Method for making a support element for the human body, such as a saddle of a vehicle, support element so obtained and relative molding unit

Abstract

The present invention relates to a method for producing a support element for the human body, a support element for the human body that can be obtained by the method mentioned above, and a molding unit for producing a support element for the human body.

Description

Technical Field

[0001] The present invention relates to a method for realizing a support element for the human body, a support element obtained by the method, and a related molding unit. Prior Technology

[0002] In the field of support elements for the human body (such as the saddle of a vehicle (e.g., a bicycle)), it is known to manufacture a pad, whether or not equipped with an external cover covering its exterior or visible surface, which, after manufacture, is constrained, for example by gluing to the upper surface of a plastic support base (e.g., referred to as the "shell" or "felt" in a bicycle). According to this particular example, a "wheel fork" can be constrained to the plastic base at its lower surface in order to bond the saddle to a seatpost of a bicycle frame.

[0003] However, typically, once manufactured, the gasket is removed from the mold and then simply glued to the plastic base, for example. In this case, it can be difficult to connect the two components because the gasket may lose its dimensional stability and therefore may be difficult to couple with the plastic base, which instead has a well-defined shape and size.

[0004] At the same time, when there is an external cover, it can be difficult to perform the necessary finishing stage because the pad is made of a soft material, and it is not easy to finish an element such as an external cover that does not have a support point but finds that it must act on a soft support (precisely, the pad): the finishing tool may not be able to find a sufficiently rigid and / or suitable guide to perform the quality work.

[0005] There is also a method that makes it possible to obtain a bicycle saddle where no adhesive bonding between the pad and the support base is required. Patent IT1207441, in the name of the same applicant, describes a method for manufacturing a saddle by placing an outer cover above a cavity in a mother portion of a mold conforming to it using a vacuum component. A material is injected into the cavity where the outer cover is placed, thereby forming the pad of the saddle itself, and then the mold is closed using a male portion. Due to the properties of the respective materials, the pad adheres to the outer cover and also to a felt or support base, because the male portion of the mold is shaped to accommodate the felt.

[0006] Therefore, in this case, the upper surface of the felt determines the lower surface of the pad, and in this sense, these two surfaces are in contact with each other. Upon the next opening of the mold, a finished seat cushion is removed, followed by trimming of any excess outer covering.

[0007] Therefore, there is a need for a method and support element that can compensate for the aforementioned disadvantages and thus achieve a high-quality product even when the liner and support base are not immediately coupled together or in the same mold.

[0008] In addition, a mold is needed to make the aforementioned advantages of the method just indicated feasible. Summary of the Invention

[0009] The objective of this invention is to overcome the shortcomings of prior art.

[0010] A further object of the present invention is to provide a practical and potentially automated method for manufacturing a support element for the human body.

[0011] Another objective of the present invention is to provide a method for accelerating and making more precise the process of obtaining a support element for the human body.

[0012] A further object of the present invention is to provide a relatively inexpensive method.

[0013] According to one aspect of the present invention, a method for manufacturing a support element as described in technical solution 1 is provided.

[0014] Another objective of this invention is to provide a support element for the human body that is easy to assemble.

[0015] A further objective of the present invention is to provide a precise support element for the human body.

[0016] According to one aspect of the present invention, a support element for the human body, as described in technical solution 10, is provided.

[0017] Another objective of the present invention is to provide a molding unit that allows a support element to be easily and quickly manufactured, as mentioned above.

[0018] Another objective of this invention is to provide a molding unit that ensures the production of a support element with higher quality and efficiency than conventional molds.

[0019] According to one aspect of the present invention, a molding unit as described in technical solution 20 is provided.

[0020] The supplementary technical solutions refer to preferred and advantageous examples of the embodiments of the present invention. Simple Explanation of the Diagram

[0021] Other features and advantages of the invention will become more apparent from the disclosure of one embodiment of the invention illustrated in the accompanying drawings:

[0022] Figure 1 is a partial top perspective view of a molding unit according to the present invention in an open position;

[0023] Figures 2 and 3 respectively illustrate a partial top view of the rear detail of one of the first components of the molding unit in Figure 1 and a top view of one of the first components of the molding unit in Figure 1, wherein in the latter case, a structural component or support component according to the present invention is applied;

[0024] Figure 4 illustrates a bottom perspective view of a padding element, one of the support elements according to the present invention;

[0025] Figure 5 shows a partial longitudinal cross-sectional view of one of the fully assembled support elements according to one of the present invention;

[0026] Figure 6 illustrates a top perspective view of one of the structural or support components according to one of the present invention;

[0027] Figure 7 illustrates a bottom view of a support element pad according to the present invention at a non-final stage of its implementation;

[0028] Figure 8 illustrates a partial side view of a support element according to the present invention at one of the final stages of its implementation;

[0029] Figures 9 and 10 each illustrate one of the automated steps of the method according to the present invention;

[0030] Figure 11 illustrates a cross-sectional view of a molding unit according to the invention in a closed position, wherein the cross-section is obtained along a transverse plane of a support element obtained therewith.

[0031] In the accompanying drawings, the same parts or components are distinguished by the same element symbols. Implementation

[0032] The present invention relates to a method for manufacturing a support element for the human body, such as a vehicle seat cushion, for example a bicycle or motorcycle seat cushion, or a backrest or seat or armrest or similar support element for an anatomical chair, or a portion thereof, and a related molding unit.

[0033] Figure 1 shows a molding unit 10 according to the present invention for producing a support element for the human body.

[0034] More specifically, unit 10 includes a first component 12 and a second component 14. The first component 12 is a punch element of the forming unit 10, and the second component 14 is a die component of the forming unit 10.

