Securing seat trim covers to foam cushions

Abstract

A seat trim cover includes a flexible web and a plurality of molded clips spaced-apart at predetermined intervals along a distal edge of the web. Each of the clips includes a base attached to the web and one or more latch elements extending from the base to a point beyond the distal edge of the web. The latch elements of each clip are configured to clasp a cushion retainer when forced into engagement with the retainer.

What is claimed is: 
     
       1. A method of securing a seat trim cover to a foam cushion, the method comprising:
 placing a flexible seat trim cover adjacent a foam bun having a foam body outlined by a contoured outer surface, the foam bun carrying an elongated cushion retainer; and 
 forcing each of a plurality of clips spaced-apart at predetermined intervals along a distal edge of a web of the seat trim cover into engagement with the cushion retainer, thereby simultaneously fastening and aligning the seat trim cover to the foam bun, 
 wherein each of the plurality of clips comprises: 
 opposing sets of one or more latch elements directly attached to opposite sides of the web, the opposing sets of latch elements being positioned offset from one another along a length of the distal edge of the web, forming a non-overlapping arrangement on the web. 
 
     
     
       2. The method of  claim 1 , wherein the opposing sets of latch elements are offset from one another by a distance less than the predetermined intervals between the clips. 
     
     
       3. The method of  claim 1 , wherein the cushion retainer is embedded in the foam bun beneath a floor of an elongated trench defined in the foam body, such that forcing the clips into engagement with the retainer comprises pushing the latch elements beyond the floor of the trench. 
     
     
       4. The method of  claim 1 , wherein each clip comprises two bases, each base secured to and extending from a respective side of the web and carrying at least one of the latch elements. 
     
     
       5. The method of  claim 4 , wherein the bases together form a unitary mass of solidified resin material. 
     
     
       6. The method of  claim 4 , wherein the bases are offset from one another along the length of the web. 
     
     
       7. The method of  claim 4 , wherein the bases are offset from one another by a distance in a direction perpendicular to the distal edge of the web. 
     
     
       8. The method of  claim 4 , wherein the bases are positioned in a non-overlapping manner with respect to a plane of the web, such that forcing the clips into engagement with the retainer comprises inducing a twist in the web. 
     
     
       9. The method of  claim 1 , wherein a first of the latch elements comprises: a base attached to a first side of the web; a neck extending from the base to beyond the distal edge of the web; and a head protruding from the neck toward a second side of the web. 
     
     
       10. The method of  claim 9 , wherein the head comprises a tapered cam surface at its distal edge, such as to help align the latch element and laterally deflect the latch element under pressure against the retainer. 
     
     
       11. The method of  claim 1 , wherein the web further comprises a listing bead reinforcing the distal edge of the web, the listing bead comprising solidified resin material over-molded along the distal edge of the web between spaced apart clips. 
     
     
       12. A method of securing a seat trim cover to a foam cushion, the method comprising:
 placing a flexible seat trim cover adjacent a foam bun having a foam body outlined by a contoured outer surface, the foam bun carrying an elongated cushion retainer; and 
 forcing each of a plurality of clips spaced-apart at predetermined intervals along a distal edge of a web of the cover into engagement with the with the cushion retainer, thereby simultaneously fastening and aligning the seat trim cover to the foam bun, 
 wherein each of the plurality of clips comprises: 
 a first set of one or more latch elements, each latch element of the first set extending contiguously from one or more bases independently attached to a first side of the web; and 
 a second set of one or more latch elements, each latch element of the second set extending contiguously from one or more bases independently attached to a second side of the web, 
 wherein the one or more bases of the first set of latch elements attached to the first side of the web are spaced-apart on the web from the one or more bases of the second set of latch elements attached to the second side of the web, forming a non-overlapping arrangement and locating the first set of latch elements in an offset position along a length of the distal edge of the web relative to the second set of latch elements. 
 
     
     
       13. The method of  claim 12 , wherein the one or more bases attached to the first side of the web are spaced-apart on the web from the one or more bases attached to the second side of the web by a distance along the length of the web. 
     
     
       14. The method of  claim 13 , wherein the distance is less than the predetermined intervals between the clips. 
     
     
       15. The method of  claim 12 , wherein the cushion retainer is embedded in the foam bun beneath a floor of an elongated trench defined in the foam body, such that forcing the clips into engagement with the retainer comprises pushing the latch elements beyond the floor of the trench. 
     
     
       16. The method of  claim 12 , wherein the retainer is secured within an elongated trench defined in the foam body and comprises a longitudinally continuous rail with a bulbous distal edge, and wherein forcing the clips into engagement with the retainer comprises forcing the latch elements over the bulbous distal edge of the rail. 
     
     
       17. A covered foam cushion, comprising:
 a foam bun having a foam body and a contoured surface outlining the foam body; 
 an elongated cushion retainer permanently secured to the foam bun; and 
 a seat trim cover secured to at least a portion of the foam bun and comprising: 
 a flexible web; and 
 a plurality of clips spaced-apart at predetermined intervals along a distal edge of the web, each of the clips comprising: 
 opposing sets of one or more latch elements directly attached to opposite sides of the web, the opposing sets of latch elements being positioned offset from one another along a length of the distal edge of the web, forming a non-overlapping arrangement on the web, 
 wherein the latch elements of each clip clasp the cushion retainer at discrete sections along its length. 
 
