SADDLE FOR A BICYCLE, ESPECIALLY MADE OF CARBON

Description

Field of invention

[0001] The invention relates to an ergonomically designed saddle made of carbon or another composite material for a bicycle. Background of the invention

[0002] Bicycle saddles are available in various materials.

[0003] Carbon fiber is known as a particularly high-quality material due to its exceptional lightness. Carbon fiber refers to a composite material made of carbon fibers and resin. Typically, such a saddle is hand-laid from carbon fiber mats impregnated with resin (CFRP). The material is then cured under heat and pressure in an autoclave.

[0004] While this manufacturing process is complex, it allows for a wide variety of shapes and, in particular, makes it possible to produce saddles weighing less than 80 g. However, a disadvantage of most carbon saddles available on the market is that, due to the material's high stiffness, they are often relatively uncomfortable compared to other technologies, such as a stretched leather shell. In particular, usually only the wings of the seat surface offer any significant give when the rider moves.

[0005] Under the trade name Gelu F.1, a carbon saddle with integrated suspension is known from practical experience. According to this prior art, the seat surface is supported by a curved leaf spring, which in turn transitions into the struts for attaching the saddle to a clamp.

[0006] This allows for improved comfort while maintaining a weight of less than 100g.

[0007] A disadvantage of this design is that, in the area where the curved leaf spring connects to the seat, there is a section where two layers of carbon fiber lie on top of each other. This results in more complex manufacturing and stiffens the area where the seat rests on the leaf spring. This limits design freedom and, furthermore, means that the rigid central section reduces the downward flex of the seat's wings.

[0008] However, the springy compression of the wings when pedaling is also an important ergonomic aspect for a bicycle saddle.

[0009] Bicycle saddles of this type are also known from documents US 2018 / 2970703 A1 and DE 10 2004 040679 B4. Another relevant bicycle saddle is known from document WO 2021 / 015979 A1. Object of the invention

[0010] In contrast, the invention is based on the objective of at least reducing the aforementioned disadvantages of the prior art. Summary of the invention

[0011] The object of the invention is already solved by a saddle for a bicycle according to claim 1.

[0012] Preferred embodiments and further developments of the invention can be found in the subject matter of the dependent claims, the description and the drawings.

[0013] The invention relates to a saddle for a bicycle. For the purposes of this invention, a bicycle is understood to be any pedal-driven vehicle, including those with an electric assist drive (e-bike, pedelec).

[0014] The saddle serves as a seat for the vehicle's user. The saddle includes a saddle nose, which transitions into a seat surface via a transition area.

[0015] It is therefore a saddle with a classic design, which tapers to a point at the front and in which the seat is located in the area of ​​the user's ischial tuberosities.

[0016] The saddle also includes rails for attachment to a seatpost head. The saddle is thus clamped to the seatpost head using these rails. The rails extend parallel to the direction of travel.

[0017] The rails can have any geometry known from the prior art; in particular, the rails can be designed as high-oval rails. The saddle nose, transition area, seat surface, and struts are made of plastic, in particular a fiber-reinforced composite material, preferably carbon.

[0018] As described at the beginning, carbon refers to a composite material consisting of carbon fibers (CFRP). Specifically, the carbon is made up of mats bonded together with a resin. The pre-impregnated mats used for this purpose are also known as prepregs.

[0019] To manufacture the saddle, the carbon layers are cut to size, arranged in suitable orientations (possibly with the aid of a mold), assembled into the saddle shape, and then hardened under pressure and heat. This can be done in an autoclave.

[0020] In an alternative embodiment, the saddle can also be designed as a die-cast plastic part. In particular, a fiber-reinforced plastic can be used. With such a plastic, the injection-moldable raw material comprises fibers that are injected into the mold together with the molten raw material. This can be, in particular, a glass- or carbon-fiber-reinforced polyacrylamide or polyetheretherketone.

[0021] According to the invention, all essential components of the saddle are therefore made of a plastic, in particular of the fiber composite material carbon, including in particular the struts.

[0022] According to one embodiment of the invention, the saddle can also be provided with padding. This can, in particular, be a foam pad and / or a saddle covering.

[0023] The padding may be additively manufactured padding, e.g. using 3D printing.