[0035] The first component 12 can be coupled to the second component 14. Specifically, when the first component 12 is abutting the second component 14, the molding unit 10 is in a closed operating configuration, and when the first component 12 and the second component 14 move away from each other, the molding unit is in an open operating configuration.

[0036] Therefore, components (not shown) that approach and remove the first component 12 relative to the second component 14 are provided, which are capable of moving the molding unit 10 from an open operation configuration to a closed operation configuration and vice versa, including all intermediate operation positions between open and closed.

[0037] Such approach-removal components, as is commonly known in the industry, may include electric, pneumatic, or other actuators designed to reciprocate to approach and / or move one of the first component 12 and the second component 14 along a straight line or in an angular or rotational direction. This means that the first component 12 may move relative to the second component 14 along a predetermined straight line, or may move or rotate relative to the second component 14 at an angle in an approach-close or remove-open mode, and vice versa.

[0038] In Figure 1, the second component 14 is positioned below one of the first components 12. However, different positions may be considered.

[0039] In this invention, the term "upper" refers to an element that is positioned above or higher or facing upwards during use; on the other hand, the term "lower" refers to an element that is positioned below or lower or facing downwards or towards the ground during use.

[0040] The term "longitudinal" refers to a direction that extends along the longest part of an element, while the term "lateral" refers to a direction that extends perpendicular to the longest part of an element or along its sides.

[0041] "Vertical" means a direction or plane that extends from the bottom to the top during use, while "horizontal" means a direction or plane that is parallel to the ground during use.

[0042] The second component 14 includes and / or defines a cavity 16 adapted to accommodate and / or fill a material of a liner 114 adapted to form a support element 100. This material can be inserted, poured, or injected into the cavity 16 and is capable of foaming and / or hardening and / or polymerizing and / or curing within the cavity 16. Therefore, the material is a hardenable and / or polymerizable and / or curable material.

[0043] Cavity 16 is recessed relative to the second component 14 and substantially negatively shaped relative to the liner 114.

[0044] In at least one first configuration or version of the invention, the cavity 16 is open at the top. Thus, the cavity 16 has an opening 16a.

[0045] The cavity 16 is formed by a recessed shaped surface 16b and by a peripheral edge 16c that defines the opening 16a.

[0046] The first component 12 includes a punch element 18. The punch element 18 is shaped to abut the cavity 16 and / or abut its peripheral edge 16c in order to determine the closure of the forming unit 10 and / or the cavity 16.

[0047] The punch element 18 rises from the first component 12 and includes a forming area 18a and an outer contour 18b.

[0048] The outer contour 18b corresponds to the peripheral edge 16c of the second component 14 and / or is adapted to contact and / or abut against the peripheral edge 16c.

[0049] At the outer contour 18b of the punch element 18, there is an abutment element 18c, shaped like a pin or cylinder, which can be accommodated in a suitable and corresponding seat hole 16d disposed at, for example, the peripheral edge 16c of the cavity 16. The abutment element 18c and the suitable seat hole 16d are matched such that when the first component 12 and the second component 14 are abutted, the abutment element 18c can be accommodated in the seat hole 16d. However, the positions of the abutment element 18c and the corresponding seat hole 16d can be reversed without departing from the scope of the invention.

[0050] The shaped surface 16b of cavity 16 is defined by a first delimiting edge 16e.

[0051] Similarly, the forming region 18a of the punch element 18 is defined by a second delimiting edge 18d.

[0052] In the closed operation configuration, the first boundary edge 16e and the second boundary edge 18d are adjacent to each other.

[0053] The molding surface 16b and the molding area 18a respectively determine the upper surface 116 and the lower surface 118 of the pad 114.

[0054] When the molding unit 10 is in a closed operation phase, the pad 114 of the support element 100 is molded.

[0055] Therefore, the method according to the present invention includes the following steps: -Provide a material adapted to manufacture a pad 114. - Provide a support component 122, - Position the support component 122 at the punch element 18 of the first component 12 of the forming unit 10. - The punch element 18 closes one cavity 16 of the second component 14 of the forming unit 10, thereby bringing the first component 12 closer to the second component 14 or vice versa, causing the support component 122 to face the cavity 16, thus determining a closed operation configuration for the forming unit 10. - Insert and / or cast and / or inject the material constituting the liner 114 into the cavity 16. - Hardening and / or polymerizing and / or curing the material to obtain a hardened and / or polymerized and / or cured material forming the gasket 114, resulting in adhesion of the support assembly 122 to the gasket 114. -Move the first component 12 away from the second component 14 or vice versa, thereby determining the open operation configuration of one of the molding units 10. - Self-forming unit 10 removes pad 114.

[0056] In one version of the present invention, the method may include the following steps: - Provide an external cover 120, Position the outer cover 120 in the cavity 16 and lock the outer cover 120 in place. - Prior to the insertion and / or casting and / or injection steps, activate the vacuum mechanism to allow the material of the outer cover 120 to adhere to one of the molding surfaces 16b of the cavity 16. - Apply a primer or compatibilizer to one of the inner surfaces 120c of the outer covering 120, as needed. - Trim an excess portion 120a of the outer covering 120 to obtain a trimmed outer covering.

[0057] The finishing step is followed by a hardening and / or polymerization and / or curing step, or a removal step and / or pick-off step.

[0058] When an external cover 120 is present, after the step of positioning the external cover, the padding material 114 is positioned in the cavity 16 and brought into contact with the external cover 120 itself.

[0059] The step of locking the outer cover 120 in place can be accomplished by locking an excess portion 120a of the outer cover 120 by means of, for example, a retaining plate 20, as better disclosed below.

