Method of production of cycling shorts

Abstract

Method of production of cycling shorts wherein a foamed padding (14) with beveled edges and a fabric cover (16) provided with a foam layer (34) are placed on a portion of elasticized fabric (2) corresponding to the crotch of the shorts by means of templates (38, 40, 44) and thermally bound by placing it in a thermoforming mould. Said mould is subjected to a closing force of not less than 7000 N and to heating to thermoform together said portion of elasticised fabric (2), said padding (14) and said covering (16) and to create along the edge of said covering a welding band to said portion of elasticised fabric of a width of not less than 7 mm and a thickness of not more than 2 mm, The resulting crotch is removed from the thermoforming mould and joined by sewing to the remaining parts of the shorts created in the meantime.

Description

[0001] METHOD OF PRODUCTION OF CYCLING SHORTS.

[0002] The present invention relates to a method of producing cycling shorts.

[0003] These are well-known shorts for cyclists, generally made of a light fabric with a certain elasticity and known with the commercial name "lycra". Due to the intended use of these shorts and the particular methods of use, they are equipped in the crotch, that is, in the part of the shorts placed between the cyclist's body and the bicycle saddle, with a "seat pad", which constitutes a sort of cushion for the cyclist, who is forced to spend long periods sitting on the saddle and to move his thighs with respect to it by pedaling.

[0004] This seat pad is generally made using traditional techniques, which involve the thermoforming of overlapping layers of synthetic materials with different characteristics (softness, elasticity, antibacterial, thermoformability, etc.) in order to create an anatomical shape suitable for the function to be performed and intended to then be sewn to the shorts already made, so as to be positioned exactly on the crotch of the latter and thus be placed between the bicycle saddle and the anatomical parts of the cyclist that are most stressed during pedaling.

[0005] Although this technique is still very widespread, it has some drawbacks, which the present invention aims to eliminate.

[0006] One of these drawbacks is that sewing the seat pad to the shorts is a rather laborious operation and requires specialized personnel to perform it.

[0007] Another drawback is that applying the pad to the shorts is a slow operation that has a significant impact on the overall cost of the shorts.

[0008] Another drawback is that applying the pad to the shorts requires considerable accuracy and although every precaution is taken to correctly position the pad on the crotch before stabilizing it by sewing, this positioning often is imprecise and can lead to unwanted production waste.

[0009] These drawbacks are partly reduced if, instead of sewing the seat pad onto the already-made shorts, the seat pad is sewn onto the portion of fabric that forms the crotch of the shorts and then the crotch thus prepared is sewn to the remaining parts of fabric that form the shorts. WO2014 / 202477 already describes a production method for cycling shorts that uses this production technique, but the results that can be obtained are not satisfactory due to a certain slowness of operation, essentially linked to the high number of operations required to make the shorts. Furthermore, the necessary breathability of the shorts at the seat pad requires that holes be made in the seat pad, which make the surface of the seat pad that comes into contact with the cyclist irregular and can cause a feeling of discomfort, especially after long periods of pedaling. In particular, WO2014 / 202477 describes a process in which free parts of the heat-adhesive film are positioned only in the areas needed to glue the seat pad, so as to have areas of the seat pad free from the heat-adhesive film, which notoriously prevents the passage of water vapor. However, this method is penalized by the difficulty of handling such numerous and thin layers of material, and positioning them correctly.

[0010] Furthermore, WO2014 / 202477 also describes a process, which has now been completely abandoned in the current production of seat pads and which consists of injection moulding with liquid polyurethanes or silicone material, which suffer from very long cross-linking and expansion times of the polymeric materials and require subsequent drilling to make the resulting seat pads breathable.

[0011] Other methods of production cycling shorts are disclosed in US10645981 and in WO2013 / 002262.

[0012] An aim of the invention is to eliminate the drawbacks present in the prior art and in particular to produce cycling shorts in a simple way even by non-specialized personnel.

[0013] Another aim of the invention is to produce cycling shorts quickly and at high production rates.

[0014] Another aim of the invention is to create cycling shorts that offer a high level of comfort for the user even after long periods of use.

[0015] Another aim of the invention is to produce cycling shorts in an extremely precise and accurate shape, with virtually no production waste.

[0016] All these aims and others that will result from the following description are jointly or separately achieved according to the invention with a method of producing cycling shorts as defined in claim 1.

[0017] The present invention is further clarified below in some of its preferred forms of practical embodiment, reported for purely exemplifying and non-limiting purposes with reference to the attached drawings, in which:

[0018] Figure 1 shows a schematic plan view of a crotch of the shorts made according to the invention with the various components arranged in the correct relative position.

