Method for manufacturing a support element for the human body, such as a vehicle saddle, the support element thus obtained, and associated molding unit - Patents.com

Abstract

The invention relates to a method for manufacturing a support element for the human body, to a support element for the human body obtainable by the method described above, and to a moulding unit for manufacturing a support element for the human body. (Figure 5 with summary)

Description

[Technical field]

[0001] The present invention relates to a method for realizing a support element for the human body, to the support element thus obtained, and to the associated shaped unit. [Background technology]

[0002] In the field of support elements for the human body, such as saddles for vehicles, for example bicycles, it is known to manufacture pads, whether or not equipped with an external cover that envelops it on its external or visible surface, which, once manufactured, are bound, for example by gluing, to the upper surface of a plastic support base, for example called a "shell" or "felt" in bicycles. According to this particular example, a "fork" can be bound on its lower surface to the plastic base in order to connect the saddle to the seat post of the bicycle frame.

[0003] However, it often happens that the pad, once produced, is extracted from the mould and is only later joined to the plastic base, for example by gluing, in which case it may be difficult to connect these two elements, since the pad may lose its dimensional stability and therefore may be difficult to join to the plastic base, which in turn has a well-defined shape and size.

[0004] At the same time, if an external cover is present, it may be difficult to carry out the necessary trimming steps, since the pad is made of a soft material and trimming an element such as the external cover, which does not have a support point, it may not be easy to find that it is necessary to work against a soft support (precisely the pad) and the trimming tool may not find a sufficiently rigid and / or adapted guide to perform quality work.

[0005] There are also methods that make it possible to obtain bicycle saddles that do not require adhesion between the padding and the support base. Patent document 1, in the name of the same applicant, describes a method for manufacturing a saddle in which an external cover is placed over a cavity in the female part of a mould, which is adapted by the use of vacuum means. A material is injected into the cavity in which the external cover is placed, forming the padding of the saddle itself, and the mould is then closed by the male part. Due to the properties of the respective materials, when the male part of the mould is moulded to accommodate said felt, the padding also adheres to the external cover and to the felt or to the support base.

[0006] In this case, the upper surface of the felt therefore determines the lower surface of the pad, in the sense that these two surfaces are in contact with each other. At the next opening of the mould, the finished saddle is extracted, followed by the trimming of the excess of the outer cover.

[0007] It is therefore necessary to provide a method and a support element that can compensate for the above-mentioned drawbacks and thus make it possible to obtain a high-quality product, even if the pad and the support base are not bonded to each other immediately or in the same mold.

[0008] Additionally, there is a need for a mold that allows for obtaining the above-mentioned advantages of the method presented herein. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Italian Patent No. 1207441 Summary of the Invention

[0010] SUMMARY OF THE PRESENT EMBODIMENT An object of the present invention is to overcome the drawbacks of the prior art.

[0011] It is a further object of the present invention to provide a method for manufacturing a support element for the human body which is practical and possibly automatable.

[0012] Another object of the invention is to provide a method for speeding up and making more accurate the steps for obtaining a support element for the human body.

[0013] A further object of the present invention is to provide a method which is relatively inexpensive.

[0014] According to one aspect of the invention, a method for manufacturing a support element as claimed in claim 1 is provided. Another object of the present invention is to provide a support element for the human body that is easily assembled. It is a further object of the present invention to provide a support element for a precise human body. According to an aspect of the present invention there is provided a support element for the human body as claimed in claim 10. A further object of the invention is to provide a moulding unit which allows easy and rapid production of a support element as described above. Another object of the invention is to provide a moulding unit which ensures that the support elements are obtained with higher quality and efficiency than with conventional moulds. According to one aspect of the present invention there is provided a moulding unit as claimed in claim 20. The dependent claims refer to preferred and advantageous embodiments of the invention.

[0015] Other characteristics and advantages of the present invention will become more apparent from the disclosure of examples of embodiments of the invention, illustrated by way of example in the accompanying drawings, in which identical parts or components are distinguished by the same reference numerals, in which: [Brief description of the drawings]

[0016] [Figure 1] FIG. 2 is a partial perspective view from above of a mold unit according to the invention in an open position; [Diagram 2] 2 shows a partial top view of a rear detail of a first component of the forming unit of FIG. 1; [Diagram 3]2 shows a partial top view of a first component of the forming unit of FIG. 1, to which a structural or support component according to the invention is applied; FIG. [Figure 4] 1 shows a perspective view from below of a pad of a support element according to the invention; [Diagram 5] 2 shows a partial longitudinal cross-sectional view of a fully assembled support element according to the invention; [Figure 6] 1 shows a top perspective view of a structural or support component according to the present invention; [Figure 7] 2 is a view from below of a support element pad according to the invention in a non-final stage of its realization; [Figure 8] 2 shows a partial side view of a support element according to the invention in the final stage of its realization; [Figure 9] 3 illustrates automated steps of the method according to the present invention. [Figure 10] 3 illustrates automated steps of the method according to the present invention. [Figure 11] 1 shows a cross-sectional view of a forming unit according to the invention in a closed position, the cross-section being taken along a cross section of the support element thereby obtained. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] The present invention relates to a method for manufacturing a support element for the human body, to the support element for the human body thus obtained, for example a vehicle saddle such as a bicycle or motorcycle saddle, or a backrest or a seat or an armrest for an anatomical chair, or a similar support element, or parts thereof, and associated shaped units.

