Method for manufacturing a bicycle saddle

Abstract

The present invention relates to a method for manufacturing a bicycle saddle provided with a central through passage (2) and with a shell (4) having a through hole (4'), a polyurethane layer (5) and a bushing (3). By means of this method it is possible to ensure that, unlike five prior art saddles, said central through passage (2) is completely devoid of edges present around the above-mentioned passage, with significant advantages from the aesthetic and functional point of view for the user.

Description

TECHNICAL FIELD

[0001] The present invention relates to a method for manufacturing a bicycle saddle according to the general part of the present application. The present invention also relates to a bicycle saddle obtained by the method set out in the present invention. BACKGROUND

[0002] In the field of bicycle saddles, those saddles having a central through passage at the intermediate part are increasingly popular. The shape of these saddles is particularly suitable for providing maximum comfort to the person using them for recreational, amateur and sports purposes, for more or less long periods of time. In fact, it is known that one of the problems encountered in using bicycle saddles is that the person riding the bicycle can feel uncomfortable for quite long periods of time, in some cases even up to several hours. Therefore, saddle manufacturers, in an attempt to overcome this drawback, have made saddles having a central passage and shaped in a particular way so as to place the ischial tuberosities of the user on a portion close to the passage, while the person's sexual organ, especially the male one, but also the female one, tends to be placed inside said passage.

[0003] Among the saddles of this type, those owned by the owner of the present application must be included, which have a large number of patents in this field, among which those described in the following European documents must be included: EP 1590229, EP 1778537, EP 1781528, EP 2029417, EP 2673183 and EP 3022110.

[0004] This saddle is provided with a central through passage and, in particular, has:

[0005] - a shell having a through hole at said central passage;

[0006] - a polyurethane layer (5) as a padding element;

[0007] - a bushing adapted to cover said polyurethane layer.

[0008] The most important prior art document is WO 2019 / 106449 A1 (relating to an international patent application, the owner of which is the same applicant of the present application), in which the following method is set out (the references in parentheses refer to the above document):

[0009] a method for manufacturing a bicycle saddle (page 1, lines 7 and 8), which provides a central passage (see Figure 5 : passage between pads P) and which has:

[0010] - a shell (S) having a through hole at the central passage of the saddle (see Figure 5 : hole between the two outer shells of the shell S);

[0011] - The polyurethane layer serving as the padding element (P) (see page 7, line 12: Pad P is made of PU);

[0012] - Bushing (C), which is adapted to cover the polyurethane layer (P) (see...) Figure 5 The method provides the following steps:

[0013] - Arrange the bushing (C) on the hollow surface of the mold (M20) (see...) Figure 4 );

[0014] - (via M23 conduit) A vacuum is created between the bushing (C) and the hollow surface to allow for perfect adhesion between the two (see...) Figure 4 );

[0015] - Pour polyurethane (5) into the hollow surface (8) previously covered by the bushing (3); - Position the housing (S) on the surface of the anti-mold (M22) (see page 8, lines 5 and 6);

[0016] -Bring the mold (M20) and the reverse mold (M22) closer together and close them (see page 8, line 6), then position the reverse mold (M22) (see...). Figure 5 At the hollow surface of the mold (M20);

[0017] - The expansion of the polyurethane (see page 8, line 6) completely fills the space between the bushing (C) and the housing (S) (see...) Figure 5 );

[0018] - Move the mold (M20) and the reverse mold (M22) apart (hint);

[0019] - Remove the assembly (hinted) of the housing (S), polyurethane (P), and bushing (C) of the mold (M20), wherein the bushing (C) has undergone the previous method steps to allow for the installation of the saddle passage (see...). Figure 5 The channel between the pads (P) will exist in the area once formed (comparison) Figure 2 and Figure 4 The bushing C in the middle has a cap-like structure (see Figure 1 and Figure 2 Before the completed bushing C is placed on the second mold M2, a cap-shaped structure is formed in the unfinished bushing C1 by means of the first mold M1, and therein occurs the process that will result in the cap-shaped structure (see...). Figure 3 The step of arranging the bushing C on the mold (M20) is noted, taking into account the arrangement of the cap-shaped structure on the protrusion (see...). Figure 2 and Figure 4: the cap-shaped structure formed in the mould M10 is positioned on the protrusion of the mould M20), in particular provided in said mould (M20), is adapted to engage with a recess (see Figure 5 : between the outer shells of the shell S.