[0019] Figure 2 shows a plan view of the seat pad padding,

[0020] Figure 3 shows it according to the enlarged section Ill-Ill of Fig. 2,

[0021] Figure 4 shows a plan view of the seat pad cover, Figure 5 shows it partially according to the enlarged section V-V of Fig. 4,

[0022] Figure 6 shows a schematic plan view of a first phase of the method according to the invention, with the portion of fabric that forms the crotch of the shorts placed on a template for assembling the various components of the crotch itself,

[0023] Figure 7 shows a plan view of a second phase of the method with the positioning template of the padding on the portion of fabric, and

[0024] Figure 8 shows a third phase of the method with the positioning template of the cover on the fabric portion and on the padding.

[0025] As can be seen from the figures, the method according to the invention first involves cutting from a piece of fabric normally used to make cycling shorts and more particularly from a piece of fabric of the type commercially known as “lycra”, a portion of fabric 2 intended to form the crotch of the shorts. This operation is preferably performed with automatic blade cutting machines.

[0026] The portion of fabric 2 thus obtained, which forms the crotch of the shorts, has an irregular but symmetrical shape with respect to an antero-posterior axis and includes:

[0027] - a front portion 4, intended to be joined to the front part of the shorts and delimited laterally by two curved lines 6, which form the front leg opening of the shorts themselves,

[0028] - a rear portion 8, intended to be joined to the rear part of the shorts and delimited laterally by two other curved lines 10, which form the rear leg opening, and

[0029] - two lateral portions 12, which are delimited anteriorly by the curved lines 6 and posteriorly by the curved lines 10.

[0030] The whole is configured to be sewn to other portions of shorts, obtained from a similar or even different piece of fabric, depending on the characteristics that the shorts must have.

[0031] Are then made separately, advantageously by die-cutting, the other parts of the seat pad that have different characteristics depending on their function and which will then have to be coupled with the portion of lycra fabric 2 to form the complete crotch to be sewn to the other portions of fabric to form the shorts.

[0032] These other components of the seat pad are essentially two, and can be defined as the padding 14 and the covering 16, the first of which is intended to be directly attached to the lycra fabric 2 and the second, larger in size, to be attached partly to the padding 14 and partly directly to the lycra fabric 2. The padding 14 is advantageously obtained by die-cutting from a roll of laminate comprising a heat-adhesive film 18 and a support layer 20, consisting of one layer but preferably several layers of expanded polyurethane having different thicknesses and densities to meet specific use requirements.

[0033] The heat-adhesive film 18 is preferably polyurethane-based, with a thickness of approximately 30 microns, a hardness of between 80 and 90 degrees Shore A and a melting point of between 155°C and 175°C, preferably approximately 160°C. It is flame-bonded to the support layer, which has a thickness of between 2mm and 15mm and a density related to the specific performance that the padding must be able to provide. More specifically, the support layer of the padding 20 may comprise a first layer 22 and eventually other layers 24 with different densities, bonded together with glue. In the case of a single layer of expanded polyurethane, the bond formed by these is affected over its entire surface by a uniform and dense through-hole pattern, and in particular by a perforation with holes preferably with a diameter of approximately 1 mm spaced apart preferably by approximately 10mm. In the case of multiple layers of expanded polyurethane, the coupled material formed by the heatadhesive film 18 and the first support layer coupled by flame with the heat-adhesive film 18 are affected by a dense perforation, while the other support layer or layers coupled with glue to the first may be affected by a less dense perforation than the previous one.

[0034] Advantageously, the padding 14 can be affected on the edge by a bevel 26 preferably at 45° to gradually and continuously connect its external surface with the surface of the lycra fabric 2, to which the padding 14 is made to adhere. This bevel 26 progressively reduces the thickness of the padding 16 towards the heat-adhesive film 18 and can also be continuously extended inside the padding, for example to form a longitudinal channel 28, which separates two lateral portions 30 in the padding.

[0035] The cover 16 is also preferably obtained by die-cutting from a roll of laminate with a total thickness of approximately 3 mm and comprising a first layer 32 consisting of a thermoformed elasticized fabric for seat pads, brushed on the side intended to come into contact with the cyclist's skin. This fabric 32 has a thickness of approximately 1 mm and is made up of approximately 80-85% polyester and approximately 15-20% elastane, and is coupled with glue to a second layer 34 of Moltopren MTP 60 type polyurethane foam with a thickness of 2 - 3 mm and a density of approximately 60 kg / m3, which in turn is flame-coupled with a third layer 36 consisting of a polyurethane-based heat-adhesive film with similar characteristics to the polyurethane-based heat-adhesive film 18 of the padding 14.