[0024] In particular, the padding can be designed as a three-dimensional grid structure.

[0025] The grid structure can support a surface structure that serves as a seat. This surface structure can be designed in a plate-like form and follows the ergonomic shape of the saddle. Furthermore, the surface structure can be provided with openings.

[0026] The padding, especially the grid structure, can span a central recess.

[0027] Furthermore, parts of the saddle, especially the seat, can be made of a composite material designed as a sandwich structure. This sandwich structure can include hollow chambers, such as honeycombs, and thus be designed as a lightweight structure.

[0028] According to the invention, the saddle nose and a rear end of the seat surface each transition to the struts via a curved leaf spring, in particular made of carbon.

[0029] In contrast to the prior art described at the beginning, in particular in the area of ​​the seat surface, not only is a curved leaf spring made of carbon inserted between the struts and the seat surface, but according to the invention the seat surface itself transitions seamlessly into the leaf spring, which then preferably transitions seamlessly into the struts.

[0030] This design ensures that the leaf spring is aligned in the direction of travel when used as intended.

[0031] It is specifically intended that the saddle has no steps or joints where two plate-shaped areas made of plastic are joined together.

[0032] Rather, preferably in each area of ​​the saddle, there is usually an uninterrupted layer of fibers, especially carbon fibers.

[0033] The design according to the invention allows the saddle to be made more aesthetically pleasing and lighter.

[0034] Furthermore, the seat surface, especially if it consists of two wings, can be made more elastic at the edges.

[0035] The curved leaf spring is preferably designed as a flat structure. A flat structure is understood to be a plate-like arrangement in which the surface area is significantly greater than the thickness of the flat structure. In particular, the flat structure has an area at least 10 times greater than its height.

[0036] The curved leaf spring preferably runs, at least in sections, perpendicular to the direction of travel and essentially in a straight line.

[0037] The leaf spring is therefore designed as a curved plate, in particular bent by about 180°, which is formed from essentially straight sections perpendicular to the direction of travel.

[0038] In a further development of the invention, the saddle includes a central recess which extends from the saddle nose to the seat area.

[0039] Preferably, the saddle is designed such that at least one central recess extends at least in the seating area between two wings, which thus form the seating area.

[0040] The two wings can converge at a rear end of the saddle, thus transitioning into a rear curved section, which is part of the leaf spring.

[0041] This eliminates the need for a connection between the leaf spring and the seat surface, allowing the seat surface itself to be part of a spring and enabling the wings to bend sideways, especially when forces are applied at the edge.

[0042] In one embodiment of the invention, the saddle nose comprises a central indentation in the front area. From this indentation, a recess can then extend towards the rear of the seat surface.

[0043] The struts can transition into a planar section at the front and / or rear, with the sections of the two struts thus formed merging into a single planar section.

[0044] It is therefore specifically intended that the two struts each merge seamlessly into a single curved leaf spring.

[0045] On the top of the saddle, the curved leaf spring sections formed in this way can then spread apart, creating a central recess.

[0046] The saddle is designed as an elliptical spring, with the elliptical spring divided into two halves on its upper side. This division into two halves allows the wings to bend around an axis that is essentially aligned with the direction of travel.

[0047] On the underside, the saddle is indeed divided into two sections by the two spaced struts. However, these are held together by the clamp.

[0048] The total cross-sectional area of ​​the saddle preferably varies by a maximum of 70% around a mean value. The stays are not included in this calculation and can be made stiffer, since they do not contribute to the spring effect, particularly in the clamping area.

[0049] The saddle can have a maximum width b of 150 to 170 mm and / or a maximum length 1 of 250 to 290 mm.

[0050] The central recess preferably has a maximum width b of 30 to 40 mm.

[0051] The saddle preferably has a total height hg of 50 to 70 mm.

[0052] In a preferred embodiment of the invention, the central recess extends beyond the end of the saddle nose and / or the end of the seat surface.

[0053] The recess is therefore wider in a middle area and then tapers off as the halves come together.

[0054] In a further development of the invention, the recess in the rear half of the seat surface widens and comes together again at the end of the seat surface.

[0055] The recess widens again in a rear area where the seat surface ends.

