Festooned trim clip system and method for attaching festooned clips to a substrate

Abstract

This invention provides a single or multi-ganged clip that can be grouped into a festooned arrangement. Clips are grouped into a discrete assembly along a line of extension so that a handler can retrieve a grouping, separate one-clip-at-a-time, and apply the separated clip to an 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 one embodiment, these ends include opposing male and female connectors. The male connector is a cylinder with an axis extending 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. An opening at the far edge of the female connector provides clearance for the base that connects the male cylinder to the clip member base end.

1 . A clip adapted to be secured into an upholstery substrate constructed from a foam compound comprising:
 a clip base and a clip leg assembly that extends from the base constructed and arranged to springingly engage a predetermined structure; and   wherein at least the clip base is composed of a polycarbonate compound in a formulation that chemically reacts with the foam in a liquid state and that permanently adheres to the foam in a cured state.   
     
     
         2 . The clip as set forth in  claim 1  wherein the predetermined structure comprises an upholstery listing bead. 
     
     
         3 . The clip as set forth in  claim 1  wherein the foam is a compound selected from a group comprising one of MDI-based foams and TDI-based foams. 
     
     
         4 . A method for assembling clips for attachment to a foam cushion substrate comprising the steps of:
 providing a grouping of a plurality of removably interconnected clips in a assembly and handling the assembly to remove one of the clips therefrom;   locating the removed clip in predetermined assembly position in a mold cavity; and   applying liquid foam to secure the clip into the cushion substrate subsequent to curing of the liquid foam.   
     
     
         5 . The method as set forth in  claim 4  wherein the step of providing comprises arranging clips that each include a plurality of ganged clip members interconnected by respective connecting segments therebetween and the step of handling includes detaching the clip members from each other. 
     
     
         6 . The method as set forth in  claim 5  wherein the step of detaching includes forcibly pulling a connector of one of the clip members into a disengaged orientation with respect to a previously interconnected connector of another of the clip members. 
     
     
         7 . The method as set forth in  claim 5  wherein the step of providing includes feeding the plurality of removably interconnected clips from a spool wound with the clips. 
     
     
         8 . The method as set forth in  claim 4  wherein the step of providing includes stacking a plurality of groupings of a plurality of removably interconnected clips in a compartment of a box with an opening adapted to remove discrete groupings for detachment of individual clips therefrom. 
     
     
         9 . A clip assembly that is adapted to secure a bead to a foam substrate comprising:
 at least one dual-ganged clip including first and second opposed clip members joined by an elongated shaft segment that spacedly disposes the first and second opposed clip members apart;   the first clip member including a first clip member base with first clip legs extending from the base and each having barbs that define an inner shoulder, the inner shoulders of respective barbs constructed and arranged to secure a bead therebetween, the bead extending from the first clip member base, and the first clip member base having opposing first base ends oriented along a first direction of grouping elongation;   a first connector and a second connector mounted at each of the opposing first base ends;   the second clip member including a second clip member base with second clip legs extending from the base and each having barbs that define an inner shoulder, the inner shoulders of respective barbs constructed and arranged to secure the bead therebetween, the bead extending from the second clip member base, and the second clip member base having opposing second base ends oriented along a second direction of grouping elongation;   the first and second directions of grouping elongation extending in parallel; and   a third connector and a fourth connector mounted at each of the opposing second base ends;   the elongated shaft segment having a length that is greater than the spacing between opposed connectors disposed at either of the clip members.   
     
     
         10 . The clip assembly as set forth in  claim 9  further including:
 at least another dual-ganged clip including third and fourth opposed clip members joined by an elongated shaft segment that spacedly disposes the third and fourth opposed clip members apart; 
 the third clip member including a third clip member base with third clip legs extending from the base and each having barbs that define an inner shoulder, the inner shoulders of respective barbs constructed and arranged to secure a bead therebetween, the bead extending from the third clip member base, and the third clip member base having opposing third base ends oriented along a third direction of grouping elongation; 
 a fifth connector and a sixth connector mounted at each of the opposing third base ends; 
 the fourth clip member including a fourth clip member base with fourth clip legs extending from the base and each having barbs that define an inner shoulder, the inner shoulders of respective barbs constructed and arranged to secure the bead therebetween, the bead extending from the fourth clip member base, and the fourth clip member base having opposing fourth base ends oriented along a fourth direction of grouping elongation; 
 the first and third directions of grouping elongation being coincident, and the second and fourth direction of group elongation being coincident; 
 a seventh connector and an eighth connector mounted at each of the opposing fourth base ends; 
 the second connector is constructed and arranged to removably engage the fifth connector along the first direction of grouping elongation; 
 the fourth connector is constructed and arranged to removably engage the seventh connector along the second direction of grouping elongation; and 
 the elongated shaft segments of both the first and second clip members having a length that is greater than the spacing between connectors disposed at any of the clip members. 
 