[0036] The laminate that forms the cover 16 is obtained by first flame-coupling the polyurethane-based heat-adhesive film 36 with the MTP polyurethane foam layer 34 and then making a uniform and dense through-hole perforation over its entire surface and throughout its thickness, similar to the perforation that affects the padding 14. Subsequently, the laminate thus obtained is in turn coupled on the side of the MTP 60 polyurethane foam layer 34 with the elasticized fabric 32 preferably with PUR glue in dots on a rolling mill engraved with hot melt coupling technology.

[0037] Advantageously, before coupling, this layer of elasticated fabric 32 can also be affected by a perforation, which is more rarefied and is preferably localised in nonprotruding parts of the seat pad, and therefore barely perceptible by the cyclist who is using the shorts.

[0038] Once obtained the piece of lycra fabric 2, the padding 14 and the cover 16, the creation of the crotch of the cycling shorts can advantageously be done in the following way: the piece of lycra fabric 2 is placed in the traditional manner on a first template 38, using the numbered position references, corresponding to the model and size of the shorts to be obtained (fig. 6).

[0039] A second template 40 is then placed on the piece of lycra fabric 2, with a central opening 42 for the correct positioning of the padding 14. Suitable references can be used for this positioning, which are also present in the same first template 38 of the lycra fabric 2 (fig. 7).

[0040] A traditional low residue adhesive is then applied to localised areas of the heat-adhesive film 18 of the padding 14, preferably by spraying, and the padding itself is then positioned on the lycra fabric 2 in correspondence with the opening 42 of the second template 40, so as to temporarily secure it to said lycra fabric 2 in the correct position.

[0041] Once this temporary pre-fixing has been obtained, the second template 40 of the padding 14 is removed and in its place, always using the appropriate references present in the first template 38, a third template 44 is placed for the covering 16. This third template 44 is also centrally affected by an opening 46 for the correct positioning of the covering itself, and since this opening 46 has larger dimensions than the padding 14, in addition to leaving this uncovered, it also leaves uncovered a band of lycra fabric 2 surrounding it (fig. 8). A temporary low-residue adhesive is also applied to the surface of the heatadhesive film 36 of the cover 16 at localised points, preferably by spraying, and the cover 16 is then placed in correspondence with the opening 46 of the third template 44, so as to temporarily adhere to the padding 14 with its central part and to the Lycra fabric 2 with its perimeter band surrounding the padding 14.

[0042] The third template 44 is then removed from the first template 38 and the temporarily pre-assembled bottom is then removed from the latter to be placed on a thermoforming mould, which advantageously is equipped with suitable laser light references to define the correct position of the cover 16 with respect to it, regardless of the shape and size of the lycra fabric 2.

[0043] The thermoforming mould is then activated, where the assembled lycra 2 + padding 14 + cover 16 is thermoformed at approximately 190°C for approximately 90

[0044] - 100 seconds, and with a mobile shaped piston, which reproduces the shape of the edge of the cover 16, this thermoforming mould exerts on this edge a force advantageously no less than 7000N.

[0045] Thanks to thermoforming, the padding 14 is stably welded to the lycra fabric 2 and the cover 16 is stably welded in its central part to the padding 14 and in its peripheral band to the lycra fabric 2. At the same time, the high pressure exerted by the shaped piston of the mould on the edge of the cover 16 causes a fusion of the layer 34 of polyurethane foam MTP 60 of the cover 16 and of the thermoadhesive polyurethane film 36 coupled to it to the lycra fabric 2 and essentially a strong and stable fixing of the cover 14 to the lycra fabric 2, comparable to that obtainable with a seam.

[0046] In this way, the crotch is obtained with the seat pad having the desired shape and with the various components correctly and stably positioned with respect to each other.

[0047] Finally, the crotch with the applied seat pad is sewn to the other pieces of fabric to form the cycling shorts.

[0048] In this way, all the operations of fixing the seat pad by sewing it onto the already made trousers are avoided and at the same time a precise, stable and rapid reciprocal positioning is obtained.

[0049] From the above it is clear that the method according to the invention is considerably more advantageous than traditional methods, and in particular:

[0050] - significantly reduces the production times of cycling shorts, as it uses products that are already coupled and perforated in the factory and therefore have quality, uniformity and inalterability characteristics over time that are much higher than those obtainable with coupling and perforation at the manufacturing site,

[0051] - it features a dense perforation that completely affects the heat-adhesive films and the respective polyurethane support layers, and therefore the entire surface of the caseback despite a reduced number of parts to assemble together,

[0052] - ensures precise positioning of the various components of the seat pad while still allowing the same equipment to be used for different sizes and models of shorts,

[0053] - drastically reduces processing waste,

[0054] - allows to make shorts with practically any type of pad, - ensures a solid and long-lasting fixing of the pad to the shorts: experimental tests carried out on dozens of cyclists wearing shorts made according to the invention have confirmed that the shorts have retained their characteristics after rides of over 5000 km interspersed with frequent washing at 40°C.