[0018] FIG. 1 shows a moulding unit 10 according to the invention for producing a support element for the human body. More specifically, the unit 10 comprises a first component 12 and a second component 14. The first component 12 is a punch component of the forming unit 10 and the second component 14 is a die component of the forming unit 10.

[0019] The first component 12 can be coupled to the second component 14. In particular, when the first component 12 abuts the second component 14, the molding unit 10 is in a closed operating configuration, whereas when the first component 12 and the second component 14 move away from each other, the molding unit is in an open operating configuration.

[0020] Thus, a means is provided for accessing and removing the first component 12 relative to the second component 14 (not shown), which can move the molding unit 10 from an open to a closed operating configuration and vice versa, including all intermediate operating positions between open and closed. Such access-removal means, as is commonly known in the industry, may comprise electric, pneumatic or other actuators designed to reciprocate and / or move the first component 12 and the second component 14 along a linear or angular or rotational direction, meaning that the first component 12 can be moved along a predetermined linear direction relative to the second component 14, or moved at an angle relative to the second component 14, rotated in an access-close mode, or moved in a fully open mode, or vice versa.

[0021] In Figure 1, the second component 14 is at a lower position than the first component 12. However, different positions can be envisaged. In this disclosure, the term "upper" refers to an element that is positioned above or above, or faces upward, when in use, while the term "lower" refers to an element that is positioned below or below, or faces downward or toward the ground, when in use. The term "longitudinal" refers to the direction extending along the longest portion of an element, and the term "lateral" refers to the direction extending perpendicular to the longest portion of an element or from side to side thereof. "Vertical" means a direction or plane that, when in use, faces downwards and "horizontal" means a direction or plane that, when in use, is parallel to the ground.

[0022] The second component 14 comprises and / or defines a cavity 16 suitable for use to contain and / or fill with a material adapted to form the pad 114 of the support element 100. This material can be inserted, poured or injected into the cavity 16 and allowed to foam and / or cure and / or polymerize and / or solidify within the cavity 16. Thus, the material is a hardenable and / or polymerizable and / or solidifiable material.

[0023] The cavity 16 is recessed relative to the second component 14 and is substantially negatively molded relative to the pad 114 . The cavity 16, in at least one first configuration or version of the invention, is open at the top, such that the cavity 16 has an opening 16a. The cavity 16 is formed by a molding surface 16b within the recess and a periphery 16c that defines an opening 16a.

[0024] The first component 12 includes a punch element 18. The punch element 18 is shaped to abut the cavity 16 and / or its periphery 16c to determine closure of the forming unit 10 and / or the cavity 16.

[0025] Punch element 18 rises from first component 12. It includes a forming region 18a and an outer contour 18b.

[0026] The outer contour 18b corresponds to and / or is adapted to contact and / or abut the perimeter 16c of the second component 14. The outer contour 18b of the punch element 18 has an abutment element 18c, shaped for example as a peg or cylinder, which can be received in a suitable and corresponding seat 16d, arranged for example on the periphery 16c of the cavity 16. The positions of the abutment element 18c and the suitable seat 16d are coincident so that when the first component 12 abuts against the second component 14, the abutment element 18c can be received in the seat 16d. However, the position of the abutment element 18c and the position of the relative seat 16d can be reversed without departing from the scope of the invention.

[0027] The molding surface 16b of the cavity 16 is defined by a first defining edge 16e. Similarly, the forming region 18a of the punch element 18 is defined by a second defining edge 18d. In the closed operating configuration, the first defining edge 16e and the second defining edge 18d abut one another. The molding surface 16b and molding area 18a define an upper surface 116 and a lower surface 118 of the pad 114, respectively. When the forming unit 10 is in the closing operation phase, the pads 114 of the support element 100 are formed.

[0028] Thus, the method according to the invention comprises the following steps: - providing a material adapted to manufacture the pad 114; - providing a support component 122; - positioning a support component 122 on the punch element 18 of the first component 12 of the forming unit 10; - closing the cavity 16 of the second component 14 of the forming unit 10 by means of the punch element 18, moving the first component 12 towards the second component 14 or vice versa, bringing the support element 122 towards the cavity 16 and determining a closing operating configuration of the forming unit 10; - inserting and / or casting and / or injecting the material constituting the pad 114 into the cavity 16; - curing and / or polymerizing and / or solidifying said material to obtain a cured and / or polymerized and / or solidified material forming the pad 114 and resulting in adhesion of the support component 122 to the pad 114; - moving the first component 12 away from the second component 14 or vice versa to determine an opening operation configuration of the moulding unit 10; - extracting the pad 114 from the moulding unit 10. In one version of the invention, the method comprises the steps of: - providing an outer cover 120; - positioning the outer cover 120 in the cavity 16 and locking the outer cover 120 in place; - activating the vacuum means so that the material of the outer cover 120 adheres to the moulding surface 16b of the cavity 16 before the inserting and / or casting and / or pouring steps; - applying a primer or compatibilizer to the inner surface 120c of the outer cover 120, if necessary; - trimming the excess portion 120a of the outer cover 120 to obtain a trimmed outer cover.

[0029] The trimming step may be followed by a curing and / or polymerizing and / or hardening step, or a detaching and / or extraction step.

[0030] If an outer cover 120 is present, after the step of positioning the outer cover, the padding material 114 is positioned within the cavity 16 so as to contact the outer cover 120 itself. Locking the outer cover 120 in place can be achieved, for example, by locking the excess portion 120a of the outer cover 120 with a retaining plate 20, as will be better disclosed below.

