Foam pad and process for production thereof

1. A foam pad comprising:

a surface to which a trim cover can be secured, the surface comprising an open channel having a longitudinal axis and a maximum width of up to about 15 mm,

the open channel having a first section, a second section, and a third section disposed serially along the longitudinal axis, the second section: (i) having a narrower width than the first and third sections when measured in a direction perpendicular to said longitudinal axis and (ii) having disposed therein one of a male portion or a female portion of a releasably engageable male-female trim cover attachment system.

2. The foam pad defined in claim 1 , wherein the channel has a maximum width of up to about 12 mm.

3. The foam pad defined in claim 1 , wherein the channel has a maximum width in the range of from about 4 to about 10 mm.

4. The foam pad defined in claim 1 , wherein the channel has a maximum width in the range of from about 4 to about 8 mm.

5. The foam pad defined in claim 1 , the channel having disposed therein the female portion of the releasably engageable male-female trim cover attachment system.

6. The foam pad defined in claim 5 , wherein the foam pad comprises a plurality of female portions disposed in the channel.

7. The foam pad defined in claim 6 , wherein the plurality of female portions are independent of one another.

8. The foam pad defined in claim 6 , wherein the plurality of female portions are interconnected to one another with at least one connecting portion.

9. The foam pad defined in claim 5 , wherein the female portion is constructed from a polymer.

10. The foam pad defined in claim 9 , wherein the polymer is selected from the group comprising thermoset polymer and thermoplastic polymers.

11. The foam defined in claim 10 , wherein the thermoplastic polymer is selected from the group consisting of polyethylene, polypropylene and mixtures thereof.

12. The foam pad defined in claim 10 , wherein the thermoset polymer comprises polyurethane.

13. The foam pad defined in claim 5 , wherein the female portion comprises a female attachment portion and base portion.

14. The foam pad defined in claim 13 , wherein the base portion has a larger surface area than a surface area of the female attachment portion attached thereto.

15. The foam pad defined in claim 14 , wherein at least a portion of the base portion is encompassed by the foam pad.

16. The foam pad defined in claim 13 , wherein the female attachment portion spans the width of the channel second section.

17. The foam pad defined in claim 13 , wherein the female attachment portion comprises a clip portion.

18. The foam pad defined in claim 17 , wherein the clip portion comprises a substantially U-shaped cross-section.

19. The foam pad defined in claim 17 , wherein U-shaped cross-section comprises a pair of generally upstanding walls defining a locking region therebetween for receiving a male portion of the male-female trim cover attachment system.

20. The foam pad defined in claim 19 , 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.

21. The foam pad defined in claim 20 , wherein the locking portion comprises a first lateral portion projecting substantially toward the locking region.

22. The foam pad defined in claim 21 , wherein the first lateral portion projects angularly with respect to the pair of generally upstanding walls.

23. The foam pad defined in claim 20 , wherein the locking portion comprising a hook-shaped portion.

24. The foam pad defined in claim 1 , further comprising a trim cover attached thereto, the trim cover comprising the other of the male portion or the female portion of the releasably engageable male-female trim cover attachment system.

25. A vehicular seat comprising the foam pad defined in claim 24 .

26. A foam pad comprising:

a surface to which a trim cover can be secured, the surface having molded therein an open channel having a longitudinal axis and a maximum width of up to about 5 mm,

the open channel having a first section, a second section, and a section disposed serially along the longitudinal axis, the second section; (i) having a narrower width than the first and third sections when measured in a direction perpendicular to said longitudinal axis; and (ii) disposed in a portion thereof at least one female portion of a releasably engageable male-female trim cover attachment system, the female portion comprising a female attachment portion and a base portion.

27. The foam pad defined in claim 26 , wherein the channel has a maximum width of up to about 12 mm.

28. The foam pad defined in claim 26 , wherein the channel has a maximum width in the range of from about 4 to about 10 mm.

29. The foam pad defined in claim 26 , wherein the channel has a maximum width in the range of from about 4 to about 8 mm.

30. The foam pad defined in claim 26 , wherein the base portion has a larger surface area than a surface area of the female attachment portion attached thereto.

31. The foam pad defined in claim 30 , wherein at least a portion of the base portion is encompassed by the foam pad.

32. The foam pad defined in claim 26 , wherein the female attachment portion spans the width of the channel second section.

33. The foam pad defined in claim 26 , wherein the female attachment portion comprises a clip portion.

34. The foam pad defined in claim 33 , wherein the clip portion comprises a substantially U-shaped cross-section.

35. The foam pad defined in claim 34 , wherein U-shaped cross-section comprises a pair of generally upstanding walls defining a locking region therebetween for receiving a male portion of the male-female trim cover attachment system.

36. The foam pad defined in claim 35 , 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.

37. The foam pad defined in claim 36 , wherein the locking portion comprises a first lateral portion projecting substantially toward the locking region.

38. The foam pad defined in claim 37 , wherein the first lateral portion projects angularly with respect to the pair of generally upstanding walls.

39. The foam pad defined in claim 36 , wherein the locking portion comprising a hook-shaped portion.

40. The foam pad defined in claim 26 , wherein the foam pad comprises a plurality of female portions disposed in the channel.

41. The foam pad defined in claim 40 , wherein the plurality of female portions are independent of one another.

42. The foam pad defined in claim 40 , wherein the plurality of female portions are interconnected to one another at least one connecting portion.

43. The foam pad defined in claim 26 , wherein the female portion is constructed from a polymer.

44. The foam pad defined in claim 26 , further comprising a trim cover attached thereto, the trim cover comprising a male portion of the releasably engageable male-female trim cover attachment system.

45. A vehicular seat comprising the foam pad defined in claim 44 .

46. A foam pad comprising:

a surface to which a trim cover can be secured, the surface having molded therein an open channel having a longitudinal axis and a maximum width of up to about 15 mm,

the open channel having a first section, a second section, and a third section disposed serially along the longitudinal axis, the second section: (i) having a narrower width than the first and second sections when measured in a direction orthogonal to said longitudinal axis; and (ii) having disposed in a portion thereof plurality of female portions of a releasably engageable male-female trim cover attachment system, the female portion comprising a clip portion and a base portion molded into the foam pad.

47. The foam pad defined in claim 46 , further comprising a trim cover attached thereto, the trim cover comprising a male portion of the releasably engageable male-female trim cover attachment system.

48. A vehicular seat comprising the foam pad defined in claim 47 .