Method and equipment for manufacturing an anatomical chamois for sportswear and corresponding chamois

Abstract

Method for manufacturing an anatomical chamois (10), comprising disposing a shaped padding (12, 112) in a positioning seating (22, 23) of a support plane (20), disposing an extendable shaped cover (11) over the padding (12, 112), wherein the cover (11) is subjected to traction and extended longitudinally, attaching the cover (11) on the support plane (21) in an extended condition, and joining together the padding (12, 112) and the extended cover (11). The invention also concerns equipment (20) for manufacturing the chamois (10, 110) and a corresponding chamois (10, 110).

Description

FIELD OF THE INVENTION

[0001] The present invention concerns a method and equipment for manufacturing an anatomical chamois for sportswear, in particular for cycling shorts, and a corresponding chamois.BACKGROUND OF THE INVENTION

[0002] As is known, some types of sportswear, such as cycling shorts in particular, are provided with a padded insert or protective chamois that, during use, is interposed between the saddle and the cyclist's body when the latter is resting on the saddle, so that the cyclist can rest comfortably on the saddle during sports activity.

[0003] The chamois is structured to be attached stably on the so-called "crotch zone" of the shorts corresponding to the area of the shorts able to be in contact with the zone of the cyclist's body intended to be disposed resting on the saddle, so as to cushion the rubbing / abrasion effect and at the same time cushion / absorb the mechanical stresses transmitted by the saddle to the user's body during sports activity.

[0004] In particular, protective chamois generally comprise a layer made of soft elastic material, also called cover, which can be made of fabric coupled to a layer of polyurethane foam that comes into contact with the cyclist's skin and occupies the entire extension surface of the chamois, and at least one padding, typically made using a soft elastic material, such as a polyurethane foam, having varying thicknesses, disposed in correspondence with the central portion of the cover, to protect the areas of the cyclist's body in contact with the bike's saddle.

[0005] The chamois is responsible for the comfort and therefore the performance of the cyclist during cycling, and it is therefore necessary to identify an optimal solution that manages to balance the requirements of comfort, anatomy, lightness as well as the production costs.

[0006] Chamois design is increasingly aimed at improving their performance, paying attention to even the smallest details that can negatively affect the cyclist's comfort.

[0007] In particular, there are known chamois having a three-dimensional spatial configuration, that is, having a curvature on orthogonal planes, so as to adapt to a user's anatomical conformation.

[0008] The different anatomical conformations of users, in particular of men compared to women, creates the need to obtain chamois having different spatial configurations, and in known solutions this often implies the need to have several different molds to obtain the desired outline.

[0009] Some known solutions provide to use special apparatuses having a male mold and a female mold, between which a sheet of thermoformable plastic material is disposed, having elastic characteristics after molding, with which one or more paddings are associated before subjecting the sheet to thermoforming so as to make it assume the three-dimensional spatial configuration corresponding to the molds and joining it to the paddings. This solution has the disadvantage that it requires pressing the sheet and the padding so that they take the desired shape, with a consequent decrease in the elastic and cushioning properties thereof, and operating costs due to the thermoforming machine.

[0010] Some solutions are also known for manufacturing chamois having a three-dimensional shape that provide to thermoform the cover so as to make it assume a three-dimensional configuration before associating it with one or more paddings by sewing or thermoforming, or to thermoform the paddings in advance before applying them to the cover. These solutions also require a compression of the padding during thermoforming, which can reduce its elastic properties and therefore reduce the cushioning performance of the final chamois, and are also expensive.

[0011] The current prior art solutions fail to optimally meet the aforementioned needs.

[0012] There is therefore the need to perfect a method and corresponding equipment that can overcome at least one of the disadvantages of the state of the art.

[0013] To do this, it is necessary to solve the technical problem of developing a method for manufacturing a chamois that allows to achieve a three-dimensional configuration thereof, without having to compress the padding in the shock-absorbing direction.