[0031] According to a further version, the outer cover 120 can be locked in place directly by the punch element 18 against the first component 12. In particular, the outer contour 18b abutting against the periphery 16c of the second component 14 locks the excess part 120a of the outer cover 120 in place.

[0032] The trimming step is quick, whether it is performed manually, for example with a special trimming machine, or in an automated manner. Thanks to the support component 122, in fact, there is no excess material to be trimmed, since the outermost edge 122c of the support component 122 is positioned at a certain distance from the trim edge 114a of the pad 114, for example about 5 mm, or between 1 mm and 10 mm.

[0033] The trim edge 114a of the pad 114 is the edge that ideally separates the excess portion 120a of the outer cover 120 from the portion that is adhered to the top surface 116 of the pad 114 itself. Trim edge 114a is the edge around which trimming of outer cover 120 occurs.

[0034] As will be better understood from the disclosure that follows, the trim edge 114a of the pad 114 is therefore determined, in use, by contact between the first and second defining edges 16e, 18d of the cavity 16 and the punch element 18, respectively.

[0035] When the support base 150 is restrained against the pad 114, the trim edge 114a is disposed inwardly relative to the support base 150 and / or its outer perimeter contour 150a. The curing and / or polymerizing and / or solidifying step includes obtaining, on the underside 118 of the pad 114, an inner region 123 in which the support component 122 is adhered to the cured and / or polymerized and / or solidified material, and an annular region 124 surrounding the inner region 123 that contains such cured and / or polymerized and / or solidified material. Interior region 123, in at least one version of the invention, is recessed relative to annular region 124. An annular region 124 is obtained adjacent the trim edge 114 a between the trim edge and the outermost edge 122 c of the support component 122 .

[0036] The method then includes a step of binding the support base 150 to the support component 122 (and / or its outer surface 122b) and / or the underside 118 (and / or annular region 124) of the pad 114 to which the support component 122 is attached, the binding step including a step of applying an adhesive or glue to the underside 118 of the pad 114 and the support component 122 (and / or its outer surface 122b) and a step of adhering the support base 150 to said underside 118 and support component 122, or vice versa. The adhesive or pressure sensitive adhesive may include a polyurethane based compound, such as a two-component polyurethane adhesive, etc. Other components may be provided depending on the particular type of material of the elements being adhered.

[0037] The adhesive or pressure sensitive adhesive may also be applied several times, for example two times, to the underside 118 of the pad 114, waiting a period of time between applications. This may be particularly useful if the adhesive is applied, for example, by a brush or similar tool, but may not be necessary if the adhesive is sprayed.

[0038] The method of the present invention may include the step of preparing and / or cleaning and / or degreasing at least the upper surface of the support base 150 to receive an adhesive or glue so that at least the upper surface of the support base can be bonded to the lower surface 118 of the pad 114 and / or the support component 122.

[0039] The method of the present invention may also include the step of preparing and / or cleaning at least the underside 118 of the pad 114. For example, such a step may be performed prior to the step of applying an adhesive or glue.

[0040] The cleaning step can be performed with special cleaning substances, including chemical-based ones, to prepare the treated and / or cleaned surface. In this way, the cleaning substances can result in the breaking of double bonds present in the hardened and / or polymerized and / or solidified material of the pad 114.

[0041] A primer and / or compatibilizer may be applied to the upper surface of the support base 150 to facilitate binding and / or adhesion to the pad 114 and / or support component 122 .

[0042] This facilitates the pad 114 restraining the support base 150 by itself. Adhesion of the support component 122 to the material that achieves the pad 114, in at least one version of the invention, is determined by chemical affinity between the two materials and / or results from a curing and / or polymerization and / or solidification reaction of the material that achieves the pad, a reaction occurring near the support component 122 itself.

[0043] In an alternative version, the step of adhering the support component 122 to the pad 114 could be assisted by applying a suitable compatibilizer and / or auxiliary agent and / or adhesive onto the inner surface 122a of the support component 122.

[0044] Constraining the support base 150 to the support component 122 and / or the underside 118 of the pad 114 to which the support component 122 is attached may also include applying an adhesive or glue to the upper surface of the support base 150 .

[0045] The step of constraining the support base 150 to the pad 114 may be performed, for example, by a compression press separate from the molding unit 10 of the present invention.

[0046] According to an alternative version, the support base 150 can be restrained by suitable engagement means to a male component (not shown in the attached figures). In the moulding unit 10, the male component is a substitute for the first component 12. Indeed, once the pad 114 has been manufactured and (if necessary) the excess portion 120a of the outer cover 120 has been trimmed, the male component can be removably joined to the second component 14, allowing the support base 150 to abut against the lower surface 118 of the pad 114 and the support component 122.

[0047] In this manner, the restraint and / or bonding of the support base 150 and the pad 114 can be accomplished through the use of this male component and thus substantially with a single molded unit 10 .

[0048] As a result of this method, the support component 122 is flush with the underside 118 of the pad 114 and / or the annular region 124. Thus, despite being manufactured with a low thickness, in at least one version of the invention, the support component 122 does not protrude relative to the pad material, which is positioned, for example, in the annular region 124.

[0049] The support element 122 is therefore arranged in a kind of corresponding imprint or recessed area (whose dimensions correspond to those of the support element 122 and its thickness) which is in fact formed by an internal area 123 determined in the pad 114 .

[0050] Thus, in at least one version of the invention, the underside 118 of the pad 114 formed by the support element 122 and the annular region 124 is substantially free of discontinuities or steps, once achieved.