[0060] According to a further version, the outer cover 120 can be directly locked in place by the punch element 18, abutting against the first component 12. Specifically, the outer contour 18b of the peripheral edge 16c of the second component 14 locks the excess portion 120a of the outer cover 120 in place.

[0061] The trimming stage is rapid, whether it is carried out manually or automatically, for example, by a special trimming machine. Due to the support assembly 122, there is actually no excess material to trim, because the outermost edge 122c of the support assembly 122 is placed at a specific distance from the trimming edge 114a of the pad 114, for example, a distance of about 5 mm or between 1 mm and 10 mm.

[0062] The trimmed edge 114a of the pad 114 is the edge that ideally separates the excess portion 120a of the outer covering 120 from the portion of the surface 116 of the pad 114 itself.

[0063] The trimmed edge 114a is along the trimmed edge of the outer covering 120.

[0064] Therefore, as will be better understood from the following disclosure, the trimming edge 114a of the liner 114 is determined in use by the contact between the first demarcation edge 16e and the second demarcation edge 18d of the cavity 16 and the punch element 18.

[0065] When a support base 150 is constrained to a pad 114, the trimmed edge 114a is positioned inside relative to the support base 150 and / or its outer peripheral contour 150a.

[0066] The hardening and / or polymerization and / or curing steps include obtaining a support component 122 at the lower surface 118 of the liner 114, thereon adhering to an inner region 123 of one of the hardened and / or polymerized and / or cured materials, and an annular region 124 surrounding the inner region 123, which includes one of the hardened and / or polymerized and / or cured materials.

[0067] In at least one version of the invention, the inner region 123 is recessed relative to the annular region 124.

[0068] Adjacent to the trimming edge 114a, an annular region 124 is obtained between the trimming edge 114a and the outermost edge 122c of the support component 122.

[0069] Subsequently, the method includes a step of constraining a support base 150 at a lower surface 118 (and / or annular region 124) of the support assembly 122 (and / or its outer surface 122b) and / or the pad 114 to which the support assembly 122 is attached, wherein the constraining step includes a step of applying an adhesive or a bonding agent to a lower surface 118 of the pad 114 and to the support assembly 122 (and / or its outer surface 122b) and a step of gluing the support base 150 to the lower surface 118 and to the support assembly 122, or vice versa.

[0070] The adhesive or bonding agent may include polyurethane-based compounds, such as two-component polyurethane adhesives. Additional components may be provided depending on the specific type of material of the elements to be glued together.

[0071] The adhesive or bonding agent may also be applied several times, for example, twice to the surface 118 below the pad 114, with a specific time interval between each application. This can be particularly useful when the adhesive is applied, for example, by a brush or similar tool, while it may not be necessary if the adhesive is sprayed.

[0072] The method according to the invention may include the steps of preparing and / or cleaning and / or degreasing at least one upper surface of the support base 150 so that it can accommodate adhesive or bonding agent and thus bond to the lower surface 118 of the pad 114 and / or to the support assembly 122.

[0073] The method according to the invention may also include the steps of preparing and / or cleaning the lower surface 118 of the pad 114. For example, these steps may be performed before the application of adhesive or bonding agent.

[0074] Special cleaning substances (including chemically based substances) may be used to perform cleaning steps in order to prepare the treated and / or cleaned surfaces. In this way, the cleaning substances can cause the double bonds present in the hardened and / or polymerized and / or cured material of the gasket 114 to break.

[0075] A primer and / or a compatibilizer may be applied to the upper surface of the support base 150 to facilitate constraint and / or bonding to the gasket 114 and / or support assembly 122.

[0076] This promotes the self-constraint of the support base 150 and the pad 114.

[0077] In at least one version of the invention, the adhesion of the material from the support component 122 to the pad 114 is determined by the chemical affinity between the two materials and / or arises from the hardening and / or polymerization and / or curing reaction of the material of the pad (a reaction occurring in the vicinity of the support component 122 itself).

[0078] In an alternative version, the step of adhering the support component 122 to the pad 114 may be assisted by applying a suitable compatibilizer and / or additive and / or adhesive to one of the inner surfaces 122a of the support component 122.

[0079] The step of constraining the support base 150 at the lower surface 118 of the support component 122 and / or the pad 114 to which the support component 122 is attached may also include applying an adhesive or glue to one of the upper surfaces of the support base 150.

[0080] The step of constraining the support base 150 to the pad 114 can be performed, for example, by a press that is separate from the molding unit 10 of the present invention.

[0081] According to an alternative version, the support base 150 can be constrained to a male component (not shown in the drawings) by means of a suitable engagement member. In molding unit 10, the male component is an alternative example of the first component 12. In fact, once the liner 114 has been manufactured, and after (if necessary) trimming of the excess portion 120a of the outer cover 120, the male component can be removably coupled to the second component 14, thereby bringing the support base 150 to abut against the lower surface 118 of the liner 114 and abut against the support component 122.

[0082] In this way, the constraint and / or engagement of the support base 150 and the pad 114 can occur through the use of this component and therefore substantially through a single molding unit 10.

[0083] As a result of this method, the support component 122 is flush with the lower surface 118 of the pad 114 and / or with the annular region 124. Therefore, although manufactured with a reduced thickness, in at least one version of the invention, the support component 122 does not protrude relative to, for example, the pad material positioned at the annular region 124.

[0084] Therefore, the support component 122 is placed in a corresponding embossed or recessed area (the size of which corresponds to the size and thickness of the support component 122) formed by the internal region 123 determined in the pad 114.

[0085] In this way, in at least one version of the invention, once implemented, the lower surface 118 of the pad 114 formed by the support component 122 and the annular region 124 is substantially without discontinuities or steps.

