Abstract:
A vehicular seat trim cover attachment device having a plurality of female attachment portions interconnected to one another by at least one connecting portion. The attachment device is preferably flexible in at least two independent planes. Each female attachment portion has a receptacle portion and a base portion. Each base portion is connected to the connecting portion. Each base portion has a lateral dimension greater than a lateral dimension of the receptacle portion. At least a portion of the connecting portion is disposed in an exoplanar relationship with respect to a pair of female attachment portions that have substantially coplanar base portions. Preferably, the connecting portion extends below the bottom surfaces of the adjacent base portions.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     The present application is a divisional application of U.S. patent application Ser. No. 10/371,204, filed Feb. 24, 2003, which claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 60/358,363, filed Feb. 22, 2002, the contents of both of which are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     In one of its aspects, the present invention relates to an attachment device, preferably to a trim cover attachment device. In another of its aspects, the present invention relates to a resilient device, preferably a foam device in a vehicular seat, incorporating the present attachment device, preferably for attachment of a trim cover to the foam device. In yet another of its aspects, the present invention provides a process for producing a resilient device, preferably a foam device in a vehicular seat, incorporating the present attachment device, more preferably a trim cover attachment device. In yet another of its aspects, the present invention provides a mold for producing a resilient device, preferably a foam device in a vehicular seat, incorporating the present attachment device, preferably for attachment of a trim cover to the foam device.  
         [0004]     2. Description of the Prior Art  
         [0005]     Attachment of a trim cover to a resilient device is generally known.  
         [0006]     In most cases, the resilient device is a foam device, although, in some cases, a fibrous matrix such as rubberized horsehair and the like is still being employed. Typically, it is desired to secure a trim cover to a resilient device to produce a vehicular seat or a component of a vehicular seat.  
         [0007]     There are three general categories of approaches in attachment of a trim cover to a resilient device: adhesive, foam-in-place and mechanical. The present invention relates to an improvement falling in the latter category and thus, prior art in this category will be discussed.  
         [0008]     In the mechanical approach for attachment of a trim cover to a resilient device, there are (at least) four sub-categories. For ease of description, reference will be made to a foam device.  
         [0009]     First, it is known in art to employ so-called “hog-rings” to secure a trim cover to a resilient device. In this approach, a metal wire is melded into the so-called A-surface of the foam device. The metal wire is exposed at selected spots, typically in a trench, on the surface of the foam device. A trim cover is provided and has a finished outer surface made of leather, cloth, vinyl or the like. Commonly attached to the underside of the trim cover is a non-woven material, a felt material and the like. A hard plastic (or other) bead is attached to the non-woven material. Of course other methods are attaching the hard plastic bead to the trim cover are used in the art. The trim cover is attached to the foam device by aligning the metal wire in the foam device with the hard plastic bead in the trim cover and thereafter engaging the two with a metal ring. Typically, the metal ring is deployed from a so-called hog-ring gun. This approach has been used for many years to secure a trim cover to a foam device. This approach suffers from a number drawbacks. For example, a significant capital cost is required to acquire the hog-ring gun and a significant associated labour cost is required to ensure that trim covers can be attached to foam devices at a rate commensurate with the rate at which the foam device is being produced. Further, since deployment of the first hog-ring immovably secures the trim cover to foam device, there is no play or give. The result of this is that perfect placement of trim cover over the foam device must be achieved prior to deployment of the first hog ring to avoid significant loss of efficiency. Still further, this approach is difficult to use reliably when producing a vehicular seat product which incorporates one or more of a seat heater and an occupant detection system. Still further, the use of metal in the foam device creates additional cost in recycling the finished product after complete of its life cycle. A modification of this approach is to replace the metal wire typically molded into the A-surface of the foam device with a mounting device made of foam—see, for example, Canada patent application 2,165,930 [Grund et al.], published on Jun. 24, 1996 and DE 44 46 450 C1 [Johnson Controls GmbH &amp; Co.], granted Apr. 4, 1996. Another modification of this approach is to utilize a mechanical clip to connect the trim cover to the metal wire molded into the A-surface of the foam device—see, for example DE 195 30 379 C2 [Johnson Controls GmbH &amp; Co.], published Dec. 19, 1996.  