[0051] Thus, the support component 122 is to some extent embedded and / or inserted into the material forming the pad 114. This means that at least the inner surface 122a of the support component 122, that which is intended to contact the pad 114, and the thickness of the support component 122, is surrounded and in contact with the material of the pad 114. Conversely, the outer surface 122b of the support component 122, which is visible after the step of manufacturing the pad and which is adapted to be restrained and / or adhered to the support base 150 in use, is not recessed or protruding relative to the material making up the pad 114 and / or the annular region 124, but is substantially planar and / or flush.

[0052] Thus, the outer surface 122b is at least partially free of the hardened and / or polymerized and / or solidified material that makes up the pad 114.

[0053] This is also evident when one considers that the outer surface 122b of the support component 122 is in use in contact with the forming region 18a of the punch element 18. Thus, the means for holding the support component 122 in place in this manner does not allow passage between the outer surface 122b and the forming region 18a of the material that constitutes the pad 114.

[0054] The method may also include polishing the material of this annular region 124 so that the annular surface is roughened and / or wrinkled and / or has a roughened and / or wrinkled pattern.

[0055] Indeed, as mentioned, the material making up the pad 114 can be at least superficially compressed after curing and / or polymerization and / or solidification. This polishing step can increase the surface absorbency of the annular region 124 of the adhesive or glue necessary for the subsequent restraint of the support base 150. The polishing step, at least in one version of the invention, can open up chemical bonds in the material making up the pad 114 and / or mechanically roughen and / or wrinkle that region to facilitate the bonding step.

[0056] The polishing step may be performed by milling and / or polishing and / or scraping and / or removing and / or mechanically etching a surface layer of said annular region 124 .

[0057] A method according to one version of the invention may provide that at least one of the steps and / or at least one of the steps of sanding and / or applying adhesive or pressure sensitive adhesive and / or trimming is automated and / or performed by a robot, e.g. an anthropomorphic.

[0058] This is another advantage conferred by the presence of the support component 122: its dimensional stability and consistency allows the pad 114, once manufactured and with the support component 122 attached to its underside 118, to be positioned on a template or special tool. In this way, the method steps and / or the steps of trimming the outer cover 120 and / or the steps of preparing the pad 114 and / or the steps of polishing (as shown in FIG. 9 ) and / or the steps of applying the adhesive or glue (as shown in FIG. 10 ) are not performed manually but automatically, e.g. by a robot, e.g. an anthropomorphic.

[0059] The template or suitable tool may, for example, have a shape that negatively corresponds to the shape of the pad 114 and / or its upper surface 116 and / or may include a vice and / or an undercut.

[0060] Finally, the step of binding or gluing the pad 114 to the support base 150 can be carried out by placing the element or elements only in an oven, for example convection, which brings the entire mass of the element or elements only to a temperature corresponding for example to about 50° C., followed by, for example, manual bonding and pressing of the two elements onto each other. In this way, in at least one version of the invention, the support element 100 is ready for marketing without the need for further finishing and / or cleaning steps.

[0061] Positioning the support component 122 on the punch element 18 includes positioning and / or fixing the support component 122 via a retaining means present on the punch element 18. Such retaining means comprises a receiving rim 22 and / or a retaining means 30, and a suitable seat and / or hole 130 in the support component 122 itself, as further defined below.

[0062] According to a version of the invention, the support element 100 can have holes, preferably through holes, in its central and / or longitudinal regions. The holes can be circular or elongated. This is particularly useful if the support element 100 is a saddle for a vehicle, where such holes can allow better ventilation or provide pressure relief to the user at certain points, such as the prostate or soft tissue points.

[0063] If such a hole is present, it can affect both the pad 114 and the support component 122. In particular, in the latter, an opening is produced, for example in a circular or elongated shape, during a preparation or shaping stage of the support component itself. With regard to the pad 114 and / or the outer cover 120, this hole can be produced even after the step of producing the pad itself, possibly in an opening provided in the support component. In this case, the method can comprise a step of forming such a hole in a substantially central and / or longitudinal part of the outer cover 120 and / or the pad 114, possibly in a corresponding opening present in the support component 122, after the steps of curing and / or polymerization and / or solidification, or after the step of spacing, or after the step of extraction. This can be carried out, for example, by a pressure cutting element or by shearing or other similar methods.

[0064] According to a version of the invention, the pad 114 may comprise at least one insert. Such an insert may be made, for example, from a polyurethane material, and / or from a material having a different density with respect to the remaining materials constituting the pad, and / or from a material having different chemical and / or physical and / or mechanical properties with respect to the remaining materials constituting the pad, and / or from a material distinguishable by at least one property from the materials constituting the remainder of the pad 114. According to one version, such at least one insert may be made from a polyurethane gel or ethylene vinyl acetate (EVA).

[0065] Such at least one insert may be positioned in at least one area of ​​the pad where it is desirable to obtain different density and / or mechanical properties than the remainder of the pad, e.g., improved comfort, and / or improved cushioning, and / or increased stiffness and / or firmness.

[0066] Thus, a method according to the present invention may include the step of providing at least one insert and positioning such at least one insert proximate to an interior side of the outer cover 120 and / or the support component 122 .

[0067] The step of providing at least one insert may include either providing an already pre-molded insert or pouring a suitable material into at least one area where such insert is to be placed.

[0068] The support element 100 obtained by the method according to the invention thus comprises a pad 114 , possibly equipped with at least one insert, and a support component 122 .