[0020] Other prior art documents are cited below: US5356205A, EP1281607A1 and DE20213536U1.

[0021] This method is well known and has been implemented in a particularly reliable manner for several years, producing particularly satisfactory embodiments both from the production point of view and from the functional point of view in favour of the user.

[0022] However, it must be considered that the bush itself constitutes an element of flat shape; moreover, considering the particular method of application of the bush, with the methods of the prior art it is also possible to create a covering of the central through passage. It is clear that this part covering the passage must be removed. This necessarily involves cutting this excess and therefore creating an edge around said central passage which passes at the contact area between the polyurethane layer and the bush. This edge is very thin, but still perceptible to the touch. It must also be considered that a bicycle saddle of this type generally has a very high sales cost, which can reach several hundred euros, and the presence of this edge, even if only for aesthetic reasons, can annoy the user. Moreover, the user's tactile discovery of the presence of this edge is obviously unpleasant. Therefore, in principle, it would be desirable to ensure that the surface of the central passage is completely smooth in an object with such a high cost, but this is not possible with the methods of the prior art. SUMMARY

[0023] The main purpose of the present invention is precisely to implement a method for manufacturing a bicycle saddle provided with a central through passage, which has the steps described in detail above and which finally results in a bicycle saddle in which the edge of the central through passage is completely smooth, which allows the aforementioned drawbacks to be overcome.

[0024] Another purpose of the present invention is to ensure that this method is simple and does not require special techniques and means to be implemented.

[0025] Furthermore, another purpose of the present invention is to implement a method which has costs in terms of equipment and materials used to manufacture the saddle comparable to similar methods of the known type.

[0026] The present invention also proposes to manufacture a bicycle saddle provided with a central through passage which is completely free of the aforementioned edge at said passage.

[0027] This is achieved by a method according to the characterizing part of the present application. Further features of the method are present in the present application. The invention also relates to a saddle manufactured by means of this method. BRIEF DESCRIPTION OF DRAWINGS

[0028] These and other features of the present application will now be described in detail with reference to the following drawings, in which:

[0029] - Figure 1 and Figure 2 show a top view and a perspective view, respectively, of a saddle manufactured according to the method of the present invention;

[0030] - Figure 3 show a cross-sectional view of the saddle according to Figure 1 taken along the line III-III;

[0031] - Figure 4 show, in cross-sectional view, the mould and counter-mould used during the method to which the present invention relates, as well as other elements constituting the saddle, namely the bush and the shell, which will be other elements of the saddle to which the present invention relates;

[0032] - Figure 5 , 6 and 7 show, in cross-sectional view, the mould used in the method of the present invention in three different steps, in which the bush used to manufacture the saddle of the present invention is also shown;

[0033] - Figure 8 show, in cross-sectional view, the mould used in the method of the present invention in the step of placing the shell on the mould;

[0034] - Figure 9 , 10 and 11 show three different steps of the method of the present invention, in which the mould, the counter-mould, the shell, the bush and the polyurethane present in the saddle of the present invention are shown;

[0035] - Figure 12 show a cross-sectional view of the saddle obtained by the method of the present invention, in which the step of cutting the parts to be removed for the complete finishing of the saddle is shown schematically;

[0036] - Figure 13 show a perspective view of a saddle with central channel belonging to the state of the art;

[0037] - Figure 14 show a cross-sectional view of the above-mentioned saddle according to Figure 13 taken along the line XIV-XIV;

[0038] - Figure 15An overall perspective view is shown of an intermediate step in the method for manufacturing the saddle of the present invention for the production of a semi-finished bushing.

[0039] - Figure 16 Two components constituting the cap portion are shown, which will be used to complete the saddle mentioned in this invention;

[0040] - Figure 17 and 18 The overall perspective view and front view of the cap are shown respectively;

[0041] - Figure 19 An overall perspective view of the electrodes used in the method described in this invention is shown;

[0042] - Figure 20 An overall perspective view of the electrode is shown during a step in the open base portion of the folded cap-like structure;

[0043] - Figure 21 An overall perspective view showing how the electrode is applied to weld the cap to the bushing inside the saddle of the present invention;

[0044] - Figure 22 The figure shown is a cut-off line XXI-XXI from the graph. Figure 20 The sectional view shown;

[0045] - Figure 23 A perspective view of the assembly consisting of the bushing and cap already welded to it is shown;

[0046] - Figure 24 It shows according to Figure 23 A cross-sectional view of the group taken by lines XXIV-XXIV, showing the excess portions to be removed and formed during the method described in this invention;

