Attachment device

• US 20030215601A1
• Filed: 02/24/2003
• Published: 11/20/2003
• Est. Priority Date: 02/22/2002
• Status: Abandoned Application

• Current Assignee: Proprietect LP
• Original Assignee: Woodbridge Foam Corporation
• Inventors: Hack, Michael, Heinl, Georg, Pedde, Burkhard, Marenne, Philippe
• Application Number:
  US10/371,204
• Publication Number:
  US 20030215601A1
• Time in Patent Office: Days
• US Class Current: 428/102
• CPC Class Codes: B29C 33/12 with incorporated means for positioning inserts, e.g. labels positioning reinforcements B29C70/541
• CPC Class Codes: B29C 44/1271 the preformed parts being partially covered
• CPC Class Codes: B29L 2031/58 Upholstery or cushions, e.g. vehicle upholstery or interior padding mattresses, cushions B29L2031/751
• CPC Class Codes: B29L 2031/771 Seats
• CPC Class Codes: B60N 2/5825 by hooks, staples, clips, snap fasteners or the like
• CPC Class Codes: B60N 2/5841 by clamping means
• CPC Class Codes: Y10T 24/318 Strap connector
• CPC Class Codes: Y10T 24/45775 having resiliently biased interlocking component or segment
• CPC Class Codes: Y10T 428/24008 including fastener for attaching to external surface
• CPC Class Codes: Y10T 428/24017 Hook or barb
• CPC Class Codes: Y10T 428/24033 including stitching and discrete fastener[s], coating or bond

Abstract

In one of its aspects, the present invention relates to an attachment device which comprises a series of attachment portions. The attachment portions are interconnected to one another by at least one connecting portion, preferably a flexible connecting portion. The attachment device is flexible in at least two independent planes. In most cases, the present attachment device will be flexible in more than two independent planes. A preferred manner by which such flexibility is conferred to the attachment device is by the provision of a trim cover attachment portion having a female attachment portion attached to a base portion. The base portion has a larger surface area than the surface area of the female attachment portion adjacent or attached thereto. The lateral dimension of the base portion is greater than the lateral dimension of the at least one connecting portion. A process of producing a resilient device (e.g., a foam element for use in a vehicular seat) is also described as is a mold for carrying out such a process. The present attachment device is particularly well suited for attaching a trim cover to a resilient (e.g., foam) body to produce a vehicular seat or a component of a vehicular seat. Other applications of the present attachment device are also contemplated.

Claims

1. An attachment device comprising a plurality of female attachment portions interconnected to one another by at least one connecting portion, the attachment device being flexible in at least two independent planes, each female attachment portion comprising a receptacle portion and a base portion connected to the connecting portion, the base portion having a lateral dimension greater than a lateral dimension of the receptacle portion.

2. The attachment device defined in claim 1, wherein the base portion has a larger surface area than a surface area of the female attachment portion attached thereto.

3. The attachment device defined in claim 1, wherein the receptacle portion comprises a substantially U-shaped cross-section.

4. The attachment device defined in claim 3, wherein the U-shaped cross-section comprises a pair of generally upstanding walls for receiving an attachment portion of an element to be attached.

5. The attachment device defined in claim 4, wherein a distal portion of each of the upstanding walls comprises a locking portion for engaging the attachment portion of the element to be attached.

6. The attachment device defined in claim 5, wherein the locking portion comprises a first lateral portion projecting substantially toward the receptacle portion.

7. The attachment device defined in claim 6, wherein the first lateral portion projects angularly with respect to the pair of generally upstanding walls.

8. The attachment device defined in claim 4, wherein each of the pair of generally upstanding walls comprises a second lateral section projecting substantially away from the receptacle portion.

9. The attachment device defined in claim 1, wherein the receptacle portion comprises a substantially C-shaped cross-section.

10. The attachment device defined in claim 1, wherein the attachment portions and the at least one connecting portion are integrally formed.

11. The attachment device defined in claim 1, wherein the attachment portions and the at least one connecting portion are detachably connected.

12. The attachment device defined in claim 1, wherein a connecting portion interconnects a pair of attachment portions at a pair of joints, wherein each of the joints is rotatable.

13. The attachment device defined in claim 1, wherein the at least one connecting portion is substantially straight.

14. The attachment device defined in claim 1, wherein the at least one connecting portion is bent.

23. A resilient device comprising a resilient body and the attachment device defined in claim 1 secured with respect to one another.