[0069] If the at least one insert is provided pre-molded, it can be, for example, bound to the inner surface 122a of the support component 122, thereby being incorporated therein after realization of the pad 114. The presence of such at least one insert, for example an insert made from EVA, makes it possible to simultaneously strengthen the material, both due to the inherent properties of such an insert and the fact that, when it is present, the volume that can be occupied by the pad 114 is reduced, and thus the same material is in fact denser and / or more expansive and / or less rigid (compared to the same material that can be positioned in a larger volume). The at least one insert can, for example, be glued to the support component 122.

[0070] When the insert is injected, the insert may be injected into a particular area of ​​the cavity 16 prior to the insertion of the material constituting the pad 114. In this case, a particular period of time can be allowed to elapse, for example, to at least partially allow polymerization and / or hardening and / or solidification of the material of the at least one insert, so that the material constituting the pad does not penetrate into the area designated for the at least one insert and / or does not mix with the at least one insert.

[0071] The support component 122 has a shape that substantially corresponds to the shape of the pad 114, but is slightly smaller than it. When the support element 100 is a vehicle saddle, such as a bicycle saddle, both the pad 114 and the support component 122 have a first portion of substantially elongated form at the front or anterior in use, and a second portion of substantially enlarged form at the posterior in use. The first portion is connected to the second portion, as the overall shape of the pad 114 and / or the support component 122 is substantially triangular with rounded edges.

[0072] According to at least one version of the invention, the side or lateral portion connecting the first portion to the second portion is at least slightly contoured to present a kind of recess (having an outwardly and laterally facing cavity). Such shaping may, for example, facilitate pedaling by the user.

[0073] The support component 122 can be manufactured from a composite material, for example a latex-impregnated cellulose aggregate, such as the commercially available material Texon, and / or a synthetic material and / or a plastic and / or a thermoplastic material, for example a material comprising or consisting of polyester and viscose, and / or a thermoforming material, and / or a rigid or flexible polyurethane, etc.

[0074] The support component 122 is at least partially inserted and / or embedded in the cured and / or polymerized and / or hardened material of the pad 114, except for its outer surface 122b. In one version of the invention, the support component 122 is not fabricated from a material such as fabric or mesh. Fabric or mesh generally do not provide the necessary stiffness desired by the support component 122 of the present invention. Furthermore, fabric or mesh (at least conventional ones) do not help maintain the dimensions of the pad, do not provide a "guide" for trimming the outer cover, and do not prevent dimensional shrinkage of the pad material itself. The support component 122 is very thin, on the order of a few millimeters or about 1 mm or less in thickness.

[0075] The support component 122 provides a particular "stiffness" to the pad 114. For example, the support component has a Young's modulus stiffness of 500 to 3000 MPa. The support component 122 is actually stiffer than the material that comprises the pad 114 and / or the material that comprises the outer cover 120 . In at least one version of the invention, support component 122 has the same stiffness as support base 150, but has a much smaller thickness compared to the latter. The support component 122, in versions of the invention, may be manufactured by a thermoforming process. The support component 122 has two major surfaces that have substantially the same shape as the shape of the support component itself, and are actually separated from each other by the thickness of the support component, which is very thin as discussed above.

[0076] The larger surfaces of the support component are an inner surface 122a adapted to face and / or be restrained by the material of the pad 144 in use, and an outer surface 122b adapted to face and / or be restrained by the support base 150 in use. The support base 150 (seen, for example, in Figures 5 and 8) may be manufactured from, for example, a plastic and / or synthetic material, such as polyamide, or a metal or composite material. At least one of the inner surface 122a and the outer surface 122b, preferably the one 122b in external use, is at least partially rough and / or comprises more or less irregular or regulated irregularities, ripples, grooves and valleys, etc. 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 an adhesive or glue used for bonding with the support base 150. In this way, it is possible to avoid using a primer between the support component and the material that will constitute the support base 150, for example.

[0077] The support element 100, in versions of the invention, may comprise at least one outer cover 120. Such an outer cover 120 may be made from fabric, leather, imitation leather, a layer of compressed and / or closed-cell or expanded polyurethane material, high-density material, plastic or natural materials such as synthetic and / or polymeric materials such as PVC or polyvinyl chloride. If the outer cover 120 is present, a layer of a primer or compatibilizer, for example based on polyurethane and / or components thereof, may be present and / or applied to facilitate adhesion of the outer cover 120 to the pad 114. In such a case, this layer is applied to a surface 120c of the outer cover 120 adapted to face and / or be bound to the upper surface 116 of the pad 114 during internal use. If the outer cover 120 is present, it is clear that the upper surface 116 of the pad 114 is not external or accessible from the outside or by the user, since it is covered by and / or bound to the outer cover 120.

[0078] The outer cover 120, if present, also has an outer surface 120b adapted for contact with a user and / or for external visibility. The materials making up the pad 114 may include foam, self-skimming foam, polyurethane foam, printed inserts, cushioning and / or comfort inserts, etc. Such materials are expandable in at least one version of the invention. Furthermore, in one version of the invention, such materials are adapted to be inserted, poured, or injected into the cavity 16 of the molding unit 10 and to foam, cure, and / or polymerize, and / or solidify within the cavity 16 itself.

[0079] Thus, as can be seen, the present invention also relates to a support element for the human body obtainable by the method according to the present invention, where the support element 100 comprises a pad 114, a support component 122 and optionally a support base 150, the pad 114 comprising a cured and / or polymerised and / or hardened material to which the support component 122 is adhered. The support component 122 may, in use, be located between the pad 114 and the support base 150, if present.

[0080] The support component 122 is adhered to the pad 114 and / or adhered to the support base 150 . There may be an outer cover 120 that at least partially or completely covers the pad 114 .