[0047] - Figure 25 An overall perspective view of a bushing for manufacturing a saddle with a central channel, according to the prior art, is shown;

[0048] - Figures 26 to 34 Views are shown of various components involved in the manufacturing process of a saddle with a central channel, according to the prior art, which respectively correspond to... Figures 4 to 12 A view relative to the method described in this invention. Detailed Implementation

[0049] from Figure 13 and 14 As can be seen, the prior art bicycle saddle 101 with a central through passage 102 is basically composed of a through hole 120 in the area occupied by the central through passage 102. Figure 26) consists of a shell 104, a polyurethane layer 105 with cushioning function and a bushing 103 covering said layer. The bushing 103 is usually made of synthetic material, but it can also be made of material of animal origin, such as leather or fabric.

[0050] The shell 104 is usually made of plastic material, but it can also be made of metal and carbon, or in any case of a material capable of providing the saddle with sufficient strength and solidity.

[0051] Said saddle 101 is usually assembled by means of a method comprising the following steps: Figures 26-34 ) :

[0052] - placing the bushing 103 on the hollow surface 108 of the mould 106 ( Figure 27 ) ;

[0053] - creating a vacuum between said bushing 103 and said hollow surface 108 by means of suitable means, such as a vacuum pump 109 ( Figure 28 ), connecting them to said hollow surface 108 with a pipe 110 to allow the perfect adhesion between the two aforementioned. The vacuum, as understood by a person skilled in the art, means a pressure significantly lower than atmospheric pressure, but still sufficient to allow said perfect adhesion;

[0054] - pouring the polyurethane 105 into the hollow surface 108 previously covered by the bushing 103 ( Figure 29 ) ; - positioning the shell 104 on the surface of the counter-mould 107 ( Figure 30 ) ;

[0055] - bringing the mould 106 and the counter-mould 107 close to each other and closing them, and subsequently positioning the counter-mould 107 at the hollow surface 108 of the mould 106 ( Figure 31 ) ;

[0056] - expansion of the polyurethane 105, which completely fills the space between the bushing 103 and the shell 104 ( Figure 32 ) ; It is known that polyurethane is a very versatile polymer, and in order to be used in the present invention, it should be stored in a container in liquid form together with a propellant, which will also be in liquid form at that pressure, before pouring the mould 106 above the bushing 103. When the mixture leaves the mixing container under pressure, the propellant will become gaseous, creating bubbles, which will cause a significant expansion of the polyurethane.

[0057] Once the above steps have been performed, it is sufficient to remove the mould 106 from the counter-mould 107 to take out the substantially finished saddle ( Figure 33However, a central through-passage does not yet exist in this saddle because a portion of the bushing still occupies the area intended for the central through-passage 102 during this step. Therefore, it is necessary to cut this portion along the edge of the central through-passage 102. Figure 34 And it is precisely this cutting operation that inevitably results in the formation of a bead 200 along the edge where the bushing and polyurethane bond, which is still visible in existing saddles.

[0058] The bead 200 does not affect the technical performance of the saddle, but it is an aesthetic defect and feels uncomfortable to the touch, especially considering the fact, as mentioned above, that saddles with this central channel 102 are usually sold at a fairly high price and are of particularly high quality.

[0059] Furthermore, since the bead 200 is located in the central channel 102, it may irritate or cause pain in the sensitive area of ​​the user's perineum, which may be located in the channel 102 during use due to the construction of the saddle.

[0060] The steps for manufacturing the saddle according to the invention can also be performed while the mold 106 is heated to a temperature of about 50°C-60°C, schematically represented by a resistor 117 of a known type. Figure 32 This facilitates perfect adhesion between the bushing 103 and the hollow surface 108 of the mold 106.

[0061] In order to eliminate the bead, according to the present invention, it is necessary to use a device with a cap-shaped structure 14 ( Figure 23 The bushing 3, the cap-shaped structure 14 is positioned at the through channel 2 ( Figure 1 The area occupied by ) includes the cap-shaped structure 14 ( Figure 23 The bushing 3 is made through the semi-finished bushing 3' ( Figure 15 This is achieved by combining the two components, in which the hole 12 has been pre-formed in the central channel 2 to be placed. Figure 1 In the area at ) . Furthermore, mold 6 and reverse mold 7 ( Figures 5-11 They must also each have a protrusion 18 and a recess 28 suitable for engaging with each other. Specifically, the size and shape of the protrusion 18 and the recess 28 allow the protrusion 18 to engage within the recess 28, substantially conforming to the dimensions.

