Festooned Trim Clips for Foam Bonding and Safer Seat Assembly
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Solution Overview
Problem
Existing methods for attaching trim and upholstery to resilient substrates, such as foam, are labor-intensive, prone to inefficiencies, and can lead to injuries due to the use of metal components, and often result in material waste and require skilled labor for repair.
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 with minimal waste and reduced detachment risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hog-ring methods are used to attach trim covers to substrate, then secure permanent attachment is achieved, but labor intensity increases and risk of worker injury increases
Solution Approach 1:
The patent removes metal components entirely from the attachment system, extracting the harmful element (metal) while maintaining the attachment function through non-metallic clips that secure trim covers without requiring hog-rings or metal fasteners
Solution Approach 2:
The patent employs disposable non-metallic clips that are inexpensive to manufacture and replace, eliminating the need for expensive metal components and specialized tools while allowing for easy replacement without skilled labor
2Ease of manufacture
If hog-ring tools are used for extended periods, then attachment work is completed, but worker injury such as carpal tunnel syndrome increases
Solution Approach 1:
The patent replaces the complex mechanical hog-ring tool system with simple manual insertion of pre-formed non-metallic clips, eliminating the need for powered tools and reducing repetitive strain on workers' hands and wrists
3Strength
If metal components are used in seats with heating elements, then structural strength is provided, but heat and electricity conduction causes safety issues
Solution Approach 1:
The patent extracts metal components from the attachment system entirely, using non-metallic materials that provide sufficient structural strength for trim attachment while eliminating conductivity-related safety hazards in heated seats
Solution Approach 2:
The patent employs composite or non-metallic materials for clips and fasteners that combine adequate mechanical strength with electrical and thermal insulation properties, replacing metal while maintaining structural integrity
4Ease of repair
If detachable connections are used for trim cover attachment, then repairability is improved, but material waste increases due to larger trench requirements
Solution Approach 1:
The patent divides the attachment system into discrete, modular non-metallic clips that can be individually applied and removed, allowing for easy repair while minimizing material usage compared to large-area detachable connection systems
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 facilitates predictable orientation and efficient handling 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 chemically bonds with the foam
Data Source
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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.