24. The resilient device defined in claim 23, wherein the resilient body is selected from the group comprising a foam, a fibrous matrix and mixtures thereof.

25. The resilient device defined in claim 23, wherein the resilient body comprises a polyurethane foam.

29. A process for producing a foam device comprising the steps of:

disposing the attachment device defined in claim 1 in a mold comprising a first mold portion and a second mold portion releasably engageable to define a mold cavity;

dispensing at least one of an expandable polymeric composition and expanded polymer particles in at least one of the first mold portion and the second mold portion;

closing the first mold portion and the second mold portion;

expanding the expandable polymeric composition or adhering the expanded polymer particles to each other to substantially fill the mold cavity and to at partially encompass at least a portion of the attachment device; and

obstructing foam entry into the plurality of attachment portions.

30. The process defined in claim 29, wherein the expandable polymeric composition comprises a liquid foamable isocyanate-based polymer.

31. The process defined in claim 29, wherein the expandable polymeric composition expands to encompass at least a portion of the at least one connecting portion of the attachment device.

32. The process defined in claim 29, wherein the expandable polymeric composition expands to encompass substantially all of the at least one connecting portion of the trim cover attachment device.

33. The process defined in claim 29, comprising the further steps of:

removing the foam device from the mold; and

securing a trim cover to the attachment device of the foam device.

15. An elongate attachment device having a longitudinal axis, the device comprising:

a plurality of female attachment portions, each female attachment portion comprising a receptacle portion having a first lateral dimension substantially orthogonal to the longitudinal axis and a base portion connected to the connecting portion, the base portion having a second lateral dimension substantially orthogonal to the longitudinal axis, the second lateral dimension being greater than the first lateral dimension;

at least one elongate flexible portion interconnecting the plurality of attachment portions, the at least one elongate flexible portion having a third lateral dimension substantially orthogonal to the longitudinal axis;

wherein second lateral dimension is greater than the third lateral dimension.

16. The attachment device defined in claim 15, wherein the receptacle portion comprises a substantially U-shaped cross-section.

17. The attachment device defined in claim 16, wherein the U-shaped cross-section comprises a pair of generally upstanding walls for receiving an attachment portion of an element to be attached.

18. The attachment device defined in claim 17, wherein a distal portion of each of the upstanding walls comprises a locking portion for engaging the attachment portion of the element to be attached.

19. The attachment device defined in claim 18, wherein the locking portion comprises a first lateral portion projecting substantially toward the receptacle portion.

20. The attachment device defined in claim 19, wherein the first lateral portion projects angularly with respect to the pair of generally upstanding walls.

21. The attachment device defined in claim 17, wherein each of the pair of generally upstanding walls comprises a second lateral section projecting substantially away from the receptacle portion.

22. The attachment device defined in claim 15, wherein the receptacle portion comprises a substantially C-shaped cross-section.

26. A resilient device comprising a resilient body and the attachment device defined in claim 15 secured with respect to one another.

27. The resilient device defined in claim 26, wherein the resilient body is selected from the group comprising a foam, a fibrous matrix and mixtures thereof.

28. The resilient device defined in claim 26, wherein the resilient body comprises a polyurethane foam.

34. A process for producing a foam device comprising the steps of:

disposing the attachment device defined in claim 15 in a mold comprising a first mold portion and a second mold portion releasably engageable to define a mold cavity;

dispensing at least one of an expandable polymeric composition and expanded polymer particles in at least one of the first mold portion and the second mold portion;

closing the first mold portion and the second mold portion;

expanding the expandable polymeric composition or adhering the expanded polymer particles to each other to substantially fill the mold cavity and to at partially encompass at least a portion of the attachment device; and

obstructing foam entry into the plurality of female attachment portions.

35. The process defined in claim 34, wherein the expandable polymeric composition comprises a liquid foamable isocyanate-based polymer.

36. The process defined in claim 34, wherein the expandable polymeric composition expands to encompass at least a portion of the at least one flexible portion of the attachment device.

37. The process defined in claim 34, wherein the expandable polymeric composition expands to encompass substantially all of the at least one flexible portion of the attachment device.

38. The process defined in claim 34, comprising the further steps of:

removing the foam device from the mold; and

securing a trim cover to the female attachment portion of the foam device.

39. The process defined in claim 38, wherein the trim cover comprises an attachment portion and the securing step comprises engaging the attachment portion with the female attachment portion of the attachment device.