[0086] Therefore, the support component 122 is embedded and / or inserted to some extent into the material forming the pad 114. This means that at least the inner surface 122a of the support component 122 (the inner surface intended to contact the pad 114) and the thickness of the support component 122 will be surrounded and in contact with the material of the pad 114. Conversely, one of the outer surfaces 122b of the support component 122, which is visible after the pad manufacturing step and adapted for restraining and / or gluing to the support base 150, is not recessed or protruding relative to the material constituting the pad 114 and / or the annular region 124, but is substantially coplanar and / or flush with it.

[0087] Therefore, at least part of the outer surface 122b is not covered by the hardened and / or polymerized and / or cured material constituting the liner 114.

[0088] It is clear that the outer surface 122b of the support assembly 122 is the outer surface that contacts the forming area 18a of the punch element 18 during use. Therefore, in this way, the component that holds the support assembly 122 in place does not allow the material constituting the pad 114 to pass between the outer surface 122b and the forming area 18a.

[0089] The method may also include a step of grinding the material of the annular region 124 to make the annular surface rough and / or wrinkled and / or have a rough and / or wrinkled pattern.

[0090] In fact, as already mentioned, it is feasible for the material constituting the gasket 114 to have a dense surface after hardening and / or polymerization and / or curing. This polishing step enables the surface of the annular region 124 to better absorb the adhesive or bonding agent required for subsequent restraint of the support base 150. In at least one version of the invention, the polishing step may open the chemical bonds of the material constituting the gasket 114 and / or mechanically roughen and / or wrinkle the region to facilitate the bonding step.

[0091] The grinding step can be performed by milling and / or grinding and / or scraping and / or removing and / or mechanically etching the surface layer of the annular region 124.

[0092] According to one version of the method of the present invention, at least one of the steps and / or at least the grinding and / or applying of an adhesive or bonding agent and / or finishing steps are automated and / or performed by a robot (e.g., anthropomorphically).

[0093] Another advantage of the presence of the support component 122 is that its dimensional stability and consistency allow the pad 114 to be positioned on a template or special tool once it is manufactured and the support component 122 is attached to its lower surface 118. In this way, the steps of the method and / or the steps of trimming the outer cover 120 and / or preparing the pad 114 and / or the grinding steps (as seen in Figure 9) and / or the steps of applying an adhesive or bonding agent (as seen in Figure 10) are performed, for example, by a robot (e.g., anthropomorphically) rather than by a human.

[0094] The template or suitable tool has, for example, a shape that negatively corresponds to the shape of the pad 114 and / or its upper surface 116 and / or includes a vise and / or an undercut.

[0095] Finally, the step of securing or gluing the pad 114 to the support base 150 can be performed by placing the components, or only one of them, in an oven (e.g., a convection oven), which brings the entire mass of the components, or only one of them, to a temperature corresponding to, for example, about 50°C. Subsequently, the two components are coupled and pressed onto one of them, for example, manually. In this way, in at least one version of the invention, the support element 100 will be ready for sale without further finishing and / or cleaning steps.

[0096] The step of positioning the support assembly 122 onto the punch element 18 includes positioning and / or securing the support assembly 122 by means of a retaining member present on the punch element 18. The retaining member includes a containment edge 22 and / or a retaining member 30 and appropriate seat holes and / or holes 130 on the support assembly 122 itself, as further specified below.

[0097] According to one version of the invention, the support element 100 may have a hole, preferably a through hole, in one of its centers and / or longitudinal regions. The hole may be circular or elongated. This is particularly useful when the support element 100 is a coordinate of a vehicle, as the hole can allow for better ventilation or provide pressure relief at certain points (such as the prostate or soft tissue points) for the user.

[0098] When this hole is present, it affects both the liner 114 and the support assembly 122. Specifically, in the support assembly 122, an opening (e.g., circular or elongated) is created during the preparation or molding stage of the support assembly itself. Regarding the liner 114 and / or the outer cover 120, this hole can still be created even after the step of creating the liner itself (possibly at the opening provided on the support assembly). In this case, the method may include a step of creating this hole at the substantially central and / or longitudinal portion of the outer cover 120 and / or the liner 114 after a hardening and / or polymerization and / or curing step, or after a step of maintaining a distance, or after a step that may involve removal at the corresponding opening in the support assembly 122. This can be performed, for example, by a pressure cutting element or by shearing or other similar methods.

[0099] According to one version of the invention, the liner 114 may include at least one insert. This insert may be made of, for example, a polyurethane material and / or a material having a different density relative to the remaining material constituting the liner and / or a material having different chemical and / or physical and / or mechanical properties relative to the remaining material constituting the liner and / or a material distinguished from the remaining portion constituting the liner 114 by at least one property. According to one version, this at least one insert may be made of polyurethane gel or ethylene vinyl acetate (EVA).

[0100] This at least one insert may be positioned in at least one area of ​​the pad where it is desired to obtain a density and / or mechanical properties different from the rest of the pad (e.g., improved comfort and / or improved cushioning and / or increased stiffness and / or firmness).

[0101] Therefore, the method according to the invention may include the steps of providing at least one insert and positioning one of the at least one insert inside the outer cover 120 and / or support assembly 122.

[0102] The step of supplying at least one insert may include a step of supplying a pre-formed insert or a step of pouring a suitable material into at least one area in which the insert is to be placed.

[0103] Therefore, the support element 100 obtained using the method according to the present invention includes a pad 114 (which may include at least one insert) and a support assembly 122.