         [0010]     Second it is known to utilize a plurality of independent or single mechanical clips to secure the trim cover to the foam device. In this approach, a series of mechanical clips is molded in the A-surface of the foam device. Each mechanical clip typically comprises a base which is molded into the foam and a receptacle or clip portion which emerges from the foam at selected locations on the A-surface of the foam device. See, for example, one or more of the following prior art references: 
        DE 299 17 372 U1 [Johnson Controls GmBH &amp; Co.], published Feb. 24, 2000; and     DE 298 21 697 U1 [Bertrand Faure Sitztechnik GmbH &amp; Co.], published Mar. 25, 1999. 
 
 For a typical vehicular seat component (e.g., a seat bottom or a seat back), it is common to require 12-30 of these clips to be molded into the foam device. This approach suffers from a number of drawbacks. For example, it is very difficult to achieve optimal alignment of the individual clips using this approach. This results in production of an unsightly product. Further, this approach requires significant time to correctly dispose the individual clips in the mold. This results in one or both of low efficiency and increased labour. 
       
 
         [0013]     Third, it is known to use so-called Velcro™-type fasteners to attach a trim cover to a foam device. These fasteners are also known in the art as touch fasteners or “hook and loop” fasteners. While this approach is reliable, it does suffer from a number of drawbacks. For example, the this type of fastener is generally regarded one of the most expensive approaches to utilize to secure a trim cover to a foam device. Further, this approach is not well suited to fastening around a curve portion of the foam device without incurring significant wastage. Third, in many applications, the use of this approach necessitates the use of a wide fastener to achieve sufficient pullout strength. The result of this is a relatively wide trench which results in a relatively unsightly product.  
         [0014]     Fourth, from U.S. Pat. No. 5,641,552 [Tillner], it is known to utilize an anchoring strip which is molded in A-surface of the foam device. The anchoring strip is in the form a wide, flat connecting bar made of a molded plastic body (polypropylene is provided as an example) and having a series of C-clips disposed at various spots along its length. The wide, flat connecting bar is described as being flexible perpendicular to its main plane. It is clear that this is the only moment of flexibility of the wide, flat connecting bar. This approach has a number of drawbacks. For example, the anchoring strip is not well suited to being used around corners and, for most cost-efficient applications, is really only applicable in straight lengths. Further, if the final product is a vehicle seat, the use of a wide, flat connecting bar made of plastic deleteriously affects comfort. Still further, demolding a foam part having a wide, flat connecting bar of this an anchoring strip is difficult to achieve reliably without tearing out of a portion of the anchoring bar from the A-surface of the foam part. Still further, it is impractical and, in most cases, not possible, to mold the anchoring strip in to foam without fouling of the C-clips.  
         [0015]     British patent application 2,238,708A [White] teaches a device for attaching material to a seat in a manner similar to the device taught by Tillner. The device is in the form of a rail having one or more clip members which form an open loop. A flat vertical connecting portion is interposed between the rail and the one or more clip members such that the clip portion and the rail are remote from one another. This approach has a number of drawbacks. First, the device taught by White is not easily useable in a commercial setting due to the fact that there is no place on the rail which provides a convenient press point for insertion of the device in a mold. In fact, White is completely silent on how the device is to be used in a mold or on a mold therefore. This disadvantage is exacerbated by the presence of the flat vertical connecting portion between the rail and the one or more clip members rendering the device cumbersome to insert in a mold. Second, the distance between the rail and the clip member(s) is too large to allow the device to be conveniently used in a process and to allow the device to be molded into many conventional dimensioned foam elements. On the latter point, for example, in a conventional vehicular seat, the thickness of the seat in the location of the trenches is about 20 to about 25 mm. This dimension renders the device taught virtually unusable as taught by White.  