40. The process defined in claim 34, wherein the obstructing step comprising disposing the female attachment portion of the attachment device in a receptacle having an upper surface against which the base portion abuts.

41. The process defined in claim 40, wherein base portion is disposed on the upper surface of the receptacle so as to provide a substantial seal against ingress of the expandable polymeric composition into the receptacle.

42. The process defined in claim 40, wherein the base portion is urged against the upper surface of the receptacle so as to provide a substantial seal against ingress of the expandable polymeric composition into the receptacle.

43. A mold for producing a resilient device incorporating an attachment device comprising a plurality of attachment portions interconnected to one another by at least one connecting portion, the mold comprising:

a first mold portion and a second mold portion releasably engageable to define a mold cavity; and

a retainer for the attachment device, the retainer comprising;

a plurality of receptacles for receiving each of the plurality of attachment portions so as to align the attachment device in a predetermined manner, and means to retain the attachment device in place during expansion of an expandable foam composition in the mold cavity.

44. The mold defined in claim 43, wherein each receptacle comprises a pair of generally upstanding walls defining a receptacle locking region therebetween for receiving the attachment portion of the attachment device.

45. The mold defined in claim 44, wherein a portion of at least one of the upstanding walls comprises a receptacle locking portion for engaging the attachment portion of the attachment device.

46. The mold defined in claim 44, wherein a portion of each of the upstanding walls comprises a receptacle locking portion for engaging the attachment portion of the attachment device.

47. The mold defined in claim 45, wherein the receptacle locking portion comprises a first lateral portion projecting substantially toward the receptacle locking region.

48. The mold defined in claim 47, wherein the first lateral portion projects a generally orthogonal direction with respect to the pair of generally upstanding walls.

49. The mold defined in claim 43, wherein the receptacles are disposed in the first mold portion and the second mold portion comprises a plurality of urging pins to urge the attachment device against the receptacles.

50. The mold defined in claim 49, wherein the number of receptacles and urging pins is the same.

51. The mold defined in claim 50, wherein the each urging pin in the second mold portion is in substantial alignment with receptacle in the first mold portion.

52. An attachment device comprising a plurality of attachment portions, each attachment portion comprising female attachment portion and a base portion at opposed ends thereof, the base portions of adjacent female attachment portions being interconnected by at least one connecting portion, the base portion having a lateral dimension greater than or equal to a lateral dimension of the female attachment portion, the attachment device being flexible in at least two independent planes.

53. An attachment device comprising a plurality of attachment portions, each attachment portion comprising female attachment portion directly connected to a base portion, the base portions of adjacent female attachment portions being interconnected by at least one connecting portion, the base portion have a lateral dimension greater than or equal to a lateral dimension of the female attachment portion.

54. An elongate attachment device having a longitudinal axis, the device comprising:

a plurality of attachment portions, each attachment portion comprising a female attachment portion directly attached to a base portion, the base portion having a first lateral dimension substantially orthogonal to the longitudinal axis and a thickness dimension substantially orthogonal to the first lateral dimension;

at least one elongate flexible portion interconnecting the plurality of attachment portions, the at least one elongate flexible portion having a second lateral dimension substantially orthogonal to the longitudinal axis;

wherein;

(i) the first lateral dimension is greater than the second lateral dimension, and (ii) the first lateral dimension is greater than the thickness dimension.

55. An attachment device comprising a plurality of attachment portions, each attachment portion comprising a female attachment portion and a base portion at opposed ends thereof, the base portions of adjacent female attachment portions being interconnected by at least one connecting portion, the base portion having a first lateral dimension which is:

(i) greater than a thickness dimension substantially orthogonal to the first lateral dimension, and (ii) greater than or equal to a second lateral dimension of the female attachment portion.

56. An attachment device comprising a plurality of attachment portions, each attachment portion comprising female attachment portion directly connected to a base portion, the base portions of adjacent female attachment portions being interconnected by at least one connecting portion, the base portion having:

(i) a width greater than its thickness, and (ii) a width greater than a width of the at least one connecting portion.

57. An attachment device comprising a plurality of attachment portions, each attachment portion comprising female attachment portion directly connected to a base portion, the female attachment portion comprising a locking portion for engaging the attachment portion of the element to be attached, the base portions of adjacent female attachment portions being interconnected by at least one connecting portion, the base portion having:

(i) a width greater than a width of the locking portion, and (ii) a width greater than a width of the at least one connecting portion.