[0014] In particular, one purpose of the present invention is to develop a method and equipment suitable for manufacturing a chamois simply and rapidly, reducing both the costs and also the production times of known solutions.

[0015] A further purpose of the invention is to provide a method and equipment that can balance the requirements of comfort, anatomical design, and lightness of the chamois on the one hand, and production costs on the other.

[0016] Another purpose is to develop a method and equipment suitable for manufacturing both chamois suited to the male anatomical shape and also chamois suited to the female anatomical shape, without requiring substantial modifications or dedicated tools.

[0017] The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.SUMMARY OF THE INVENTION

[0018] The present invention is set forth and characterized in the independent claims. The dependent claims describe other characteristics of the present invention or variants to the main inventive idea.

[0019] In accordance with the above purposes and to solve the technical problem described above in a new and original way, also achieving considerable advantages compared to the state of the prior art, a method for manufacturing an anatomical chamois comprises: disposing a shaped padding in a positioning seating of a support plane; disposing an extendable shaped cover over the padding, wherein the cover is subjected to traction and extended longitudinally so as to lengthen; attaching the cover on the support plane in an extended condition; joining together the shaped padding and the cover while this is kept in an extended condition; releasing the cover from the support plane and removing the anatomical chamois.

[0020] When the cover is released, it tends to return to a non-extended condition and exerts a traction on the padding, consequently curving the latter, giving the chamois an anatomical three-dimensional configuration.

[0021] The new solution has the advantage of not requiring any compression of the padding whatsoever before it is associated with the cover, therefore it is not damaged in any way, and the resulting chamois offers better performance than those obtained with conventional processes.

[0022] In accordance with one aspect of the invention, the length of the cover in the extended condition is greater than a length of the cover in the non-extended condition by an amount comprised between 2% and 25%, preferably from 2.5% to 15%, even more preferably from 2.5% to 10%.

[0023] The greater the traction exerted on the cover, the greater the curvature created in the padding and therefore in the anatomical chamois obtained.

[0024] In accordance with one aspect of the invention, the padding is positioned on the support plane in a flat shape, and the cover is positioned and applied onto the padding in a flat shape.

[0025] In accordance with another aspect, the method provides to attach the cover on the support plane by inserting holes, provided on opposite borders of the cover in a longitudinal direction, on pins protruding from the support plane.

[0026] The pins are disposed outside the positioning seating, preferably in pairs on opposite sides in a longitudinal direction and symmetrical with respect to a central axis.

[0027] In accordance with another aspect of the invention, the method provides to use a support plane in which the at least one positioning seating is made through, apply a mask having at least one shaped window over the extended cover, with the window aligned with the positioning seating, and then join the cover and the padding by sewing, in correspondence with the shaped window.

[0028] According to one aspect of the invention, the outline of the window has a shape and sizes that substantially correspond to those of the padding.

[0029] In accordance with a variant, before disposing the cover over the padding, it can be provided to apply an adhesive layer on at least one of them, and the union can occur by gluing.

[0030] According to another aspect of the invention, the method provides to use a substantially pear-shaped single-piece padding with a rear portion having a greater width connected to a front portion having a smaller width. This allows to manufacture a chamois particularly suited to female anatomical shapes.

[0031] According to this embodiment, the method can provide to sew the cover and padding together peripherally and centrally, possibly creating a channel in correspondence with the rear part, in order to separate a right lateral portion and a left lateral portion from each other and allow for a reciprocal movement of one with respect to the other, thus better adapting to a female user's shape and movements.

[0032] According to another aspect of the invention, the method provides to use a padding comprising a first and a second element, and to position them facing each other in a symmetrical position with respect to a longitudinal axis on the work plane before laying the extended cover and joining it to both. This allows to manufacture a chamois particularly suited to the male anatomical shape. If sewing is used, it is preferably of the perimeter type and does not involve portions of the cover adjacent to the center plane between the two paddings, since in this position the sewing would be bothersome and uncomfortable for the user.