[0056] This has the advantage that the saddle is then divided in the rear area in such a way that the two divided opposing flat areas of the leaf spring still noticeably compress during torsion, thus enabling movement of the two wings.

[0057] Preferably, the curved leaf spring has a width b S of 25 to 35 mm at the tip of the saddle and / or a width b E of 35 to 45 mm at the end of the saddle.

[0058] The saddle according to the invention can weigh less than 100 g, preferably less than 90 g. In particular, the saddle weighs between 70 g and 90 g.

[0059] According to another aspect, the invention relates to a saddle according to one or more of the features described above.

[0060] The saddle includes a saddle nose that transitions into a seat surface via a transition area, as well as two struts for attachment to a seat post head.

[0061] The saddle nose, transition area, seat surface and struts are, as described above, made of plastic, in particular a fiber composite material, in particular carbon.

[0062] According to this aspect, the disclosure is defined by the fact that the saddle is designed as an elliptical spring, wherein the saddle nose, transition area and seat surface form an upper part of the elliptical spring and struts and surface areas adjacent to the struts form a lower part of the elliptical spring.

[0063] Viewed from the side, the saddle is designed as a preferably continuous spring, consisting of an upper and a lower half.

[0064] The two halves of the elliptical spring are connected at the front and rear ends. Preferably via a seamless transition, meaning there is no area where at least one layer of fibers, especially carbon fibers, is not continuous.

[0065] In a further development of the invention, at least one layer of an elastic material is arranged in the seat surfaces. In particular, at least one layer of an elastic material, especially an elastomer, can be arranged between the carbon fiber layers. For this purpose, an uncrosslinked rubber can be used in particular, which cures together with the carbon prepregs to form an elastic layer.

[0066] The layer of elastic material can be positioned particularly in the outer half of the wings. This allows for a softer saddle at the edges of the wings. Brief description of the drawings

[0067] The subject matter of the invention will below be described with reference to the drawings. Figs. 1 to 12 will be explained in more detail. Fig. 1 is a perspective view of an embodiment of a saddle according to the invention. Fig. 2is a perspective view showing the underside. Fig. 3 This is a top view of the saddle. Fig. 4 is a sectional view along line AA according to Fig. 3 . Fig. 5 This is a top view of the underside of the saddle. Fig. 6 This is a side view. Fig. 7 is a central longitudinal section of the drawings Figs. 1 to 6 depicted saddle. Fig. 8 In contrast, the figure shows a longitudinal section of an alternative embodiment of a saddle according to the invention. Fig. 9 is a perspective view and Fig. 10 is a cross-sectional view of another embodiment of a saddle in which the rear curved leaf spring only splits in the area of ​​the seat surface. Fig. 11 - Fig. 12 show a saddle which is equipped with padding that was produced using an additive manufacturing process. Fig. 11 This is a top view of the saddle. Fig. 12shows the saddle base of the saddle. Detailed description of the drawings

[0068] Fig. 1 Figure 1 shows a perspective view of an embodiment of a saddle according to the invention.

[0069] The saddle 1 is monolithically formed from carbon. In another embodiment, not shown here, the saddle 1 can be provided with a covering and / or padding.

[0070] The saddle 1 includes a pointed nose 2, which transitions via a transition area 3 into the seat 4.

[0071] The seat 4 is formed by two wings 5a, 5b separated in the middle.

[0072] In this embodiment, a central recess 6 extends from the saddle nose 2 to the rear end of the saddle 1.

[0073] At the beginning of the nose 2, the saddle 1 is not yet divided into two halves. In this embodiment, there is a recess 7 at this point, beyond the end of which the upper surface of the saddle splits into two halves.

[0074] In terms of shape, the top of the saddle is bent by about 180° at both ends, namely at the front and rear ends, so that a curved leaf spring 9a, 9b is formed in each case.

[0075] The curved leaf spring 9a, 9b then transitions into the struts 8a, 8b. The struts 8a, 8b serve to clamp the saddle 1 to the head of a seat post and can, in particular, be designed as a high oval.

[0076] Due to its overall design, the saddle 1 has the shape of an uninterrupted elliptical spring, which is divided into two halves due to the central recess on the top 6.