[0104] When at least one insert is provided preformed, it can be constrained to, for example, the inner surface 122a of the support assembly 122, such that it is incorporated therein after the pad 114 is implemented. Due to both the inherent characteristics of this insert and the fact that the volume occupied by the pad 114 can be reduced in its presence, and therefore (compared to the same material that could be positioned in a larger volume) the same material would be in fact denser and / or less expensive and / or stronger, the presence of at least one insert, for example made of EVA, makes it feasible to simultaneously strengthen the material. For example, at least one insert can be glued to the support assembly 122.

[0105] When casting the insert, the insert may be cast into a designated area of ​​cavity 16 before the material constituting liner 114 is inserted. In this case, a specific time period may be allowed (e.g.) to at least partially achieve polymerization and / or hardening and / or curing of the material of at least one insert, such that the material constituting the liner does not intrude into the area designated for at least one insert and / or mix with at least one insert.

[0106] The support component 122 has a configuration that substantially corresponds to but is slightly smaller than that of the pad 114.

[0107] When the support element 100 is a seat cushion (such as a self-forming coordinate) of a vehicle, both the cushion 114 and the support assembly 122 have a first portion (used front or front part) having a substantially elongated configuration and a second portion (used rear part) having a substantially enlarged configuration. The first portion connects to the second portion because the overall configuration of the cushion 114 and / or the support assembly 122 is substantially a triangle with rounded edges.

[0108] According to at least one version of the invention, the first portion is connected to the side or lateral portion of the second portion, which is at least slightly contoured to present a concave shape (where a cavity faces outward and to the side). For example, this shaping can facilitate user stepping.

[0109] The support component 122 may be made of a composite material, such as a latex-impregnated cellulose aggregate (such as commercially available material Texon) and / or a synthetic material and / or a plastic and / or a thermoplastic material (such as a material comprising polyester and a viscous compound or composed of polyester and a viscous compound) and / or a thermoformable material and / or a rigid polyurethane or a soft polyurethane, etc.

[0110] The support component 122 is at least partially inserted into and / or embedded in the hardened and / or polymerized and / or cured material of the liner 114, except for its outer surface 122b.

[0111] In one version of the invention, the support component 122 is not made of a material such as a fabric or a mesh. Generally speaking, fabrics or meshes do not provide the necessary stiffness required for the support component 122 of the present invention. Furthermore, fabrics or meshes (at least conventional fabrics or meshes) do not help maintain the size of the padding, do not provide a "guide" for adjusting the outer covering, and do not prevent the padding material itself from shrinking.

[0112] The support component 122 has a very thin thickness, approximately a few millimeters or about 1 mm or less.

[0113] The support component 122 provides a specific "stiffness" to the pad 114. For example, the support component has a Young's modulus stiffness of 500 to 3000 MPa.

[0114] In fact, the support component 122 is stronger than the material constituting the pad 114 and / or the material constituting the outer cover 120.

[0115] In at least one version of the invention, the support component 122 has the same stiffness as the support base 150 but has a significantly reduced thickness compared to the support base 150.

[0116] In one version of the invention, the support component 122 can be produced by a thermoforming process.

[0117] The support component 122 has two main surfaces that have a configuration substantially identical to that of the support component itself. In fact, these main surfaces are spaced apart by the thickness of the support component (which, as mentioned, is very thin).

[0118] The larger surface of the support component is an inner surface 122a adapted to face and / or constrain the material of the pad 114 in use, and an outer surface 122b adapted to face and / or constrain the support base 150 in use.

[0119] For example, the support base 150 (as seen in Figures 5 and 8) may be made of a plastic and / or synthetic material (such as polyamide) or a metal or composite material.

[0120] At least one of the inner surface 122a and the outer surface 122b (preferably the outer surface 122b) is at least partially rough and / or contains more or less irregularity or adjusted inhomogeneity, ripples, grooves, and valleys. In this way, the support component 122, through its outer surface 122b having this particular pattern or texture, more easily retains and / or is more easily impregnated by the adhesive or glue used to bond with the support base 150. In this way, for example, it is possible to avoid using a primer between the support component and the material constituting the support base 150.

[0121] In one version of the invention, the support element 100 may include at least one external cover 120. This external cover 120 may be made of a plastic or natural material, such as a layer of fabric, leather, artificial leather, dense and / or closed-cell or foamed polyurethane material, a high-density material, a synthetic and / or polymeric material (such as PVC or polyvinyl chloride), etc.

[0122] When an external cover 120 is present, a layer of primer or compatibilizer based on polyurethane and / or its components may be present and / or applied to promote adhesion of the external cover 120 to the pad 114. In this case, this layer is applied to an inner surface 120c of the external cover 120 used internally, adapted to face and / or constrain to the upper surface 116 of the pad 114. It should be understood that when the external cover 120 is present, the upper surface 116 of the pad 114 is not external or accessible from the outside or by a user because it is covered and / or constrained to it by the external cover 120.

[0123] The outer cover 120 also has an outer surface 120b, which is adapted to be in contact with the user and / or visible from the outside when in existence.

[0124] For example, the material constituting the pad 114 may include a foam, a self-splashing foam, a polyurethane foam, or a printed insert, using a three-dimensional printer, a cushioning and / or comfort insert, etc. In at least one version of the invention, this material is expandable. Furthermore, in one version of the invention, this material may be inserted, poured, or injected into the cavity 16 of the molding unit 10 and adapted to foam, harden, and / or polymerize and / or cure within the cavity 16 itself.

[0125] Therefore, as can be seen, the present invention also relates to a support element for the human body that can be obtained by a method according to the invention, wherein the support element 100 includes a pad 114, a support assembly 122, and, where appropriate, a support base 150, wherein the pad 114 includes a hardened and / or polymerized and / or cured material to which the support assembly 122 is adhered. When the support base 150 is present, the support assembly 122 can be placed between the pad 114 and the support base 150 in use.