[0033] The present invention also concerns equipment for manufacturing a chamois comprising a support plane provided with at least one positioning seating for a padding, and attachment members able to attach a cover on the support plane over the padding in an extended condition, and to keep the cover in an extended condition while it is joined to the padding.

[0034] In accordance with one aspect of the invention, the attachment members comprise protruding pins, located in correspondence with opposite borders of the work plane and configured to be inserted in respective holes provided on the cover.

[0035] According to another aspect of the invention, the equipment comprises a mask provided with one or more shaped windows having shape and sizes substantially corresponding to those of the padding of the chamois to be manufactured.

[0036] The invention also concerns an anatomical chamois having an arched shape with respect to a longitudinal direction of the chamois, comprising a cover made of extendable elastic material and a padding, wherein the padding is joined to the cover, and the arched shape is determined by the traction exerted by the cover on the padding.

[0037] According to one aspect of the invention, the cover is made of a fabric coupled to a 1-10 mm layer of polyurethane foam.

[0038] The at least one padding can be made of polyurethane foam, with thicknesses ranging from 2 mm to 20 mm.

[0039] The padding can be a single layer or comprise two or more overlapping layers with equal or variable thicknesses, the sum of which falls within the range of 2 mm to 20 mm.

[0040] According to one aspect of the invention, the padding is continuous in terms of its plan extension. The padding can be made as a single piece or be composed of a plurality of padding parts placed side by side or overlapping.

[0041] According to another aspect of the invention, the padding comprises a first and a second part substantially symmetrical with respect to a longitudinal center plane, separate from each other and both joined to a same cover.DESCRIPTION OF THE DRAWINGS

[0042] These and other aspects, characteristics and advantages of the present invention will become apparent from the following description of some embodiments, given as a non-restrictive example with reference to the attached drawings wherein: fig. 1 is a three-dimensional view of a chamois according to a first embodiment of the present invention; figs. from 2 to 7 are schematic views illustrating operating steps of the method and corresponding equipment for manufacturing the chamois of fig. 1 according to the present invention; fig. 8 is a three-dimensional view of a chamois according to a second embodiment of the present invention; fig. 9 is a schematic exploded view of the equipment for manufacturing the chamois of fig. 8; fig. 10 is a schematic exploded view of the equipment for manufacturing a chamois according to a third embodiment of the invention; figs. 11A and 11B are schematic plan views of a step of the method for manufacturing an anatomical chamois in accordance with a third embodiment of the present invention.

[0043] We must clarify that the phraseology and terminology used in the present description, as well as the figures in the attached drawings also in relation as to how described, have the sole function of better illustrating and explaining the present invention, their purpose being to provide a non-limiting example of the invention itself, since the scope of protection is defined by the claims.

[0044] To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one embodiment can be conveniently combined or incorporated into other embodiments without further clarifications.DESCRIPTION OF SOME EMBODIMENTS OF THE PRESENT INVENTION

[0045] With reference to fig. 1, a chamois 10 is shown having a three-dimensional configuration, in particular a shape arched in the longitudinal direction of the axis X.

[0046] The chamois 10 comprises a layer made of soft elastic material, also called cover 11, which comes into contact with the cyclist's skin, and at least one padding 12, disposed in correspondence with the central portion of the cover 11, to protect the areas of the cyclist's body in contact with the bike's saddle.

[0047] The padding 12 and the cover 11 are joined together by sewing or gluing.

[0048] Sewing is usually preferred, as long as it is of the perimeter type, since this guarantees greater reciprocal stability between cover 11 and padding 12 even after a high number of washes of the garment.

[0049] The cover 11 occupies the entire extension surface of the chamois 10.

[0050] The cover 11 is made of a material extendable at least in the longitudinal direction X, for example a fabric coupled to a layer of polyurethane foam, wherein both the fabric and also the polyurethane foam are elastic and allow the cover 11 to extend. The polyurethane foam layer can have a thickness S1 of 1 mm - 10 mm.