[0081] In at least one version of the invention, the pad 114 with the support component 122 attached constitutes a semi-finished assembly. In this case, it therefore constitutes part of the support element 100. In order to obtain a usable and / or complete support element 100, it is useful in practice for the support base 150 to also be present. However, as mentioned above, due to the presence of the support component 122, the dimensional stability of the molded pad 114 is maintained and it can then be sold or stored as is for later application of the support base 150.

[0082] Due to the presence of the support component 122, the bonding operation between the pad 114 and the support base 150 takes a few seconds, whereas if the support component is not present or due to the application of materials other than those listed here for the support component 122, the bonding operation takes minutes. Furthermore, if the support component 122 is not present, the operator's ability dictates the correct binding with the support base. Conversely, this operation is also very easy for the operator when the support component 122 is present.

[0083] The benefit of the support component 122 is also measured in terms of its effectiveness during the operation of trimming the excess portion 120a of the outer cover 120. Indeed, the benefit is in having a consistent and compact component, namely the support component 122, that makes it easy for an operator to perform this task.

[0084] The present invention also has as its object a forming unit 10, which is adapted to be used for the realization of the method according to the invention and / or the support element described above. If the outer cover 120 is present, the moulding unit 10 may be equipped with vacuum means and / or a special holding plate (e.g. indicated by 20 in FIG. 1 ). The holding plate 20 is positioned above the cavity 16 such that a layer of material adapted to produce the outer cover, when present, is positioned in the cavity 16. The size of the outer cover layer is larger than the size of the cavity such that, when positioned in the cavity 16, it can overlap against the periphery 16c and / or the first defining edge 16e of the excess portion 120a (visible, for example, in FIG. 7 ).

[0085] The retaining plate 20 locks the outer cover 120 in place by pressing and restraining the excess portion 120a, and then the vacuum means is activated and the outer cover 120 assumes the shape of the forming surface 16b and adheres to the forming surface. The retaining plate 20 has a generally annular surface and is provided with an opening therethrough which corresponds to the opening 16 a of the cavity 16 .

[0086] In particular, the outer cover has an outer surface 120b adapted to contact the cavity 16 and intended to constitute the outermost layer of the padding 114 in use, and an inner surface 120c adapted to contact the padding material 114. The inner surface 120c of the outer cover 120 in use is not visible. However, in the absence of outer cover 120, the material making up pad 114 may independently form a more compact film and / or more closed and / or less expanded cells (compared to the material making up the remainder of pad 114) in contact with molding surface 16b.

[0087] Advantageously, as mentioned above, the punch element 18 comprises retaining means for the support component 122 . Such a retaining means, for example located in the forming region 18a of the punch element 18, may comprise a receiving rim 22 adapted to receive and / or retain the support component 122 and / or the retaining means 30 in use. In one version of the invention, the rim 22 can prevent the material that makes up the pad from passing through the rim itself and overlapping the outer surface 122b of the support component 122. The containment rim 22 is internal with respect to the outer contour 18b and / or the second defining edge 18d of the punch element 18. In fact, the outer contour 18b has a size larger than the second defining edge 18d and / or the containment rim 22. According to one version of the invention, the containment rim 22 is located approximately 1 cm from the outer contour 18b. The area enclosed by the containment rim 22 is therefore smaller than the area enclosed by the second defining edge 18d corresponding to the forming area 18a, and thus smaller than the area enclosed by the outer contour 18b. Thus, the containment rim 22 divides the molding area 18 a into an interior region 23 of the rim 22 and an annular region 24 which surrounds the interior region 23 .

[0088] The containment rim 22 projects relative to the molding area 18a, as shown in FIG. In another version not shown, the containment rim 22 can be flush with the molded region 18a and surround an interior region 23 that is recessed relative to the molded region 18a. The depth of the recess of this interior region can correspond to the thickness of the support component 122. In such a case, the annular region 24 will also be flush with the rim 22. The rim 22 is therefore determined by the difference in depth between the interior region and the annular region. However, as can be seen, for example, in Figures 2 and 3, molded area 18a is molded to correspond to lower surface 118 of pad 114, as described above. Thus, the interior region 23 determines the formation of the underside 118 and / or majority of the interior region 123 of the pad 114 , and the annular region 24 determines the formation of the annular region 124 of the pad 114 .

[0089] Thus, the annular region 24 extends from the rim 22 to the second defining edge 18d of the punch element 18, as seen in Figures 2 and 3. It may be inclined outwardly, for example downwardly and outwardly, away from the rim 22, according to the view of Figure 2. The inclined surface may be straight or curved, with a convexity toward the inside or outside of the punch element 18 .

[0090] As mentioned above, in at least one version of the invention, punch element 18 can be provided with a suitable retention means 30 for support component 122, such as a connecting pin (visible in FIG. 2).

[0091] Such a retaining means 30 may, for example, be molded as a pin 30a having a first end restrained or connected to the molded area 18a and a second or free end 30b opposite the first end having a cross-section larger than the cross-section of the pin 30a. The cross section of the peg 30a may be circular or polygonal, and similarly the cross section of the free end 30b may be circular or polygonal. The height of the peg 30a may correspond to the thickness of the support component 122 or be slightly greater than it. Naturally, the holding means 30 may have any other form suitable for the purpose without departing from the scope of protection of the invention. In an alternative version, the retaining means 30 may not be present as the support component may be held in place exclusively by the rim 22 . According to a further version of the invention, the retaining means 30 may be present but the rim 22 is absent. There may then be means for creating a vacuum adapted to hold the support component 122 in place on the punch element 18 in the presence or absence of the rim 22 and / or the holding means 30. When the retaining means 30 is present, the support component 122 has a special seat or a special through hole 130 (which can be seen, for example, in Figures 4 and 6) with a circular or polygonal cross section adapted to retain the support component 122 on the punch element 18 while allowing the passage of the retaining means itself.