         [0016]     Thus, despite the advances made to date, there is still room for improvement. Specifically, it would be advantageous to have an attachment device which obviates or mitigates and least one of the above-mentioned drawbacks of the prior art. It would be particularly advantages if the attachment device was not only well suited for attachment of a trim cover to a resilient body but could also be use to attach other elements to the resilient body.  
       SUMMARY OF THE INVENTION  
       [0017]     It is an object of the present invention to provide an attachment device, preferably a trim cover attachment device, which obviates or mitigates at least one of the above-mentioned disadvantages of the prior art.  
         [0018]     It is another object of the present invention to provide a novel resilient device incorporating the present attachment device, more preferably a trim cover attachment device.  
         [0019]     It is another object of the present invention to provide a novel foam device incorporating the present attachment device, more preferably a trim cover attachment device.  
         [0020]     It is yet another object of the present invention to provide a novel process for production of the present resilient device.  
         [0021]     It is yet another object of the present invention to provide a novel mold for production of the present resilient device.  
         [0022]     Accordingly, in one of its objects, the present invention provides 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.  
         [0023]     In another of its aspects, the present invention provides an elongate attachment device having a longitudinal axis, the device comprising:  
         [0024]     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;  
         [0025]     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;  
         [0026]     wherein second lateral dimension is greater than the third lateral dimension.  
         [0027]     In yet another of its aspects, the present invention provides a resilient device comprising a resilient body and the present attachment device secured with respect to one another.  
         [0028]     In yet another of its aspects, the present invention provides a foam device comprising a foam body and the present attachment device secured with respect to one another.  
         [0029]     In yet another of its aspects, the present invention provides a process for producing a foam device incorporating 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, the process comprising the steps of:  
         [0030]     disposing the attachment device in a mold comprising a first mold portion and a second mold portion releasably engageable to define a mold cavity;  
         [0031]     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;  
         [0032]     closing the first mold portion and the second mold portion;  
         [0033]     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  
         [0034]     obstructing foam entry into the plurality of attachment portions.  
         [0035]     In yet another of its aspects, the present invention provides a process for producing a foam device incorporating 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, the process comprising the steps of:  
         [0036]     disposing the attachment device in a mold comprising a first mold portion and a second mold portion releasably engageable to define a mold cavity;  
         [0037]     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;  
         [0038]     closing the first mold portion and the second mold portion;  
         [0039]     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  
         [0040]     obstructing foam entry into the plurality of female attachment portions.  
         [0041]     In yet another of its aspects, the present invention provides 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:  
         [0042]     a first mold portion and a second mold portion releasably engageable to define a mold cavity; and  
         [0043]     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.  
         [0044]     The present inventors have developed an attachment device, preferably a trim cover attachment device, having a combination of some or all of the following advantages:  
         [0045]     relatively efficient to “load” on the mold,  
         [0046]     can be made of polymer to facilitate recyclability of the final product,  
         [0047]     relatively inexpensive,  
         [0048]     does not require the use of expensive and/or dangerous equipment attach the trim cover (or other element) thereto,  
         [0049]     can be used to attach a trim cover (or other element) to a foam device around a curved portion,  
         [0050]     can be easily used to provide straight-line attachment of the trim cover (or other element) to the foam device,  
         [0051]     can provide some play or give during initial and final attachment of the trim cover (or other element) to the foam device,  
         [0052]     can be used to secure a trim cover (element) to a foam device with adversely affecting other elements of the foam device (e.g., heating elements, occupant detection systems and the like),  
         [0053]     can be used facilitate original assembly and subsequent disassembly of the foam device for maintenance or any other purpose,  
         [0054]     can be deployed in relatively narrow trenches without compromising pull-out strength, and  
         [0055]     does not render the final foam product difficult to demold.  