[0126] This support component 122 is adhered to the pad 114 and / or glued to the support base 150.

[0127] An outer cover 120 may be present that at least partially or completely covers one of the pads 114.

[0128] In at least one version of the invention, the pad 114 attached to the support assembly 122 constitutes a semi-finished assembly, and thus, in this case, forms part of a support element 100. In fact, a support base 150 is also useful for obtaining a usable and / or complete support element 100. However, due to the presence of the support assembly 122, as mentioned above, maintaining the dimensional stability of the molded pad 114, the molded pad 114 can then be sold or stored for subsequent application to the support base 150.

[0129] Due to the presence of support component 122, the coupling operation between the pad 114 and the support base 150 takes several seconds, whereas without the support component, or by applying a material other than that listed herein for support component 122, the coupling operation takes several minutes. Furthermore, without support component 122, the operator's skill is crucial for proper constraint of the support base. Conversely, with support component 122 present, this operation is very easy for the operator.

[0130] The advantages of the support assembly 122 are also measured based on its effectiveness during the trimming operation of the excess portion 120a of the outer cover 120. In fact, the advantage lies in having a consistent and tight assembly (i.e., the support assembly 122), which facilitates the operator in carrying out this operation.

[0131] The present invention also includes a molding unit 10 as an objective. This molding unit 10 is adapted for use in the method according to the present invention and / or for implementing the support element described above.

[0132] When an external cover 120 is present, the molding unit 10 may include a vacuum member and / or a special retaining plate (e.g., indicated by 20 in FIG. 1). The retaining plate 20 is positioned above the cavity 16 such that, when the external cover is present, a layer of material adapted to manufacture it is positioned at the cavity 16. The size of the external cover layer is larger than the size of the cavity such that, once positioned at the cavity 16, it can overlap with the peripheral edge 16c and / or the first demarcation edge 16e of an excess portion 120a (e.g., visible in FIG. 7).

[0133] The retaining plate 20 locks the outer cover 120 in place by pressing and restraining the excess portion 120a, and then actuates the vacuum member and the outer cover 120 adheres to the molding surface 16b, thereby presenting the configuration of the molding surface 16b.

[0134] The retaining plate 20 has a substantially annular surface and a through opening corresponding to the opening 16a of the cavity 16.

[0135] Specifically, the outer cover has an outer surface 120b adapted to contact the cavity 16 and intended to form the outermost layer of the padding 114 used, and an inner surface 120c adapted to contact the padding material 114. The inner surface 120c of the outer cover 120 is not visible in use.

[0136] However, in the absence of the external cover 120, the material constituting the pad 114 can independently produce a more compact film and / or have more closed and / or less swollen units (compared to the material constituting the remaining portion of the pad 114) in contact with the molded surface 16b.

[0137] Advantageously, and as mentioned, the punch element 18 includes a retaining member for supporting the assembly 122.

[0138] For example, the retaining member placed at the forming area 18a of the punch element 18 may include a retaining edge 22 and / or retaining member 30 adapted to accommodate and / or retain a support assembly 122 in use.

[0139] In one version of the invention, the containment edge 22 is able to prevent the material constituting the pad from traveling through the edge itself and overlapping the outer surface 122b of the support component 122.

[0140] The confining edge 22 is internal relative to the outer contour 18b and / or the second demarcation edge 18d of the punch element 18. In fact, the outer contour 18b has a larger size than either the second demarcation edge 18d or the confining edge 22. According to one version of the invention, the confining edge 22 is positioned approximately 1 cm from the outer contour 18b. Therefore, the area enclosed by the confining edge 22 is smaller than the area enclosed by the second demarcation edge 18d (which corresponds to the forming area 18a), and the area enclosed by the second demarcation edge 18d is subsequently smaller than the area enclosed by the outer contour 18b.

[0141] Therefore, the enclosure edge 22 divides the forming region 18a into an inner region 23 at the enclosure edge 22 and an annular region 24 surrounding the inner region 23.

[0142] This confining edge 22 protrudes relative to the forming region 18a, as shown in Figure 2.

[0143] In an alternative version not shown in the figure, the containment edge 22 may be flush with the forming region 18a and may enclose an inner region 23 that is recessed relative to the forming region 18a. The indentation depth of this inner region may correspond to the thickness of the support component 122. In this case, the annular region 24 will also be flush with the containment edge 22. Therefore, the containment edge 22 will be determined by the depth difference between the inner region and the annular region.

[0144] However, as mentioned and can be seen in Figures 2 and 3, the forming region 18a is formed to correspond to the lower surface 118 of the pad 114.

[0145] Therefore, the inner region 23 determines the formation of the lower surface 118 of the liner 114 and / or most of the inner region 123, while the annular region 24 determines the formation of the annular region 124 of the liner 114.

[0146] Therefore, as can be seen in Figures 2 and 3, the annular region 24 extends from the confining edge 22 to the second demarcation edge 18d of the punch element 18. According to the view in Figure 2, it may slope outward (e.g., downward and outward) away from the confining edge 22.

[0147] This inclined surface can be straight or curved, with the concavity facing inward or outward toward the punch element 18.

[0148] As already mentioned, in at least one version of the invention, the punch element 18 may include a suitable retaining member 30 (such as a coupling pin) of the support assembly 122 (as seen in FIG2).

[0149] This retaining member 30 may be formed, for example, as a pin 30a having a first end constrained or connected to one of the forming regions 18a and a second end or free end 30b opposite the first end having a cross section larger than that of the pin 30a.