[0092] In one version of the invention, the retaining means 30 is positioned in the molding region 18 a , or rather in the interior region 23 , possibly adjacent the annular region 24 . At the support base 150, if the support element 100 is a vehicle, in particular a bicycle saddle for example, a fork 152 of a type known in the art can be connected to the bicycle or vehicle frame.

[0093] In one version of the invention, the forming unit 10 and / or at least the first component 12 are manufactured from aluminum or other suitable metallic material. The first component 12 and / or the second component 14 comprise a main plate from which the punch element 18 is raised and / or into which the cavity 16 is recessed, respectively. In the closed operating position of the molding unit 10, the first component 12 and the second component 14 may also contact their respective main plates. Thus, a tight seal (if necessary with a special gasket) of the cavity 16 with the punch element 18, or rather with its forming area 18a, is produced. Features defined for one variant or embodiment may also be present in other variants or embodiments, unless stated otherwise. Modifications and variations of the invention are possible within the scope of protection defined by the claims.

Claims

1. A method for manufacturing a support element for the human body, such as a vehicle saddle, a bicycle or motorcycle saddle, a backrest or seat or armrest for an anatomical chair, or a similar support element, comprising: - providing a material suitable for manufacturing the pad (114) of the support element (100); - providing a support component (122) having an outer surface (122b) suitable for being constrained to the support base (150) of the support element during use; - placing the support component (122) on the punch element (18) of the first component (12) of the forming unit (10); - inserting and / or pouring and / or injecting the material into the cavity (16) of the second component (14) of the forming unit (10); - closing the cavity (16) by the punch element (18), bringing the first component (12) closer to the second component (14) or vice versa, directing the support component (122) towards the cavity (16), and determining a closing operating configuration for the forming unit (10); - hardening and / or polymerizing and / or solidifying the material to obtain a hardened and / or polymerized and / or solidified material forming the pad (114), resulting in an adhesion of the support component (122) to the pad (114), wherein the support component (122) is at least partially inserted and / or embedded in the hardened and / or polymerized and / or solidified material of the pad (114), such that the outer surface (122b) of the support component (122) is not at least partially covered by the hardened and / or polymerized and / or solidified material of the pad (114); - moving the first component (12) away from the second component (14) or vice versa to determine an open operating configuration of the forming unit (10); - extracting the pad (114) from the forming unit (10).

2. - providing an external cover (120); - placing the external cover in the cavity (16) and locking the external cover (120) in a predetermined position. - Before the step of inserting and / or pouring and / or injecting, operating vacuum means so that the material of the outer cover (120) adheres to the molding surface (16b) of the cavity (16); - Trimming the surplus portion (120a) of the outer cover (120) to obtain the trimmed outer cover (120), wherein the trimming step follows the step of curing and / or polymerizing and / or solidifying, or follows the step of moving away so as to release or the step of extracting; The method according to claim 1.

3. Including the step of restraining the support base (150) on the outer surface (122b) of the support component (122) and / or the lower surface (118) of the pad (114) to which the support component (122) is adhered, the restraining step including applying an adhesive or adhesive to the lower surface (118) of the pad (114) and the outer surface (122b), and adhering the support base (150) to the lower surface (118) and the outer surface (122b) or vice versa; The method according to claim 1.

4. The step of curing and / or polymerizing and / or solidifying includes obtaining, at the lower surface (118) of the pad (114), an internal region (123) to which the support component (122) is adhered to the cured and / or polymerized and / or solidified material, and an annular region (124) surrounding the internal region (123) and including the cured and / or polymerized and / or solidified material; The method according to claim 1.

5. Including the step of polishing the surface of the annular region (124) to be rough and / or wrinkled; The method according to claim 4.

6. Including the step of polishing the surface of the annular region (124) to be rough and / or wrinkled, the step being automated and / or performed by a robot, such as anthropomorphically; The method according to claim 4.

7. The step of applying an adhesive or adhesive and / or the step of trimming are automated and / or performed by a robot, such as anthropomorphically; The method according to claim 2 or 3.

8. The method according to claim 1, wherein the step of arranging the support component (122) comprises positioning and / or fixing the support component (122) on the punch element (18) via holding means (30) for the support component (122), the holding means (30) comprising, for example, a receiving rim (22) suitable for receiving and / or holding the support component (122) in use, and / or holding means (30), and suitable seats and / or holes (130) present in the support component (122).

9. The method according to claim 1, comprising forming holes in substantially central and / or longitudinal portions of the outer cover (120) and / or the pad (114) either after the step of hardening and / or polymerizing and / or solidifying, or after the step of moving away to release, or after the step of extracting, in corresponding openings present in the support component (122).

10. The method according to claim 1, comprising providing at least one insert and arranging the at least one insert near the outer cover (120) and / or the support component (122) to obtain the pad (114) comprising the at least one insert.