[0051] The cover 11 can be configured to extend in the longitudinal direction by an amount ΔL equal to at least 2% more than the length L of the cover in the non-extended condition, preferably from 2% to 25%, from 2.5% to 15%, even more preferably from 2.5% to 10% or 5%-10%.

[0052] The at least one padding 12 can be made using soft elastic material, such as a polyurethane foam, and can have varying thicknesses. The padding 12 can have a thickness S2 varying between 2 mm and 20 mm.

[0053] In the chamois 10 according to the embodiment of fig. 1, the padding 12 is made in a single piece in plan extension and is substantially pear-shaped, that is, with a conformation similar to a bicycle saddle, with a rear portion 14 having a greater width connected to a front portion 15 having a smaller width.

[0054] This conformation of the padding 12 allows to obtain an anatomical chamois 10 particularly suited to the female anatomy.

[0055] In the example case, the cover 11 and the padding 12 are joined by a seam 13.

[0056] The seam 13 follows the shape of the perimeter of the padding 12 for most of its extension, possibly leaving only a rear segment free, defining a channel 16 between a right part 17 and a left part 18 of the rear portion 14.

[0057] The seam 13 can also have one or more segments of stitches in correspondence with an intermediate zone of the padding 12.

[0058] The shape and position of the seam 13 can however vary depending on requirements.

[0059] Figs. from 2 to 8 show the equipment 20 during subsequent steps of a method for manufacturing the chamois 10 of fig. 1.

[0060] The method according to the invention provides to prepare a shaped padding 12 and position it in a positioning seating 22 of a support plane 21 (fig. 2).

[0061] The positioning seating 22 can be made passing through the support plane 21, thus allowing for a precise and stable positioning of the padding 12 and at the same time allowing to sew the same to the cover11 by means of sewing machines 40 of a known type.

[0062] The positioning seating 22 can advantageously be mating in shape with the padding, in terms of both outline as well as size, so that the padding 12 can be positioned therein without undergoing any deformations. However, as will be described below, depending on the type of chamois 10 to be manufactured, the shape of the positioning seating 22 can also be different from that of the padding 12, or narrower.

[0063] The outlines of the cover 11 and / or the padding 12 can be obtained by die-cutting from a sheet respectively made with the material and the layering suitable for the specific component.

[0064] The method also provides to dispose an extendable shaped cover 11 over the padding 12 (fig. 3).

[0065] The cover 11 is subjected to traction so as to be extended longitudinally, that is, elongated, and attached in an extended condition on the support plane 21 (fig. 4).

[0066] In this regard, the support plane 21 can be provided with attachment members 24 able both to attach the cover 11 and also to keep it in an extended condition.

[0067] The attachment members can comprise protruding pins 25 located in correspondence with opposite sides 26, 27 of the support plane 21 with respect to the longitudinal direction X and configured to be inserted in respective holes 19 provided on the cover 11.

[0068] For example, two pairs of pins 25 can be provided, one on each side, preferably symmetrical with respect to a center plane M-M. It can also be provided that the support plane 21 comprises a plurality of seatings 28 able to receive a respective pin 25 so as to be able to modify the position of the pins 25 as a function of the type or size of chamois 10 to be manufactured.

[0069] Advantageously, a plurality of holes 19 can be provided so as to facilitate the attachment of the cover 11 according to the position of the pins 25.

[0070] In place of, or in addition to, the pins 25, clamps or hooks can be provided to be fastened to the cover 11, or adhesive or Velcro elements able to engage with the cover 11 so as to keep it elongated in an extended condition.

[0071] Fig. 3 shows the cover 11 positioned on the padding 12 in a non-extended condition, attached on one side 27 only and having a length L.