[0150] The cross-section of the stud 30a can be circular or polygonal. Similarly, the cross-section of the free end 30b can be circular or polygonal.

[0151] The height of the stud 30a may correspond to or be only slightly greater than the thickness of the support component 122.

[0152] Naturally, retaining member 30 may have any other form suitable for this purpose without departing from the scope of protection of the invention.

[0153] In an alternative version, the retaining member 30 may be absent, since the support component can be held in place by the confining edge 22 alone.

[0154] According to a further version of the invention, a retaining member 30 may be present, but a blocking edge 22 may not be present.

[0155] Then, a component for generating a vacuum may be present, which is adapted to hold the support assembly 122 in the appropriate position on the punch element 18 with or without the presence of the confining edge 22 and / or the retaining component 30.

[0156] When the retaining member 30 is present, the support assembly 122 will have a special seat hole or special through hole 130 (for example, as seen in Figures 4 and 6), which has a circular or polygonal cross section adapted to allow the retaining member itself to pass through while holding the support assembly 122 on the punch element 18.

[0157] In one version of the invention, the retaining member 30 is positioned at the forming region 18a, or at the inner region 23, possibly near the annular region 24.

[0158] At the support base 150, when the support element 100 is attached to a seat of a vehicle, specifically, for example, for a bicycle, a fork 152 of one type known in the art can be attached to the bicycle or vehicle frame.

[0159] In one version of the invention, the molding unit 10 and / or at least the first component 12 are made of aluminum or other suitable metal materials.

[0160] The first component 12 and / or the second component 14 each include a punch element 18 protruding from and / or recessed into a main board with a cavity 16.

[0161] In the closed operation position of the molding unit 10, the first component 12 and the second component 14 can also contact their respective main boards.

[0162] Therefore, a sealing condition is created for cavity 16 using punch element 18 or its forming area 18a (by means of a special gasket if necessary).

[0163] Features defined for one variant or embodiment may also exist for other variants or embodiments, unless otherwise explicitly provided.

[0164] Modifications and variations of this invention are permissible within the scope of protection defined by the patent application.

[0165] 10: Molding Unit 12: First Component 14: Second Component 16: cavity 16a: Opening 16b: Molded surface 16c: Peripheral edge 16d: Seat Hole 16e: First Boundary Edge 18: Punch component 18a: Forming area 18b: External outline 18c: Adjacent element 18d: Second boundary edge 20: Holding plate 22: Enclosure Edge 23: Internal Area 24: Circular area 30: Retaining components 30a: Pin / Stud 30b: Second end / Free end 100: Support element 114: Padding 114a: Trim edges 116: Upper surface 118: Lower surface 120: External coverings 120a: Excess portion 120b: Outer surface 120c: Inner surface 122: Support Components 122a: Inner surface 122b: Outer surface 122c: Outermost edge 123: Internal area 124: Circular area 130: Kong 150: Support base 150a: External peripheral outline 152: Wheel Fork

Claims

1. A method of manufacturing a support element for the human body, comprising the steps of: providing a material suitable for manufacturing a pad (114) of the support element (100); providing a support assembly (122) including an inner surface (122a) of a support base (150) of the support element suitable for constraint in use; placing the support assembly (122) at a punch element (18) of a first component (12) of a molding unit (10); casting or injecting the material into a cavity (16) of a second component (14) of the molding unit (10); closing the cavity (16) using the punch element (18) to bring the first component (12) closer to the second component (14) or vice versa, so that the support assembly (122) faces the cavity (16); and determining a closed operation configuration for the molding unit (10). The material is hardened or cured to obtain a hardened or cured material forming a liner (114), and then the support component (122) is adhered to the liner (114), wherein the support component (122) is at least partially inserted or embedded in the hardened / or cured material of the liner (114) such that at least part of the outer surface (122b) of the support component (122) is not covered by the hardened or cured material of the liner (114), the first component (12) is moved away from the second component (14) or vice versa, thereby determining an open operating configuration of the molding unit (10), and the liner (114) is removed from the molding unit (10).

2. The method of request item 1, wherein the method includes: An outer cover (120) is provided, placed in the cavity (16), and locked in place. Before the pouring or injection step, a vacuum component is activated to adhere the material of the outer cover (120) to a molding surface (16b) of the cavity (16). An excess portion (120a) of the outer cover (120) is trimmed to obtain a trimmed outer cover (120), wherein the trimming step follows the hardening or curing step, the removal step, or the take-off step.

3. The method of claim 2, comprising a step of constraining the support base (150) at the outer surface (122b) of the support assembly (122) or at a lower surface (118) to which the support assembly (122) is adhered, wherein the constraining step comprises a step of applying an adhesive or a bonding agent to a lower surface (118) of the pad (114) and to the outer surface (122b) and a step of gluing the support base (150) to the lower surface (118) and to the outer surface (122b) or vice versa.

4. The method of claim 3, wherein the hardening or curing step includes obtaining the support component (122) at the lower surface (118) of the pad (114) and thereon region (124) of the hardened or cured material in which the support component (122) is adhered to the lower surface (118) of the pad (114) and the inner region (123) of the inner region (123) including the hardened or cured material.

5. The method of claim 4, which includes a step of grinding the surface of the annular region (124) to roughen or wrinkle it.

6. The method of claim 5, wherein the steps of grinding the surface of the annular region (124), applying the adhesive or the bonding agent, or trimming the excess portion (120a) of the outer covering (120) are automated.

7. The method of claim 1 or 2, wherein the step of placing the support assembly (122) includes a step of positioning or securing the support assembly (122) to the punch element (18) by means of a retaining member (30) for the support assembly (122), which includes a containment edge (22) or retaining member (30) suitable for housing or holding the support assembly (122) in use and any suitable seat hole or hole (130) present in the support assembly (122).