         [0056]     The attachment device comprises a plurality of attachment portions. The attachment portions are interconnected to one another by at least one connecting portion, preferably at least one flexible connecting portion. The attachment device is flexible in at least two independent planes. Thus, unlike the Tillner attachment device discussed above, which is flexible only in a direction perpendicular to the main plane of the connector bar, the present attachment is flexible in at least two independent planes. In most cases, the present attachment device will be flexible in more than two independent planes. Further, unlike the White attachment device discussed above, the lateral dimension of the base portion of the present attachment device allow the present attachment device to be readily adapted to use in a commercial setting (i.e., the present attachment device is much simpler to “load” or dispose in a mold). Further, by not having the receptacle portion and the base portion in the present attachment device significantly separated as shown in White, it is possible to incorporate the present attachment device in conventionally dimensioned foam elements such as vehicular seats.  
         [0057]     Flexibility may be conferred to the attachment device in a number of different ways, such as: (i) selection of the appropriate material or materials, (ii) the geometry of the connecting portions between the attachment portions, (iii) the mode of securing the connecting portions to the attachment portions, (iv) the relative geometry of the connecting portions and the attachment portions, or (v) any combination of any of (i), (ii), (iii) and (iv).  
         [0058]     In a preferred embodiment, flexibility may be conferred by the provision of a plurality of attachment portions, each attachment portion comprising 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 plurality of attachment portions are interconnected by one or more connecting portions, preferably one or more flexible connecting portions. The lateral dimension of the base portion is greater that the lateral dimension of the one or more connecting portions.  
         [0059]     The present attachment device comprises a plurality of attachment portions (also referred to in some cases in this specification as female attachment portions). The precise number of such portions is not particularly restricted and depends, at least in part, on the overall dimensions and shape of the finished product. In most cases, the present attachment device, when used in a trim cover attachment application, will comprise from 2 to 10, more preferably from 4 to 8, trim cover attachment portions. Typically, a connecting portion, preferably a flexible connecting portion will interconnect adjacent pairs of attachment portions.  
         [0060]     The present attachment system is particularly well suited to be incorporated in a resilient device such as a foam element to a trim cover may be secure and the finished product utilized as a component of a vehicular seat. While use of the present attachment device as a trim cover attachment device is highly preferred, those of skill in the art will readily appreciate the present attachment device may be used in a multitude of other applications. For example, it is possible to utilize the present attachment device to attach components other than a trim cover to a resilient body. Such other components may include heating elements, occupant detection systems, load sensors, conduits for air passageways (e.g., for use in a climate control vehicular seat), auxiliary resilient elements (e.g., multiple hardness foam elements) and like. Further, when the present attachment device is used in a vehicular seat application, it may be used to attach another to any surface of the resilient body (i.e., A-surface, B-surface, etc.). Thus, while the following description of the preferred embodiments of the present attachment device refers to a trim cover attachment device (a highly preferred application of the invention), the scope of the invention is not to be construed as limited to the use of the present attachment device solely in trim cover attachment applications.  