[0062] from Figures 5 to 12 As can be seen, the method according to the present invention includes the following steps:

[0063] - An assembly of bushings including a cap-shaped structure 14 is arranged on the hollow surface 8 of the mold 6, noting that the cap-shaped structure 14 is arranged on the protrusion 18. Figure 5 );

[0064] - by using a vacuum pump 9 connected to the hollow surface 8 of the mould 6, for example by means of a duct 10, a vacuum is created between the bush 3 and the hollow surface 8 to allow perfect adhesion between the two, and subsequently perfect adhesion of the cap structure 14 to the protrusion 18 Figure 6 ) ;

[0065] - pouring the polyurethane 5 into the hollow surface 8 previously covered by the bush 3 Figure 7 ) ;

[0066] - positioning the shell 4 on the surface of the counter-mould 7, paying attention to arranging the through hole 4' of the shell 4 at the recess 28 of the counter-mould 7 Figure 8 ) ;

[0067] - bringing the mould 6 and the counter-mould 7 close to each other and closing them, subsequently positioning the counter-mould 7 on the hollow surface 8 of the mould 6 Figure 9 ), and engaging the protrusion 18 covered by the cap structure 14 with the recess 28 of the counter-mould 7, so that the cap structure 14 covering the protrusion 18 extends inside the recess 28 of the counter-mould 7 through the through hole 4' of the shell 4 Figure 8 and 12 ). This means that the protrusion 18 is sized so that, when the mould is closed, the cap structure extends above the shell 4 Figure 5 ) ; - expansion of the polyurethane 5 until it completely fills the space between the bush 3 and the shell 4 Figure 10 ) ; - after the necessary curing / polymerization time of the polyurethane has elapsed, and after the combined shell 4, polyurethane 5 and bush 3 have been removed from the mould 6, the mould 6 and the counter-mould 7 are moved away from each other Figure 11 ) ;

[0068] - mechanically removing the portion 19 of the cap structure covering the protrusion 18 and protruding with respect to the edge of the hole 4' of the shell 4 Figure 12 ). It is also possible to provide for removing a transverse excess portion 30 of the portion of the bush 3 located at the interface between the mould and the counter-mould, which does not occupy the hollow surface 8 of the mould 6.

[0069] The prior art does not give any indication as to how to industrially manufacture said bush 3 provided with the cap structure 14.

[0070] Advantageously, according to the present application, it can be manufactured by means of a method comprising the following steps:

[0071] forming a hole 12 on the semi-finished bush 3' at the area present in the channel 2 of the saddle 1 once it has been formed Figure 15 ) ;

[0072] - Two elements 13' and 13" with a length substantially similar to that of hole 12 are welded together to form a cap-shaped structure 14. Figure 16 , 17 and 18);

[0073] - Along the edge of the area that will be folded onto the outer wall 16' of electrode 16 ( Figure 19 ) For components 13', 13" ( Figure 16 and 17 ) Perform micro-drilling 31;

[0074] Insert elements 13' and 13" into the electrode, fold a portion of the opening base of the cap-shaped structure 14, and place the aforementioned elements against the outer wall of the electrode 16. Figure 20 );

[0075] - The assembly of electrode 16 and cap structure 14 is arranged in the hole 12 present in the bushing (in Figure 15 On the edge (visible in the middle);

[0076] -Actuation electrode 16, which, by means of a high-frequency current, will allow localized melting, which will result in adhesion between the portion of the cap-shaped structure 14 in contact with the bushing and the same semi-finished bushing 3'. Figure 21 and 22 );

[0077] -Remove electrode 16 ( Figure 23 );

[0078] -The portion 15 of the cap-shaped structure 14 placed against the outer surface of the electrode 16 is cut off. Figure 24 The bonding process between the cap-shaped structure 14 and the semi-finished bushing 3' can also be performed by welding using a coating.

[0079] This method can be advantageously achieved by using a working surface 40 ( Figure 21 and 22 ) and locking surface 41 ( Figure 21 To perform this, a hole 12 is placed on the working surface 40. Figure 15 The semi-finished bushing 3' (visible in the middle) is fully stretched and held in a completely flat position, locking surface 41 ( Figure 21 ) in the hole 12 of the bushing (in Figure 15 Hole 41' is visible in the corresponding area (as seen in the middle). Figure 21 The electrode 16, in which the cap-shaped structure 14 has been applied, is inserted into the hole 41'. The locking surface 41 keeps the semi-finished bushing 3' stationary during the cap welding process, thereby preventing movement that could compromise the structural quality of the final assembly.