[0077] Due to the central cutout 6, the wings 5a, 5b can also deflect along an axis pointing in the direction of travel due to torsion under load. This improves the ergonomics of the saddle 1 during the rider's movements.

[0078] The wings 5a, 5b can include a layer of elastic material between the carbon fiber layers in an outer area. This area is marked by line 21 and is therefore softer. The boundary between the softer area and the subsequent harder area without the layer of elastic material preferably runs in an arc from front to back across the seat surface.

[0079] Fig. 2 is another perspective view of saddle 1, in which the underside of the saddle is now shown in particular.

[0080] In this embodiment of the invention, the curved leaf spring 9a has a first bend 10a and a second bend 11a at the nose of the saddle 1, from where the underside 12a initially runs essentially horizontally and then splits into the two halves 13a and 13b, which transition seamlessly into the struts 8a, 8b.

[0081] Instead of the creases (not shown), a completely rounded, i.e. U-shaped, design can also be chosen.

[0082] On the upper side of the saddle, the wings 5a, 5b meet again at the rear end of the saddle and form the rear curved leaf spring 9b.

[0083] The rear leaf spring 9b initially runs diagonally backwards (in relation to the intended installation) and changes direction at the bend 10b, in order to then run diagonally downwards on the underside 12b.

[0084] On the underside 12b, the rear curved leaf spring 9b also forks and transitions into the struts 8a, 8b.

[0085] The bends 10a, 11a, 10b, especially bend 10b, allow for the targeted provision of zones with higher mechanical stress under load, thereby increasing the spring effect in these areas.

[0086] According to another embodiment of the invention (not shown), the bend 10b can also be omitted, so that the saddle 1 is also U- or C-shaped at the rear end in the side view.

[0087] Fig. 3 This is a top view of the upper side of the saddle.

[0088] The saddle has a (maximum) width b, which in this embodiment lies between 130 and 170 mm.

[0089] At the tip, the curved leaf spring 9a has a width b S of 25 to 35 mm and at the rear end, the curved leaf spring 9b has a width b E of 35 to 45 mm.

[0090] The central recess 6, which divides the saddle 1 into two halves on the upper side, is so wide that torsion springs 14a, 14b are formed from the transition area 3 towards the nose 2.

[0091] This allows a spring constant DR to be assigned to the outer edge of the respective wing 5a, 5b when loaded vertically from above.

[0092] The spring constant DR is preferably between 1 and 1,000 N / mm, preferably between 5 and 50 N / mm.

[0093] Preferably, the spring constant remains within this range under a vertical load from above up to a deflection of at least 3 mm.

[0094] It is understood that the spring constant at the point shown here at the edge is primarily provided by a torsion of the wings 5a, 5b.

[0095] Therefore, the central recess behind the wings 5a, 5b, i.e., behind the area where the driver's seat humps are located, widens again. At point 15, the width of the recess 6 is preferably at least 1.5 times the width of the preceding constriction 16.

[0096] Despite the flat design, the underlying halves 11b of the rear curved leaf springs 9 can be subjected to torsion.

[0097] Fig. 4 is a sectional view along line AA according to Fig. 3 .

[0098] It can be seen that the saddle 1 is thinner in the area of ​​the wings 5a, 5b than in the underlying area of ​​the underside 12b of the curved leaf spring 9b.

[0099] This compensates for the larger surface area on the top side, and all areas contribute together to the spring effect.

[0100] Fig. 5 This is a top view of the underside of the saddle 1. It can be seen again here that the curved leaf springs 9a, 9b transition seamlessly, in particular monolithically, into the rails 8a, 8b.

[0101] The distance between the rails 8a, 8b can roughly correspond to the size of the central recess 6.

[0102] Fig. 6 This is a side view.

[0103] The spring action of the clamped saddle can be characterized by the three spring constants DN, DM and DS.

[0104] At the point spaced 20 mm from the saddle tip, the spring constant DN is preferably between 10 and 1,000 N / mm.

[0105] At point DS, which is spaced 20 mm apart by a distance a2, the spring constant is between 10 and 5,000 N / mm.

[0106] In the center, the saddle has a spring constant DM of 10 to 5,000 N / mm, where this refers to the spring constant under load in the vertical direction only.