     
     
         11 . The clip assembly as set forth in  claim 10  wherein the first connector and the fourth connector each comprise a male cylinder and the second connector and the third connector each define a female inner semi-cylindrical surface having an inner diameter that conforms to an outer diameter of the male cylinder, the female inner semi-cylindrical surface including a gap constricted and arranged to provide clearance from a connector base that supports the male cylinder. 
     
     
         12 . The clip assembly as set forth in  claim 11  wherein the fifth connector and the eighth connector each comprise a male cylinder and the sixth connector and the seventh connector each define a female inner semi-cylindrical surface having an inner diameter that conforms to an outer diameter of the male cylinder, the female inner semi-cylindrical surface including a gap constricted and arranged to provide clearance from a connector base that supports the male cylinder. 
     
     
         13 . The clip assembly as set forth in  claim 9  wherein the elongated shaft segment has a length greater than a width of the clip member base, as measured in the direction of the length of the elongated shaft segment, to assist in grasping the clip at the elongated shaft segment and the elongated shaft segment has opposed ends that extend in a direction between facing side surfaces of the respective first and second clip member bases. 
     
     
         14 . The clip assembly as set forth in  claim 13  wherein the length of the elongated shaft segment is an order of magnitude greater than the clip member base width and the elongated shaft segment opposed ends connect into the clip member bases at the respective facing surfaces. 
     
     
         15 . The clip assembly as set forth in  claim 9  wherein the first connector and the second connector extend outwardly from a central portion of the first clip member base to each of the opposing first base ends along the first direction of grouping elongation, such that the first connector and the second connector are disposed outwardly beyond the first clip legs and the first clip barbs along the first direction of grouping elongation so that the first clip member is allowed to angularly deflect about a respective rotational axis relative to an adjacent clip member. 
     
     
         16 . The clip assembly as set forth in  claim 9  wherein the first connector comprises a male connector for the first clip member base, and the male connector is arranged on a pair of outwardly extending side braces that define an opening between a central portion of the first clip member base and the male connector. 
     
     
         17 . The clip assembly as set forth in  claim 16  wherein a relative arrangement of the first connector and the second connector allows a plurality of connected clip members to bend at relative angles in excess of 90 degrees. 
     
     
         18 . The clip assembly as set forth in  claim 9  wherein each of the clip members are constructed and arranged to be mounted on rails in a mold cavity such that, as liquid foam is introduced to the mold cavity, the rails define trenches within the foam and the clip members reside in the trenches with gaps between their respective clip legs exposed for insertion of a listing. 
     
     
         19 . The clip assembly as set forth in  claim 9  wherein each clip member base has a central axis that is coincident with an elongated axis of the elongated shaft segment with each of the clip legs comprising a pair of legs having one leg of the pair disposed outwardly from the central axis of the base the same distance that the other leg of the pair is disposed outwardly from the central axis on the opposed side of the central axis. 
     
     
         20 . The clip assembly as set forth in  claim 19  wherein the first and second connectors are also disposed at the respective base ends, each at a distance from an adjacent leg that is greater than the distance from the leg to the central axis. 
     
     
         21 . The clip assembly as set forth in  claim 9  wherein the barbs of adjacent legs define therebetween a gap that is less than the distance between a bottom of the legs of a clip member base, and each barb is directed inwardly and downwardly at an angle to a top of the legs. 
     
     
         22 . A clip assembly comprising:
 a clip including first and second opposed clip members joined by an elongated shaft segment that spacedly disposes the first and second opposed clip members apart;   the first clip member including a first clip member base with first clip legs extending from the base and each having barbs that define an inner shoulder, the inner shoulders of respective barbs constructed and arranged to secure a bead therebetween, the bead extending from the first clip member base, and the first clip member base having opposing first base ends oriented along a first axis;   a first connector and a second connector mounted at each of the opposing first base ends;   the second clip member including a second clip member base with second clip legs extending from the base and each having barbs that define an inner shoulder, the inner shoulders of respective barbs constructed and arranged to secure the bead therebetween, the bead extending from the second clip member base, and the second clip member base having opposing second base ends oriented along a second axis;   the first and second axes extending in parallel; and   a third connector and a fourth connector mounted at each of the opposing second base ends;   the elongated shaft segment having a length greater than a width of the clip member base, as measured in the direction of the length of the elongated shaft segment, and the elongated shaft segment has opposed ends that extend in a direction between facing side surfaces of the respective first and second clip member bases.   
     
     
         23 . The clip assembly as set forth in  claim 22  wherein the barbs of adjacent legs define therebetween a gap that is less than the distance between a bottom of the legs of a clip member base, and each of the barbs is, respectively, directed inwardly and downwardly at an angle to a top of the legs.