[0072] In fig. 4 the cover 11 is shown in an extended condition, attached on both sides 26, 27 and having a length L + ΔL, wherein ΔL is the amount of elongation, which can be comprised between 2% and 25%, preferably from 2.5% to 15%, even more preferably from 2.5% to 10% with respect to the length L. The quantity ΔL can vary as a function of the type of chamois 10 to be manufactured, the elasticity of the material of the cover 11, and / or the characteristics of the padding 12, for example shape, thickness, material.

[0073] The method also provides to join the padding 12 and the cover 11 together while the cover 11 is kept in an extended condition (figs. 5, 6).

[0074] According to some embodiments, the union between the padding 12 and the cover 11 occurs by sewing.

[0075] The equipment 20 can comprise a sewing mask 30 having at least one shaped window 32, 33, able to be positioned aligned with the positioning seating 22, 23.

[0076] The mask 30 can be advantageously connected to the support plane 21 by means of hinges 31 to facilitate the alignment of the components.

[0077] The mask 30 can be closed above the stretched cover 11 (fig. 5) and the support plane 21 can be translated in proximity to a traditional type sewing machine 40 so as to create the desired seam 13 (fig. 6).

[0078] The shape and position of the seam 13 can be defined on the basis of the characteristics of the chamois 10 and the user's comfort needs.

[0079] For example, in the case of a chamois 10 suited to the female anatomy and comprising a single-piece padding 12, the method can provide to make a seam 13 peripherally in correspondence with the front portion 15 and most of the rear portion 14, creating a channel 16 in correspondence with the rear portion to separate the right part 17 from the left part 18 (fig. 7).

[0080] According to possible variants, the union between padding 12 and cover 11 can occur by gluing. In this case, before positioning the cover 11 in an extended condition over the padding 12, an adhesive layer can be applied on one or both of either the cover 11 or the padding 12 at predefined points, lines or areas, so as to obtain a stable union between them.

[0081] It is also possible to provide to perform an at least partial gluing of the padding 12 to the cover 11, preferably alongside and not in total replacement of the seam 13.

[0082] At the end of the union step, the method provides to release the cover 11 from the support plane 21 and remove the anatomical chamois 10 thus obtained. The anatomical three-dimensional shape of the chamois 10 is achieved thanks to the withdrawal of the cover 11, which tends to return to the non-extended condition and exerts a traction on the padding 12 connected to it, curving it in the longitudinal direction 11. As can be seen in fig. 1, in the chamois 10 the cover 11 faces the concave side, while the padding 11 is located on the convex side.

[0083] Fig. 8 shows a second embodiment of a chamois 110 comprising a cover 11 and a padding 112 comprising a first 12A and a second portion 12B separated from each other and both joined to the same cover 11.

[0084] The method for manufacturing this chamois 110 differs from what previously described only in the fact that it requires disposing the two parts 12A, 12B in one or in a respective positioning seating 22, 23 of the support plane 21 before attaching the cover 11.

[0085] According to this example, the two parts 12A, 12B are shaped as approximately half a pear, and are substantially the same, but can also differ from each other: the specific geometry, generally dictated by comfort and / or size requirements, has no relevance for the purposes of the present invention.

[0086] Fig. 9 shows the support plane 21 with two positioning seatings 22, 23 respectively aligned with respective windows 32, 33 provided on the mask 30.

[0087] In this case, the method can provide to position the two parts 12A, 12B respectively facing in a symmetrical position with respect to the center plane M of the support plane 21, and join a single cover 11 in an extended condition to both parts 12A, 12B.

[0088] Also in this case, the union can occur by sewing and / or gluing.

[0089] In the example case, it can be provided that the seams 13 are made only perimetrically, leaving the zone in correspondence with the center plane M free, since in this position the seams would be bothersome and uncomfortable for the user.

[0090] In the embodiment of fig. 9, the parts 12A, 12B of the padding 112 have substantially the same outline as the positioning seatings 22, 23.

[0091] According to a variant described with reference to fig. 10, the outline of each part 12A, 12B is different from the outline of a respective positioning seating 22, 23, and the parts 12A, 12B are deformed manually so as to be inserted each into a respective positioning seating 22, 23 before being joined to the cover 11.