8. The method of claim 1 or 2, which includes a step of making a hole in a substantially central or longitudinal portion of the outer cover (120) or the liner (114) after the hardening or curing step, after the removal step, or after the removal step present in a corresponding opening in the support assembly (122).

9. The method of claim 1 or 2, comprising the step of providing at least one insert and placing the at least one insert near the outer cover (120) or the support assembly (122) to obtain the pad (114) including the at least one insert.

10. A support element for the human body that can be obtained by any one of claims 1 to 9, wherein the support element (100) is a vehicle seat, a bicycle or motorcycle seat, a backrest or seat or armrest or similar support element or part thereof for an anatomical chair, comprising a pad (114), wherein the pad (114) comprises a hardened or cured material, characterized in that it comprises a support assembly (122) adhered to the pad (114), wherein the support assembly (122) is at least partially inserted or embedded in the hardened or cured material of the pad (114) and comprises an outer surface (122b) suitable for constraint to a support base (150) of the support element in use.

11. The support element of claim 10, comprising the support base (150), wherein the support assembly (122) is placed between the pad (114) and the support base (150) or wherein the support assembly (122) is adhered to the pad (114) and glued or constrained to the support base (150).

12. The support element of claim 10 or 11 includes an outer cover (120) wherein the outer cover (120) at least partially or completely covers the pad (114) or wherein the outer cover (120) is trimmed.

13. The support element of claim 10 or 11, wherein the pad (114) includes a trimmed edge (114a) wherein the trimmed edge (114a) is positioned internally relative to the support base (150) or relative to its peripheral profile (150a).

14. The support element of claim 10 or 11, wherein the pad (114) has a lower surface (118) suitable for adhesion to the support assembly (122) and to the support base (150) in use.

15. The support element of claim 10 or 11, wherein the pad (114) has a lower surface (118), wherein the lower surface (118) includes the support assembly (122) thereon to an inner region (123) of the hardened or cured material and an annular region (124) of the hardened or cured material surrounding the inner region (123) including the hardened or cured material adapted to adhere to the support base (150) in use, or wherein the outer surface (122b) of the support assembly (122) and the annular region (124) are substantially coplanar or flush.

16. The support element of claim 10 or 11, wherein the annular region (124) has a rough or wrinkled surface pattern.

17. The support element of claim 10 or 11, wherein the support assembly (122) comprises a composite material, wherein the support assembly (122) has a stiffness greater than that of the hardened or cured material of the liner (114) or wherein the support assembly (122) has a stiffness having a Young's modulus in the range of 500 to 3000 MPa.

18. The support element of claim 10 or 11, wherein the pad (114) or the hardened or cured material comprises a foam, a self-skinning foam, a polyurethane foam, or a molded insert, by means of a three-dimensional printer or a cushioning or comfort insert.

19. The support element of claim 10 or 11, comprising at least one insert placed internally against the external cover (120) or the support assembly (122) such that the pad (114) includes the at least one insert.

20. A molding unit for manufacturing a support element for the human body as claimed in any one of claims 10 to 19, the support element comprising a pad (114), a support assembly (122), and, if applicable, a support base (150), wherein the molding unit (10) comprises: A first component (12) equipped with a punch element (18), and a second component (14) equipped with a cavity (16), wherein the cavity (16) has a molding surface (16b) having a configuration substantially corresponding to the configuration of the pad (114) or one of its upper surfaces (116) and is capable of receiving or filling a hardenable or curable material suitable for forming the pad (114), wherein the punch element (18) can be approached in use by the second component (14) or the cavity (16) or vice versa, thereby determining a closed operation configuration for the molding unit (10), characterized in that the punch element (18) has a holding member for the support component (122).

21. The molding unit of claim 20, wherein the cavity (16) has an opening (16a) and a peripheral edge (16c) defining the opening (16a), and when the molding unit (10) is in the closing operation configuration, the opening (16a) or the peripheral edge (16c) contacts the punch element (18) such that the cavity (16) is closed by the punch element (18).

22. The forming unit of claim 20 or 21, wherein the punch element (18) rises from the first component (12) or includes a forming region (18a) substantially corresponding to a lower surface (118) of the pad (114) and an outer contour (18b), wherein the outer contour (18b) abuts the peripheral edge (16c) of the cavity (16).

23. The molding unit of claim 20 or 21, comprising a vacuum member or a retaining plate (20) placed above the cavity (16) for holding in place, in use, an outer cover (120) adapted to cover at least a portion of the liner (114) or for retaining an excess portion (120a) of the outer cover (120), or wherein the retaining plate (20) has a substantially annular surface and an opening corresponding to the opening (16a) of the cavity (16).

24. The molding unit of claim 20, wherein the retaining member for the support assembly (122) includes a containment edge (22) or retaining member (30) adapted to accommodate or retain the support assembly (122) in use.

25. The molding unit of claim 20 or 21, wherein the molding surface (16b) of the cavity (16) is defined or delimited by a first delimiting edge (16e), the molding area (18a) of the punch element (18) is defined or delimited by a second delimiting edge (18d), or wherein in the closed operation configuration of the molding unit (10), the first delimiting edge (16e) and the second delimiting edge (18d) are adjacent to each other.

26. The forming unit of claim 20 or 21, wherein the containment edge (22) is inside the outer contour (18b) or the second delimiting edge (18d) of the punch element (18), or wherein the containment edge (22) faces an inner region (23) of the forming surface (18a), or wherein an annular region (24) of the forming surface (18a) is enclosed between the containment edge (22) and the second delimiting edge (18d).

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