[0107] Since the saddle top is divided into two parts in this area, the spring constant DM can be determined by not applying a point load during measurement, but by measuring the compression at the marked point in the middle using a horizontally arranged rod oriented perpendicular to the direction of travel.

[0108] Furthermore, this illustration shows that on the underside, in the area of ​​the saddle nose 2, the saddle transitions into the rails 8a, 8b via a curved section 17. This reduces the tension present in the rails 8a, 8b during suspension compression.

[0109] Fig. 7 is a central longitudinal section of the saddle 1.

[0110] The cross-sectional view shows that a single undivided curved leaf spring 9a, 9b is located in each of the two edge areas.

[0111] The leaf spring 9a and 9b then splits on the underside 12b into the struts 8b (and 8a).

[0112] On the upper side, the curved leaf feather 9a, 9b splits into the wings.

[0113] The in Fig. 7 The saddle shown is designed such that the struts 8a, 8b are essentially aligned with the seat surface.

[0114] Accordingly, the struts 8a and 8b are approximately horizontal when used as intended. However, it goes without saying that the saddle's tilt can be adjusted via the clamp according to the rider's preference.

[0115] Fig. 8 is an alternative embodiment.

[0116] In this embodiment, the slopes run obliquely to the seat surface of the saddle. In particular, the struts 8a, 8b can assume an angle of 5 to 20° to the horizontal.

[0117] In contrast to the embodiment according to Fig. 7 The curved leaf spring 9b also includes a curved area 18 which supports the compression.

[0118] Fig. 9 Figure 1 is a perspective view of a saddle 1 according to a further embodiment. In contrast to the embodiments shown previously, the rear curved leaf spring 9b only splits into two longitudinally divided areas in the region of the seat surface 4, which form the wings 5a and 5b.

[0119] In the still undivided area there is a depression 19, which serves as a relief zone for the buttocks of the traveler.

[0120] The wings 5a, 5b deflect less strongly compared to the previously described embodiments when subjected to lateral torsion.

[0121] Otherwise, this saddle can be designed exactly like other versions.

[0122] As shown in the cross-sectional view according to Fig. 10 The saddle (in all embodiments) can be provided with a stiffening rib 20.

[0123] The stiffening web 20 can extend in particular around the central recess 6 located between the wings 5a, 5b.

[0124] Referring to Fig. 11 - Fig. 12 This will be explained using an exemplary embodiment in which the saddle 1 is provided with padding 30.

[0125] As in Fig. 11 As shown, the saddle 1 is formed from a saddle base 1a and padding 30.

[0126] The saddle base 1a comprises, as in Fig 12 As shown, a central recess 6. In particular, the saddle base 1a can be compared to the one shown in the drawings. Fig. 1-10 The illustrated embodiments of a saddle correspond, wherein the saddle is additionally provided with the padding 30, so that the saddle in the preceding drawings can also be regarded as a saddle base.

[0127] As in Fig. 11 As shown, the padding 30 extends from the saddle nose 2 to the rear area of ​​the seat 4.

[0128] The surface of the padding 30 is formed, at least in sections, as a surface structure 31. The surface is therefore smooth in the area of ​​the surface structure 31 and forms a skin, which, however, follows the ergonomic shape of the saddle 1. The surface structure 31 can thus be formed as a skin that sits on top of the underlying grid structure 33.

[0129] In this embodiment, the surface structure 31 extends over the seat surface 4 and the saddle nose, while the grid structure 33 is exposed in a central area.

[0130] In this embodiment example, the surface structure 31 is provided with openings 32. The stiffness of the padding 30 can be determined by the size and number of the openings 32.

[0131] In this embodiment, the proportion of openings 32 is greater in the area of ​​the saddle nose 2 than in the area of ​​the seat surface 4.

[0132] The openings 32 serve not only to influence the mechanical properties but also to improve the ventilation of the saddle 1.

[0133] The padding 30 is manufactured using an additive process, for example, by 3D printing. It can then be attached to the saddle base, e.g., by gluing or melting.

[0134] In another embodiment, the padding can also be printed directly onto the saddle base 1a.

[0135] The padding 30 comprises a grid structure 33. In such a grid structure, struts are provided which, in the form of a three-dimensional grid, provide a three-dimensional, elastic structure.