[0092] Figs. 11A, 11B show details of the steps of inserting the parts 12A, 12B of the paddings into the corresponding positioning seatings 22, 23.

[0093] It is clear that modifications and / or additions of parts may be made to the chamois 10, 110, to the method and equipment 20 for manufacturing the chamois as described heretofore, without thereby departing from the field and scope of the present invention, as defined by the claims.

[0094] It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art will be able to achieve other equivalent forms of chamois, method and equipment for manufacturing the chamois, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.

[0095] In the following claims, the sole purpose of the references in brackets is to facilitate their reading and they must not be considered as restrictive factors with regard to the field of protection defined by the claims.

Claims

1. Method for manufacturing an anatomical chamois (10) comprising: - disposing a shaped padding (12, 112) in a positioning seating (22, 23) of a support plane (20); - disposing an extendable shaped cover (11) over said padding (12, 112), wherein said cover (11) is subjected to traction and extended longitudinally; - attaching said cover (11) on the support plane (21) in an extended condition; - joining together said padding (12, 112) and said extended cover (11); - releasing said cover (11) from the support plane (21) and removing the anatomical chamois (10).

2. Method as in claim 1, characterized in that the length of said cover (11) in the extended condition is greater than the length (L) of the cover (11) in the non-extended condition by an amount (ΔL) comprised between 2% and 25%, preferably from 2.5% to 15%, even more preferably from 2.5% to 10%.

3. Method as in claim 1 or 2, characterized in that it provides to attach said cover (11) on the support plane (21) by inserting holes (19) provided on opposite borders of the cover (11) in a longitudinal direction on pins (25) protruding from the support plane (21).

4. Method as in any claim from 1 to 3, characterized in that it provides to use a support plane (21) in which the at least one positioning seating (22, 23) is made through, apply a mask (30) having at least one shaped window (32, 33) over the extended cover (11), with the shaped window (32, 33) aligned with the positioning seating (22, 23), and join said cover (11) and said padding (12) by sewing, in correspondence with said shaped window (32, 33).

5. Method as in any claim hereinbefore, characterized in that before disposing said cover (11) on said padding (12, 112), an adhesive layer is applied on defined lines or points of at least one of them, and the union occurs by gluing.

6. Method as in any claim hereinbefore, characterized in that it provides to use a substantially pear-shaped single-piece padding (12) with a rear portion (14) having a greater width connected to a front portion (15) having a smaller width.

7. Method as in any claim hereinbefore, characterized in that it provides to use a padding (112) comprising a first and a second part (12A, 12B) separated from each other, position them facing each other in a symmetrical position with respect to a center plane (M) of the support plane (21), and join a single cover (11) in an extended condition to both said parts (12A, 12B).

8. Method as in claim 7, characterized in that the outline of each of said parts (12A, 12B) is different from the outline of a respective positioning seating (22, 23), and said parts (12A, 12B) are manually deformed in order to be inserted each into a respective positioning seating (22, 23) before being joined to said cover (11).

9. Equipment (20) for manufacturing an anatomical chamois (10) comprising a support plane (21) provided with at least one positioning seating (22, 23) for a padding (11), and attachment members (24) able to attach a cover (11) on the support plane (21) keeping it in a condition extended in a longitudinal direction (X).

10. Equipment (20) as in claim 9, characterized in that said attachment members (24) comprise pins (25) protruding in correspondence with opposite sides (26, 27) of the support plane (21) with respect to the longitudinal direction (X) and configured to be inserted in respective holes (19) provided on the cover (11).

11. Anatomical chamois (10) having an arched shape with respect to a longitudinal direction (X) and comprising a cover (11) made of extendable elastic material and a padding (12, 112) joined to said cover (11), wherein said arched shape is determined by the traction exerted by said cover (11) on said padding (12).

12. Sportswear comprising a chamois (10) as in claim 11.

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