Claims

C L A I M S1 . Method of production of cycling shorts characterized in that:- a portion (2) of shorts is obtained from an elasticized fabric intended to form the crotch of the shorts,- a padding (14) for the seat pad of said shorts is obtained from a first roll, which comprises a first polyurethane-based heat-adhesive film (18) coupled by flame with at least one support layer of expanded polyurethane (20) and perforated together with this,- a bevel (26) is created on the edge of said padding (14) which reduces its thickness towards said first heat-adhesive film (18),- a cover (16) for said padding (14) is obtained from a second roll, which comprises a second polyurethane-based heat-adhesive film (36), flame-coupled to a layer of polyurethane foam (34) and perforated with this, and an elasticized thermoformed fabric (32) for seat pads, which is brushed and glue-coupled with said polyurethane foam layer (34), already flame-coupled with said heat-adhesive film (36),- said portion of elasticized fabric (2), which forms said crotch, is placed on a first template (38) in correspondence with reference marks provided therein,- a second template (40) is placed on said portion of elasticized fabric (2), using suitable signs provided in said first template (38), said second template (40) having a first opening (42), which leaves a central part of said portion of elasticized fabric (2) free for the correct positioning of said padding (14),- said padding (14) is temporarily bound by points to said portion of elasticized fabric (2) in correspondence with said first opening (42) by means of a low residue adhesive applied to the side of said padding (14) to which said first polyurethane- based heat-adhesive film (18) is applied,- said second template (40) is removed and a third template (44) is positioned on said first template (38), using suitable marks provided therein, said third template (44) being provided with a second opening (46), larger than said first opening (42), for the correct positioning of said covering (16), which partly overlaps said padding (14) and partly overlaps a band of said portion of elasticized fabric (2) surrounding said padding (14),- said covering (16) is temporarily bound to said portion of elasticized fabric (2) and to said padding (14) at said second opening (46) by means of a low residue adhesive, applied to the side of said covering (16), to which said second polyurethane-based heat-adhesive film (36) is applied,- the assembly formed by said portion of elasticized fabric (2), said padding (14) and said covering (16) temporarily bound together is positioned inside a thermoforming mold which has an imprint corresponding to the seat pad to be made,- said mould is subjected to a closing force of not less than 7000 N and to heating to thermoform together said portion of elasticised fabric (2), said padding (14) and said covering (16) and to create along the edge of said covering a welding band to said portion of elasticised fabric of a width of not less than 7 mm and a thickness of not more than 2 mm,- the resulting crotch is removed from the thermoforming mould and joined by sewing to the remaining parts of the shorts created in the meantime.

2. Method according to claim 1 characterised in that said padding (14) is obtained from a laminate comprising said first polyurethane-based heat-adhesive film (18), a first layer (22) of expanded polyurethane coupled with glue to said heat-adhesive film and one or more subsequent layers (24) of expanded polyurethane of different thicknesses and / or different densities, coupled with glue to each other.

3. Method according to claim 1 characterised in that in addition to creating the bevel (26) on the edge of said padding (14), an internal part of said padding is also removed to give a shape to said layer (20) of expanded polyurethane.

4. Method according to one or more of the preceding claims characterised in that a polyurethane-based heat-adhesive film (18,36) with a thickness of approximately 30 microns, hardness between 80 and 90 degrees Shore A and melting point between 155°C and 175°C, preferably approximately 160°C, is used for the coupled materials forming said padding (14) and / or said covering (16).

5. Method according to one or more of the preceding claims characterised in that said support layer (20) of said covering (16) has a thickness between 2 mm and 15 mm and consists of multiple layers of expanded polyurethane having different densities.

6. Method according to one or more of the preceding claims characterised in that the layer (34) of polyurethane foam which forms said covering (16) consists of Moltopren MTP 60 with a thickness of 2 - 3 mm and a density of approximately 60 Kg / m3.

7. Method according to one or more of the preceding claims characterised in that the layer (32) of elasticized thermoformed fabric which forms said covering (16) has a thickness of approximately 1 mm and is made up of approximately 80-85% polyester and approximately 15-20% elastane.

8. Method according to one or more of the preceding claims characterised in that a bevel (26) of approximately 45° is made on said padding (14).

9. Method according to one or more of the preceding claims characterised in that the perforation which affects the flame-bonded coupling of said first heat-adhesive film (18) with the support layer (20) of the padding (14) and the flame-bonded coupling of said second heat-adhesive film (36) with the polyurethane foam layer (34) of said covering (16) is formed by holes with a diameter of approximately 1 mm spaced approximately 10 mm apart.

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