         [0061]     As used throughout this specification, the term “receptacle portion” is intended to mean that portion of the attachment device which receives the attachment element of the device which is to be attached (e.g., the trim cover). Further, as used throughout this specification, the term “locking portion” is intended to mean that portion of the attachment device which retains in the attachment device the attachment element of the device which is to be attached (e.g., the trim cover). 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0062]     Embodiments of the present invention will be described with reference to the accompanying drawings in which like reference numerals denote like elements and in which:  
         [0063]      FIG. 1  illustrates a perspective view of first embodiment of the present trim cover attachment device;  
         [0064]      FIG. 2  illustrates an enlarged perspective view of second embodiment of the present trim cover attachment device;  
         [0065]      FIG. 3  illustrates an enlarged perspective view of third embodiment of the present trim cover attachment device;  
         [0066]      FIG. 4  illustrates a perspective view of attachment of a trim cover to the trim cover attachment device illustrated in  FIG. 1 ;  
         [0067]      FIG. 5  illustrates a section view of attachment of a trim cover to the trim cover attachment device illustrated in  FIG. 1  which has been molded into a foam element;  
         [0068]      FIG. 6  illustrates a sectional view of a mold for producing a foam element incorporating the present trim cover attachment device;  
         [0069]      FIG. 7  illustrates a perspective view of attachment of a trim cover to the element produced in the mold of  FIG. 6 ;  
         [0070]      FIG. 8  illustrates a perspective view of a fourth embodiment of the present trim cover attachment device;  
         [0071]      FIG. 9  illustrates an enlarged perspective view of the trim cover attachment device illustrated in  FIG. 8  as it would be retained in mold like the one illustrated in  FIG. 6 ;  
         [0072]      FIG. 10  illustrates a sectional view along line X-X in  FIG. 9 ;  
         [0073]      FIG. 11  illustrates a perspective view of how a portion of the trim cover attachment device illustrated in  FIG. 8  would retained in a mold like the one illustrated in  FIG. 6  to obviate or mitigate ingress of foam material into the trim attachment portion of the trim cover attachment device;  
         [0074]     FIGS.  12  is similar to  FIG. 9  with addition of a molded foam element encompassing a portion of the trim cover attachment device;  
         [0075]      FIG. 13  illustrates the product shown in  FIG. 12  after it has been demolded; and  
         [0076]      FIGS. 14-16  illustrate various view of use of a trim cover attachment device which is a hybrid of the trim cover attachment devices illustrated in  FIG. 2  and  FIG. 8 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0077]     With reference to  FIGS. 1, 4  and  5 , there is illustrated a trim cover attachment device  100 . Trim cover attachment device  100  comprises a series of trim cover attachment portions  110  which are interconnected by a series of flexible portions  120 . Each trim cover attachment portion  110  comprises a base  130  and a female attachment portion  140 . As illustrated, base  130  has a generally rectangular shape and a larger surface area than the surface area of female attachment portion  140  which is attached to base  130 .  
         [0078]     Female attachment portion  140  is generally U-shaped and comprises a pair of generally upstanding walls  150  between which is defined a receptacle portion  155 . Walls  150  are reversibly movable with respect to one another—e.g., they may be biased toward or away from each other. As illustrated, for each female attachment portion  140 , walls  150  are generally mirror images of one another along an axis perpendicular to the longitudinal axis of trim cover attachment device  100 . In the distal region of each wall  150  there is provided a hook  160  which acts as an element of the locking portion of attachment device  100 .  
         [0079]     As shown in  FIG. 1 , trim cover attachment device  100  is flexible in at least two planes. Plane # 1  contains the major surface of base  130  and the flexibility of trim cover attachment device  100  in this plane is shown with reference to Arrows A. Plane # 2  is orthogonal to plane # 1  and the flexibility of trim cover attachment device  100  in this plane is shown with reference to Arrows B. Of course those of skill in the art will recognize that trim cover attachment device  100  may be flexible in one or more planes beyond plane # 1  and plane # 2 . As is clearly shown in  FIG. 1 , the flexible portion  120  has a length in the direction of its longitudinal axis that is greater than a length of the base portion  130  in the direction of said longitudinal axis.  
         [0080]     With reference to  FIGS. 2 and 3 , there are illustrated alternate embodiments to the trim cover attachment device illustrated in  FIGS. 1, 4  and  5 . For ease of understanding, reference numerals in  FIGS. 1-5  have the same final two digits denote like elements. For example, female attachment portion  140 ,  240  and  340  is the same element in  FIGS. 1-5 .  