     
     
       18. The cushion of  claim 17 , wherein at least one of the clips comprises a base secured to the distal edge of the web and carrying one or more of the latch elements. 
     
     
       19. The cushion of  claim 18 , wherein the base is over-molded onto the distal edge of the web. 
     
     
       20. The cushion of  claim 19 , wherein the base and the one or more latch elements comprise a molded unitary mass of solidified resin material. 
     
     
       21. The cushion of  claim 17 , wherein the opposing sets of latch elements are offset from one another by a distance less than the predetermined intervals between the clips. 
     
     
       22. The cushion of  claim 17 , wherein each of the clips comprises two bases, each base secured to and extending from a respective side of the web and carrying at least one of the latch elements, and wherein the bases are offset from one another along the length of the web. 
     
     
       23. The cushion of  claim 22 , wherein the bases together form a unitary mass of solidified resin material. 
     
     
       24. The cushion of  claim 17 , further comprising a listing bead reinforcing the distal edge of the web, the listing bead comprising solidified resin material over-molded along the distal edge of the web between spaced apart clips. 
     
     
       25. The cushion of  claim 17 , wherein at least one of the latch elements defines a hole having an edge from which an angled flap of the latch element extends across a plane of the web. 
     
     
       26. The method of  claim 1 , wherein at least one of the clips comprises a base secured to the distal edge of the web and carrying one or more of the latch elements. 
     
     
       27. The method of  claim 26 , wherein the base is over-molded onto the distal edge of the web. 
     
     
       28. The method of  claim 27 , wherein the base and the one or more latch elements comprise a molded unitary mass of solidified resin material. 
     
     
       29. A covered foam cushion, comprising:
 a foam bun having a foam body and a contoured surface outlining the foam body;   an elongated cushion retainer permanently secured to the foam bun; and   a seat trim cover secured to at least a portion of the foam bun and comprising:
 an elongated flexible web; 
 a plurality of resin clips directly attached to the web at spaced-apart at predetermined intervals along the web, wherein each of the clips comprises an opposing set of one or more latch elements located on either side of the web, the opposing sets of latch elements being positioned offset from one another along a length of the web, forming a non-overlapping arrangement on the web; and 
 a continuous reinforcement bead comprising solidified resin material formed along a length of the web; 
   wherein the latch elements of each clip clasp the cushion retainer at discrete sections along its length.   
     
     
       30. The cushion of claim 29, wherein the opposing sets of latch elements are offset from one another by a distance less than the predetermined intervals between the clips. 
     
     
       31. The cushion of claim 29, wherein each of the clips comprises two bases, each base secured to and extending from a respective side of the web and carrying at least one of the latch elements, and wherein the bases are offset from one another along the length of the web. 
     
     
       32. The cushion of claim 29, wherein the reinforcement bead extends along a distal edge of the web. 
     
     
       33. The cushion of claim 29, wherein the reinforcement bead is of molded resin. 
     
     
       34. The cushion of claim 33, wherein the reinforcement bead connects the spaced-apart clips. 
     
     
       35. A method of securing a seat trim cover to a foam cushion, the method comprising:
 placing a flexible seat trim cover adjacent a foam bun having a foam body outlined by a contoured outer surface, the foam bun carrying an elongated cushion retainer, the seat trim cover having an elongated web with
 a longitudinally continuous reinforcement bead of resin extending along a length of the web; and 
 plurality of resin clips molded onto the web at predetermined intervals along a distal edge of the web, wherein each of the plurality of clips comprises an opposing set of latch elements positioned offset from one another along a length of the web, forming a non-overlapping arrangement on the web; and 
   forcing each of the plurality of clips into engagement with the cushion retainer, thereby simultaneously fastening and aligning the seat trim cover to the foam bun.   
     
     
       36. The method of claim 35, wherein the opposing set of latch elements comprises latch elements directly attached to opposite sides of the web. 
     
     
       37. The method of claim 35, wherein each of the plurality of clips comprises two bases, each base secured to and extending from a respective side of the web and carrying at least one latch element. 
     
     
       38. The method of claim 37, wherein the bases are offset from one another along the length of the web. 
     
     
       39. The method of claim 37, wherein the bases are positioned in a non-overlapping manner with respect to a plane of the web, such that forcing the clips into engagement with the retainer comprises inducing a twist in the web. 
     
     
       40. A method of making a seat trim cover flange, the method comprising:
 molding a series of resin clips along a longitudinal edge of a fabric strip, the clips each molded directly onto the fabric strip and comprising a latch element projecting beyond the longitudinal edge of the web, the clips spaced along a length of the strip, wherein each of the clips comprises an opposing set of latch elements positioned offset from one another along a length of the longitudinal edge of the fabric strip, forming a non-overlapping arrangement on the fabric strip; and   forming a continuous bead of resin extending longitudinally along a face of the strip.   
     
     
       41. The method of claim 40, wherein forming the continuous bead of resin comprises over-molding the bead to the fabric strip. 
     
     
       42. The method of claim 40, wherein the formed bead connects the clips to one another.