to each other by at least one connecting member (18).

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