Claims

1. A method for manufacturing a bicycle saddle, said bicycle saddle providing a central through passage (2) and having: - a shell (4) having a through hole (4') at said central through passage (2) of said saddle (1); - a polyurethane layer (5) as a padding element; - a bushing (3) adapted to cover said polyurethane layer (5), said method providing the following steps: - arranging said bushing (3) on a hollow surface (8) of a mold (6); - creating a vacuum between said bushing (3) and said hollow surface (8) to allow perfect adhesion between the aforesaid surfaces; - pouring polyurethane (5) into said hollow surface (8) previously covered by said bushing (3); - positioning said shell (4) on a surface of a counter-mold (7); - approaching and closing said mold (6) and said counter-mold (7) to each other and subsequently positioning said counter-mold (7) at said hollow surface (8) of said mold (6); - expansion of said polyurethane (5) which completely fills the space between said bushing (3) and said shell (4); - moving said mold (6) and said counter-mold (7) away from each other; said bushing (3) being subjected to previous processing steps so as to present, at the area where said passage (2) of said saddle (1) will be once formed, a cap-like structure (14) and wherein the step of arranging said bushing (3) presenting said cap-like structure on said mold (6) occurs, noting that said cap-like structure (14) is arranged on a protrusion, in particular provided in said mold (6), adapted to engage with a recess (28) in particular provided in said counter-mold (7); said method being characterized in that, at the end of all the previous steps, the portion of said cap-like structure (14) covering said protrusion (18) and protruding above the edge of said through hole (4') of said shell (4) is mechanically removed and wherein said bushing (3) is made by the following steps: - forming a hole (12) on a semi-finished bushing (3') at the area where said passage (2) of said saddle (1) will be once formed; - welding a cap-like structure (14) to said semi-finished bushing (3') at said hole (12) so that the open edge of said cap-like structure (14) substantially coincides with the edge of the aforesaid hole (12). said cap-like structure (14) being obtained by means of previous steps of mutual welding of two elements (13', 13") whose length is substantially similar to the length of said hole (12). it provides: - inserting said cap-like structure (14) into a through hole present in an electrode (16), said through hole present in said electrode (16) being substantially similar in shape to said hole (12) present on said bushing (3); - inserting said elements (13', 13") inside said electrode and folding a portion of the open base of said cap-like structure (14) and placing the aforesaid elements against the external wall of said electrode (16); ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ - extracting the combination of the shell (4), the polyurethane (5) and the bushing (3) of the mold (6), wherein, ​ ​ ​ ​ ​ 2. The method of claim 1, wherein, ​ 3. The method of claim 2, wherein, ​ ​ ​ - arranging the assembly of the electrode (16) and the cap-shaped structure (14) on the edge of the hole (12) present in the semi-finished bushing (3'); - effecting welding to cause the adhesion by interpenetration between the portion of the cap-shaped structure (14) in contact with the semi-finished bushing (3') and the same bushing (3); - removing the electrode (16); - cutting the portion of the cap-shaped structure (14) placed against the external surface of the electrode (16) to facilitate the removal of the portion of the cap-shaped structure (14) placed against the external surface of the electrode (16).

4. The method of claim 3, wherein, high-frequency welding is effected by means of the electrode (16) to cause the adhesion by interpenetration between the portion of the cap-shaped structure (14) in contact with the semi-finished bushing (3') and the same bushing (3).

5. The method of claim 3, wherein, it provides for welding with cladding to cause the adhesion by interpenetration between the portion of the cap-shaped structure (14) in contact with the semi-finished bushing (3') and the same bushing (3).

6. The method of claim 2, 3, 4, or 5, wherein, The two elements (13', 13") suitable for forming the cap-shaped structure (14) are subjected to a micro-drilling step along the edge of the area intended to be folded on the external wall (16') of the electrode (16).

7. The method of claim 3, 4 or 5, wherein, The bushing (3') is positioned on a work surface (40) so as to be fully stretched and blocked by a locking surface (41) having a hole (41') in the area corresponding to the hole (12) of the semi-finished bushing (3').

8. Bicycle saddle, characterized in that, It is manufactured by the method according to one or more of the preceding claims. It is manufactured by the method according to one or more of the preceding claims.

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