11. The support element for a human body obtained by the method according to claim 1, wherein the support element (100) is a saddle for a vehicle, a saddle for a bicycle or a motorcycle, a backrest or a seat or an armrest for an anatomical chair, or a similar support element, or a part thereof, comprising a pad (114), the pad (114) comprising a hardened and / or polymerized and / or solidified material, comprising a support component (122) adhered to the pad (114), the support component (122) being at least partially inserted and / or embedded in the hardened and / or polymerized and / or solidified material of the pad (114) and having an outer surface (122b) suitable for use in being constrained to a support base (150) of the support element.

12. The support element according to claim 11, comprising the support base (150), wherein the support component (122) is disposed between the pad (114) and the support base (150) and / or the support component (122) is adhered to the pad (114) and adhered and / or constrained to the support base (150).

13. The support element according to claim 11, comprising an outer cover (120) including, for example, a fabric, leather, imitation leather, a layer of compressed and / or closed-cell or expanded polyurethane material, a high-density material, a synthetic and / or polymeric material such as PVC or polyvinyl chloride, or a plastic or natural material, wherein the outer cover (120) at least partially or completely covers the pad (114) and / or the outer cover (120) is trimmed.

14. The support element according to claim 11, wherein the pad (114) comprises a trim edge (114a), and the trim edge (114a) is disposed inwardly with respect to the support base (150) and / or its outer peripheral contour (150a).

15. The support element according to claim 11, wherein the pad (114) has a lower surface (118) suitable for being adhered to the support component (120) and the support base (150) during use.

16. The support element according to claim 11, wherein the pad (114) has a lower surface (118), the lower surface (118) comprising an inner region (123) to which the support component (122) is adhered to the cured and / or polymerized and / or solidified material, and an annular region (124) surrounding the inner region (123) and including the cured and / or polymerized and / or solidified material adapted to be adhered to the support base (150) during use, and / or the outer surface (122b) of the support component (122) is substantially coplanar and / or flush with the annular region (124), and / or the annular region (124) has a rough and / or wrinkled surface pattern.

17. The support component (122) includes a composite material, such as a cellulose aggregate impregnated with latex, such as a material called Texon, and / or a synthetic material and / or a plastic material, such as a material comprising or consisting of polyester and viscose, and / or a thermoformed material, and / or a rigid polyurethane or a flexible polyurethane, etc., and / or the support component (122) has a higher rigidity than the cured and / or polymerized and / or solidified material of the pad (114), and / or the support component (122) has a rigidity having a Young's modulus included in the range of 500 to 3000 MPa. The support element according to claim 11.

18. The pad (114) and / or the cured and / or polymerized and / or solidified material includes a foam, a self-skinning foam, a polyurethane foam, such as a molded insert by a three-dimensional printer, a cushion and / or a comfort insert, etc. The support element according to claim 11.

19. The support element according to claim 11, comprising at least one insert disposed internally with respect to the outer cover (120) and / or the support component (122) such that the pad (114) comprises the at least one insert.

20. A forming unit for manufacturing a support element for a human body, such as a vehicle saddle, a bicycle or motorcycle saddle, a backrest or seat or armrest for an anatomical chair, or a similar support element, or a part thereof, comprising the pad (114), the support component (122), and optionally a support base (150) according to claim 11, wherein the forming unit (10) a first component (12) comprising a punching element (18); a second component (14) comprising a cavity (16), the cavity (16) having a shape substantially corresponding to the shape of the pad (114) and / or its outer surface (116), and having a forming surface (16b) capable of accommodating and / or filling a curable and / or polymerizable and / or solidifiable material suitable for forming the pad (114). A second component. The punch element (18) can approach the second component (14) and / or the cavity (16) during use, or vice versa, and determines a closing operation configuration for the shaping unit (10), The punch element (18) has holding means for the support component (122), and the holding means for the support component (122) includes a receiving rim (22) adapted to accommodate and / or hold the support component (122) during use, and / or holding means (30) shaped as a coupling pin, and / or means for forming a vacuum adapted to hold the support component (122) in a predetermined position on the punch element (18). A shaping unit, characterized by this.

21. The cavity (16) has an opening (16a) and a peripheral edge (16c) defining the opening (16a). When the shaping unit (10) is in the closing operation configuration, the opening (16a) and / or the peripheral edge (16c) contacts the punch element (18), whereby the cavity (16) is closed by the punch element (18). The shaping unit according to claim 20.

22. The punch element (18) has a shaping region (18a) that protrudes from the first component (12) and / or substantially corresponds to the lower surface (118) of the pad (114), and an outer contour (18b) whose outer contour (18b) abuts against the peripheral edge (16c) of the cavity (16). The shaping unit according to claim 20.

23. For holding an external cover (120) arranged above the cavity (16) and adapted to externally cover at least a part of the pad (114) in a predetermined position during use, and / or for holding, for example, an excess portion (120a) of the external cover (120), and having vacuum means and / or a holding plate (20), and / or the holding plate (20) has a substantially annular surface and is provided with an opening corresponding to the opening (16a) of the cavity (16). The shaping unit according to claim 20.

24. The shaping surface (16b) of the cavity (16) is defined and / or delimited by a first defining edge (16e), the shaping area (18a) of the punch element (18) is defined and / or delimited by a second defining edge (18d), and / or in the closing operation configuration of the shaping unit (10), the first defining edge (6e) and the second defining edge (18d) are in contact with each other. The shaping unit according to claim 20.

25. The receiving rim (22) is internal to the outer contour (18b) of the punch element (18) and / or the second defining edge (18d), and / or the receiving rim (22) encloses an internal area (23) of the shaping surface (18a), and / or an annular area (24) of the shaping surface (18a) is enclosed between the receiving rim (22) and the second defining edge (18d). The shaping unit according to claim 20.

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