         [0081]     With reference to  FIG. 2 , there is illustrated a trim cover attachment device  200 . The principal difference between trim cover attachment device  200  and trim cover attachment device  100  illustrated in  FIGS. 1, 4  and  5  is the provision of curved or non-linear flexible portion  220  in trim cover attachment device  200  (i.e., flexible portions  120  of trim cover attachment device  100  are straight sections). As illustrated in  FIG. 2 , flexible portion  220  is curved out of plane # 1  described above (i.e., the plane which, in  FIG. 2 , would contain the major surface of base  230 ). Of course, those of skill in the art will recognize that flexible portion  220  may curved in a multitude of other directions.  
         [0082]     With reference to  FIG. 3 , there is illustrated a trim cover attachment device  300 . One difference between trim cover attachment device  300  and trim cover attachment device  100  illustrated in  FIGS. 1, 4  and  5  is the provision of base  330  in trim cover attachment device  300  having a hexagonal shape and have disposed at opposed locations a pair of receptacles. Another difference between trim cover attachment device  300  and trim cover attachment device  100  illustrated in  FIGS. 1, 4  and  5  is the provision of utilizing flexible portion  320   a  or  320   b  in trim cover attachment device  300 . Each of flexible portions  320   a  and  320   b  comprise at opposed ends thereof a pair of pins  325 . Pins  325  are size to fit snugly into receptacles  335  on base  330 . As clearly shown in  FIG. 3 , the pins  325  are cylindrically-shaped to fit within circularly-shaped complementary receptacles  335 , so that they form rotatable joints. Thus, as will be appreciated by those of skill in the art, trim cover attachment device  300  allows for onsite customization of the distance between adjacent pairs of trim cover attachment portions  310 . That is, the attachment device base  330  is attachably/detachably connected to the flexible connecting portions  320   a  and  320   b.  The amount of customization can be easily controlled by the number of lengths of flexible portions  320   a,    320   b,  etc. which are stocked. It is possible to modify pins  325  and receptacles  335  to include define a ball and socket joint (e.g., pins  325  could be modified to include the “ball” and receptacles  335  could be modified to include the “socket”) once assembled. This would serve to increase flexibility of trim cover attachment device  300 . With further reference to  FIGS. 4-5 , use of trim cover attachment device  100  to secure a trim cover  10  is illustrated. Thus, trim cover  10  comprises a cover stock material  15 . As is known in the art cover stock material  15  may be made of leather, cloth, vinyl and the like. A pocket  20  is attached to cover stock material  15  via stitching  25 . Disposed with pocket  20  is a rod  30 . Rod  30  may be made of plastic or any other suitable material. When it is desired to attach trim cover  10  to trim cover attachment device  100 , rod  30  is moved in the direction of Arrow C. The surface of pocket  20  adjacent rod  30  contacts hooks  160  of trim cover attachment device  100 . With continued urging of rod  30  in the direction of Arrow C, walls  150  are biased open to allow rod  30  to clear hooks  160  and enter receptacle portion  155 . Once hooks  160  are cleared by rod  30 , walls  150  return to the resting state and rod  30  is received by receptacle portion  155  and retained female attachment portion  140  by hooks  160  (these elements serve as the locking portion). Those of skill in the art will recognize that rod  30  may be modified to have a non-circular cross-sectional shape or may be substituted with a strip having a barb-shaped or arrow-shaped profile.  
         [0083]     With particular reference to  FIG. 5 , trim cover attachment device  100  is illustrated as incorporated in a foam element  50 . As illustrated, flexible portion  120  and base  130  are embedded below a surface foam element  50 , and walls  150  emerge upwardly into a trench  55  disposed in foam element  50 .  
