Festooned Trim Clip Assembly for Faster Foam Attachment
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Solution Overview
Problem
Traditional methods for attaching trim covers to resilient substrates, such as foam, are labor-intensive, prone to errors, and can lead to injuries due to the use of metal components, and result in material waste and inefficiencies in clip placement during manufacturing.
Innovation Solution
A system of single or multi-ganged clips arranged in a festooned grouping, with male and female connectors allowing for easy handling and placement, constructed from materials that chemically bond with foam, enabling efficient and secure attachment to substrates with minimal waste and improved handling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hog-rings are used to secure trim covers to substrates, then a permanent and secure joint is achieved, but the method becomes labor-intensive, requires significant skill, and can lead to worker injuries
Solution Approach 1:
The invention extracts the problematic hog-ring application process and replaces it with a pre-formed clip system that is molded directly into the substrate. This eliminates the need for manual hog-ring application while maintaining secure attachment, thereby improving productivity without sacrificing joint security.
Solution Approach 2:
The clip is pre-formed and molded into the substrate during substrate manufacturing, before the trim cover is installed. This preliminary action eliminates the need for skilled manual intervention during assembly, allowing faster installation while ensuring reliable attachment through the pre-positioned clip structure.
2Reliability
If hog-rings are used to create permanent joints, then secure attachment is achieved, but repair becomes difficult and requires significant skill
Solution Approach 1:
The invention segments the attachment system into a removable trim cover portion and a permanent substrate portion with molded-in clips. This allows the trim cover to be easily removed and reinstalled on different substrates, while the substrate retains its permanent clip features. Repair becomes simple matter of removing the trim cover rather than requiring skilled intervention to undo hog-rings.
3Reliability
If metal components are used in the attachment system, then secure mechanical attachment is achieved, but compatibility with electrical heating elements is compromised due to heat and electricity conduction
Solution Approach 1:
The invention changes the material parameter of the clip from metal to foam (the same material as the substrate). This foam material provides sufficient mechanical attachment through its resilient properties and ability to be molded into secure clip shapes, while simultaneously eliminating the harmful electrical and thermal conduction associated with metal components.
4Ease of repair
If hook and loop fasteners are used for detachable connections, then ease of repair is improved, but material waste increases and a large trench width is required
Solution Approach 1:
The invention makes the substrate self-service by molding the attachment clips directly into the substrate during its manufacturing process. This eliminates the need for separate fastener components and the large trenches required by hook-and-loop systems. The trim cover simply needs to engage with the pre-formed clip recesses, achieving easy detachment without significant material waste.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for predictable and efficient orientation and placement of clips, reducing labor and material waste, while providing strong adhesion to foam substrates, minimizing detachment and ensuring durability under cyclic loads.
Implementation Method 1
clips can be constructed from a material that reacts chemically with the foam in a liquid state
Data Source
AI summary
This invention provides a single or multi-ganged clip that can be grouped into a festooned arrangement. That is, a plurality of clips are arranged together into a discrete assembly along a line of extension so that a human or automated handler can retrieve a grouping, separate one-clip-at-a-time from the grouping, and apply the separated clip to a mold cavity or other assembly structure. Each clip can include a base with opposing ends aligned in the direction of extension and transverse to an elongation direction for a connecting segment (if any) between ganged clip members. In an illustrative embodiment, these base ends include opposing male and female connectors. In this embodiment the male connector is a cylinder with an axis that extends transverse to the direction of elongation and the female connector defines a conforming cylindrical inner diameter, which allows it to nest over the male cylinder. A gap opening is provided at the far edge of the female connector to provide clearance for the base that connects the male cylinder to the clip member base end. This gap can be sized to allow a predetermined range of angular rotation of the male connector within the female connector. Clips can be stored as discrete groupings that are stacked in a container, or paid out in a continuous grouping from a spool.