[0136] The elasticity of the cushion 30 can be optimized to meet ergonomic needs by adjusting the type and density of the structure.

[0137] The invention made it possible to provide a very lightweight carbon saddle whose ergonomic properties are significantly improved compared to known carbon saddles. Reference symbol list

[0138] 1 Saddle 1a Saddle base 2 Nose 3 Transition area 4 Seat 5a, 5b Wing 6 Central cutout 7 Indentation 8a, 8b Struts / Rails 9a, 9b Curved leaf spring 10a, 10b Bend 11a Bend 11b Half 12a Underside 12b Underside 13a, 13b Half 14a, 14b Torsion spring 15 Point of maximum width of the cutout on the seat 16 Constriction 17 Curved area 18 Curved area 19 Indentation 20 Stiffening rib 21 Line 30 Padding 31 Surface structure 32 Opening 33 Grid structure

Claims

1. A saddle (1) for a bicycle, the saddle (1) comprising a saddle nose (2) that transitions into a seating surface (4) via a transition region (3), and comprising two rails (8a, 8b) for attachment to a saddle seatpost top; the saddle nose (2), transition region (3), seating surface (4) and rails (Sa, 8b) being made of plastics material, in particular carbon; wherein the saddle nose (2) and a rear end of the seating surface (4) each transition to the rails (8a, 8b) via a curved leaf spring (9a, 9b); characterised in that the curved leaf springs (9a, 9b) transition seamlessly from the rails (8a, 8b) into the seating surface (4) and the saddle nose (2), respectively.

2. The saddle (1) according to the preceding claim, characterised in that each of the curved leaf springs (9a, 9b) is in the form of a planar structure.

3. The saddle (1) according to any one of the preceding claims, characterised in that the curved leaf spring (9a, 9b) extends, at least in sections, substantially straight perpendicular to the direction of travel.

4. The saddle (1) according to any one of the preceding claims, characterised in that the saddle (1) has a central recess (6) which extends from the saddle nose (2) to the seating surface (4).

5. The saddle (1) according to any one of the preceding claims, characterised in that the seating surface (4) is defined by two wings centrally separated from each other.

6. The saddle (1) according to any one of the preceding claims, characterised in that the saddle nose (2) has, in its front portion, a central indentation (19).

7. The saddle (1) according to any one of the preceding claims, characterised in that the rails (8a, 8b) each transition into a planar section at their front and / or rear ends, the so defined sections of the two rails (8a, 8b) merging to form a single planar section.

8. The saddle (1) according to any one of the preceding claims, characterised in that the saddle (1) is covered with a padding (30); and / or that the total cross-sectional area of the saddle (1) with the exception of the rails (8a, 8b) varies by not more than 70 %, preferably not more than 40 %, around a mean value; and / or that the saddle (1) has a maximum width b of 150 to 170 mm and / or a maximum length 1 of 250 to 290 mm; and / or that the central recess (6) has a maximum width of 30 to 40 mm; and / or that the saddle (1) has a height hg of 50 to 70 mm; and / or that the central recess terminates before the end of the saddle nose (2) and / or the end of the seating surface (4) by that fact that the halves defined by the recess (6) are converging; and / or that the central recess (6) diverges in a rear half of the seating surface (4) and converges again at the rear end of the seating surface (4); and / or that the curved leaf spring (9a, 9b) has a width bS of 25 to 35 mm at the tip of the saddle (1) and / or a width bE of 35 to 45 mm at the end of the saddle (1); and / or that the saddle (1) has a weight between 70 g and 90 g.

9. The saddle (1) according to any one of the preceding claims, characterised in that the saddle (1) comprises a padding (30) which is produced by an additive manufacturing process.

10. The saddle (1) according to the preceding claim, characterised in that the padding (30) is formed as a three-dimensional grid structure (33).

11. The saddle (1) according to the preceding claim, characterised in that the grid structure (33) supports a planar structure (31), in particular a planar structure (31) having openings.

12. The saddle (1) according to any one of the three preceding claims, characterised in that the padding (30) spans a central recess.

13. The saddle (1) according to any one of the preceding claims, characterised in that at least one layer of an elastic material is arranged in the seating surfaces (4).