         [0084]     With reference to  FIG. 6 , there is illustrated a sectional view of a mold  60 . Mold comprises a bowl  62  and a lid  64  which swings about a hinge  66 . The lower surface of bowl  62  corresponds to the A-surface of the finished foam part and includes a pair of platforms  68 . Platforms  68  retain trim cover attachment device  100  in a manner which will be discussed below. When it is desired to produced foam element  50 , lid  64  of mold  60  is placed in the open position. Trim cover attachment devices  100  are retain in platforms  68  and a liquid foamable polymeric composition is dispensed in bowl  62 . Thereafter, lid  64  is closed in the direction Arrow D and the foam composition expands to fill the mold cavity. Once expansion is complete, lid  64  is opened and foam element  50  is removed or demolded from bowl  62 . Trim cover  10  may then be secured to trim cover attachment device  400  (this device will be described below) as described above with references to  FIGS. 4 and 5 —this is shown schematically in  FIG. 7 .  
         [0085]     With reference to  FIGS. 8-13 , there is illustrated a highly preferred embodiment of the present trim cover attachment device, name a trim cover attachment device  400 . For ease of understanding, reference numerals in  FIGS. 1, 4 ,  5  and  8 - 13  have the same final two digits denote like elements. For example, base  130  and  430  are the same element in  FIGS. 1-5  and  8 - 13 .  
         [0086]     The principal difference between trim cover attachment device  100  and trim cover attachment device  400  is the provision of retention members  470  on the outside of walls  450  of trim cover attachment device  400 .  
         [0087]     Trim cover attachment device  400  is well suit to shielding of female attachment portion  440  during the foaming operation. This may be done through the use of a receptacle  70  disposed on platform  68  of bowl  62 . Receptacle  70  comprises an opposed pair of lugs  72 . As shown in  FIG. 9 , as female attachment portion  440  is pushed into receptacle  70 , the distal portions of walls  450  contact lugs  720 . Walls  450  are then biased toward each other until they clear lugs  72 . This action serves to urge or otherwise secure base  430  against the upper surface  74  of receptacle  70  with two resultant advantages: (i) ingress of foam into receptacle  70  is obviated or mitigate thereby avoiding fouling female attachment portion  440 —i.e. effective seal is formed, and (ii) trim cover attachment device  400  will not “float” or “swim” away from platform  68  as the liquid foamable polymeric compositions expands and begins to engulf flexible portions  420  and base  430 .  FIG. 11  illustrates a schematic of how female attachment portion  440  is encompassed by the combination of receptacle  70  and base  430 .  
         [0088]     The resultant foam part  50  is shown in-mold in  FIG. 12  and de-molded in  FIG. 13 . As illustrated in  FIGS. 9 and 12 , upper surface  74  of receptacle  70  is raised with respect to platform  68  of bowl  62 . This facilitates having foam element  50  encompass flexible portions  420  and bases  430  of trim cover attachment device  400  thereby improving the pull-out strength of the latter.  
         [0089]     With reference to  FIGS. 14-16  there is illustrated use of a trim cover attachment device which is a “hybrid” of trim cover attachment device  200  (as to curved or non-linear flexible portions  220 ) illustrated in  FIG. 2  and trim cover attachment device  400  (as to all elements except flexible portion  420 ) illustrated in  FIG. 4 . For ease of understanding,  FIGS. 14-16  utilize the appear reference numerals to denote the respective elements from trim cover attachment device  200  and trim cover attachment device  400 . The use of the “hybrid” trim cover attachment device is the same as discussed above with reference to  FIGS. 8-13 . One difference is that platform  69  of bowl  62  is designed to have the same height as receptacle  70  in the space between adjacent receptacles  70 . The result is that bases  430  are not complete engulfed by foam element  50 . Pullout is not deleteriously compromised, however, due to the presence of curved or non-linear flexible portions  220  which serve to anchor the trim cover attachment device in foam element  50 .  
         [0090]     While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. For example, it is possible to modify the specific process discussed above to utilize expanded polypropylene beads (or any other expanded polymer beads) during which individual beads would be adhered together to produce a molded part without necessarily expanding individual beads. It is therefore contemplated that the appended claims will cover any such modifications or embodiments.  
         [0091]     All publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety.