Saddle for vehicles, method and mold for its making

Abstract

The present invention relates to a saddle for vehicles, such as bicycles or motorcycles and a method for making a saddle and / or for applying a covering element or cover to a padding component of a saddle for vehicles, such as bicycles or motorcycles. The present invention also relates to a mold for making a saddle, and in particular for applying a covering element or cover to a padding component of a saddle for vehicles, such as bicycles or motorcycles, for example by means of the aforementioned method.

Description

[0001] “SADDLE FOR VEHICLES, METHOD AND MOLD FOR ITS MAKING”.

[0002] TECHNICAL FIELD OF THE INVENTION

[0003] The present invention relates to the field of saddles for vehicles, such as bicycles or motorcycles, and in particular concerns a saddle equipped with a padding component and a covering element or cover, as well as a method for making a saddle or a padding component of a saddle and / or for applying such covering element or cover to the padding component.

[0004] The present invention also relates to a mold for making a padding component of a saddle or a saddle itself and / or for applying a covering element or cover to a padding component of a saddle for vehicles, such as bicycles or motorcycles, for example by implementing the aforementioned method.

[0005] STATE OF THE PRIOR ART

[0006] Technologies that use three-dimensional (3D) printing techniques are undergoing increasingly widespread diffusion in various production sectors, from design to research in general.

[0007] The term 3D printing generally refers to the creation of three-dimensional objects having a variety of functions and shapes, by means of an additive manufacturing technique starting from a three-dimensional digital model. The digital model can be obtained through a dedicated software and subsequently processed in order to be manufactured using different technologies and / or a 3D printer.

[0008] Saddles for vehicles, such as bicycles or motorcycles, represent fundamental components for the comfort and performance of the user and are subject to specific requirements of ergonomics, strength, and lightness. Traditionally, such saddles are made using a combination of materials such as, for example, metal, plastic, and gel, with the aid of standard manufacturing processes such as injection molding and / or mechanical processing. However, these methods present limitations in terms of customization and optimization of the mechanical properties and weight of the saddles.

[0009] 3D printing represents a significant step forward, allowing the creation of saddles with a complex and highly customizable internal structure. The three- dimensional structure can be designed to vary in density, shape, and size, thus optimizing mechanical properties such as, for example, shock absorption and weight distribution. This level of control and customization is impossible to achieve with traditional manufacturing methods.

[0010] Such saddles, however, being often made with padding formed by structures composed of a plurality of interconnected and open cells, sometimes suffer from problems of too much or too little adherence and / or grip in the areas of contact with the user’s body.

[0011] Moreover, such plurality of interconnected and open cells allows for the accumulation of dirt inside the cells themselves, especially in disciplines such as MTB and Gravel.

[0012] Therefore, is necessary and advantageous to design and realize a saddle for vehicles, such as bicycles or motorcycles, a method and a mold for the realization of said saddle or of at least a part thereof, which allow overcoming the disadvantages of the prior art listed above.

[0013] OBJECTS OF THE INVENTION

[0014] The technical task of the present invention is to improve the state of the prior art relating to saddles for vehicles, with particular reference to bicycle or motorcycle saddles.

[0015] Within this task, an object of the present invention is to provide a saddle for vehicles, such as bicycles or motorcycles, capable of offering, during use, an improved sensation of adherence or grip for the user.

[0016] A further object of the present invention is to provide a saddle for vehicles, such as bicycles or motorcycles, that prevents or reduces the accumulation of dirt inside the padding of the saddle itself.

[0017] Yet another object of the present invention is to provide a saddle for vehicles, such as bicycles or motorcycles, with high comfort for the user.

[0018] A still further object of the present invention is to provide a method and a mold for applying a covering element or cover to a padding component of a saddle for vehicles, such as bicycles or motorcycles, which is easy and quick to use.

[0019] A further object of the present invention is to provide a method and a mold for applying a covering element or cover to a padding component of a saddle for vehicles, such as bicycles or motorcycles, which allows for the optimal application and adhesion of a covering element or cover only on specific zones of the padding component of the saddle itself.

[0020] This task and these objects are achieved by a saddle for vehicles, such as bicycles or motorcycles, according to claim 1, by a method for making a saddle for vehicles, such as bicycles or motorcycles, according to claim 7, and by a mold for making a saddle for vehicles, such as bicycles or motorcycles and / or for applying a covering element to a padding component of a saddle for vehicles, such as bicycles or motorcycles, according to claim 16.

[0021] The dependent claims refer to preferred and advantageous embodiments of the invention.

[0022] BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Other features and advantages of the invention will be more evident from the description of an embodiment of a saddle for vehicles, such as bicycles or motorcycles, of a method and of a mold for applying a covering element or cover to a padding component of a saddle for vehicles, such as bicycles or motorcycles, illustrated by way of example in the attached drawings in which:

[0024] - figure 1 is a top view of a saddle for vehicles, such as bicycles or motorcycles, according to an embodiment of the present invention,

[0025] - figure 2 illustrates a detail of the saddle of figure 1,

[0026] - figure 3 illustrates another detail of the saddle of figure 1,

[0027] - figure 4 illustrates yet another detail of the saddle of figure 1, - figure 5 is an exploded view of a final stage of a method for applying a covering element or cover to a padding component of a saddle for vehicles, such as bicycles or motorcycles, according to an embodiment of the present invention,

[0028] - figures 6, 7, 8, 9 and 10 each illustrate a step of a method for applying a cover element or cover to a padding component of a saddle for vehicles, such as bicycles or motorcycles, according to an embodiment of the present invention,

[0029] - figure 11 is an exploded view of a final step of a method for applying a cover element or cover to a padding component of a saddle for vehicles, such as bicycles or motorcycles, according to another embodiment of the present invention, and

[0030] - figures 12, 13, 14 and 15 each illustrate a step of a method for applying a cover element or cover to a padding component of a saddle for vehicles, such as bicycles or motorcycles, according to another embodiment of the present invention.

[0031] In the attached drawings, identical parts or components are identified by the same reference numbers.

[0032] EMBODIMENTS OF THE INVENTION

[0033] With reference to the attached figures, the number 1 wholly indicates a saddle for vehicles, such as bicycles or motorcycles, in particular for bicycles, according to a non-limiting embodiment of the present invention.

[0034] The saddle 1 defines a rear portion RP, a front portion FP, and an intermediate portion IP for connection between the rear portion RP and the front portion FP.

[0035] The saddle 1 comprises a support component 2 and at least one padding component 3 fixed to the support component 2.

[0036] The padding component 3 constitutes the elastic and / or cushioning and / or comfort portion of the saddle 1.

[0037] The support component 2, on the other hand, constitutes the stiffer portion of the saddle 1 and serves to support the weight of the user and / or to provide a rigid structure to the saddle 1.

[0038] Therefore, the support component 2 is stiffer and less elastic than the padding component 3. Consequently, the padding component 3 is more elastic and less stiff than the support component 2.

[0039] The padding component 3 comprises a honeycomb structure that includes a plurality of cells 4. According to a preferred version of the invention, the padding component 3 is manufactured by three-dimensional printing.

[0040] Optionally, the support component 2 may also be manufactured by three- dimensional printing.

[0041] Preferably, the support component 2 does not comprise a plurality of cells as it must fulfill its support function, and the presence of voids within the cells could compromise such function.

[0042] In this regard, the support component 2, although not being populated by cells, according to at least one version of the invention, may be emptied based on stress areas derived from the application of loads simulating its use: these maps can be defined using finite element simulation methods, and the topology of the component can be emptied to remove areas not subject to stress. This type of approach can generate complex shapes that only three-dimensional printing, in particular additive manufacturing, can realize / produce.

[0043] Therefore, in such a case, the support component 2 is advantageously three- dimensionally printed in order to obtain a structure, if desired also complex, capable of having the mechanical features required or desired.

[0044] Optionally, the support component 2 may be made of thermosetting or thermoplastic material.

[0045] If desired, such thermosetting or thermoplastic material may comprise, for example, at least one of the following materials or resins: a polyurethane (PU), a thermoplastic polyurethane (TPU), a thermoplastic resin, at least one component from the thermoplastics family, preferably TPU, other polymers, etc.

[0046] The thermosetting or thermoplastic material may also comprise reinforcing fibers such as, for example, carbon fibers, glass fibers, kevlar, etc. As for the manufacturing techniques of the support component 2, in the case of three-dimensional printing, the latter may be produced by FDM (Fusion Deposition Modeling) or MJF (Multi Jet Fusion) or SLS (Selective Laser Sintering) or similar.

[0047] In the case in which the support component 2 is not manufactured by three- dimensional printing but by traditional techniques, its material may be, for example, carbon and / or a thermoplastic material and / or a composite material.

[0048] Regarding the constraint between the support component 2 and the padding component 3, the latter may be directly molded onto the support component 2 or may be bonded to it by adhesive means.

[0049] With reference to the plurality of cells 4 of the padding component, each cell 4 may have a polyhedral and / or parallelogram shape or any other shape defined according to the needs of the user and / or the manufacturer.

[0050] In particular, each cell 4 advantageously has a substantially three- dimensional structure or conformation, formed by a plurality of faces, of the lattice-like or reticular or open-cell type.

[0051] Each face may have a substantially parallelepiped or polygonal shape, for example triangular, square, rectangular, hexagonal, pentagonal, octagonal, etc., or circular or ovoidal.

[0052] Alternatively, each cell may have a gyroid shape. This type of cell 4 may provide advantages in terms of weight and thickness of the padding component 3.

[0053] Moreover, it is possible that such a shape of cell 4 results in a non- continuous and / or undulated support surface for the user.

[0054] Each cell 4 may have two faces substantially lying on parallel planes, for example a horizontal, in use, extension plane of the saddle or a support plane for the user on the saddle, and at least two other faces arranged substantially perpendicular or orthogonal to the parallel faces or with a certain draft angle. The parallel faces may be axially offset from each other or may be axially aligned.

[0055] Advantageously, the space enclosed by the cells 4 and / or their faces is an empty space. This allows to reduce the weight of the saddle 1. Preferably, the padding component 3 may comprise cells 4 having different shapes and / or sizes and / or densities and / or stiffnesses from cell to cell and / or from area to area of the padding component 3.

[0056] For example, the padding component 3 may be composed of cells 4, for example honeycomb-shaped, in which the mechanical and / or elastic response can be modulated through the size of the cell 4 and / or the thickness of the sides or branches that constitute it. In general, a large cell “gives” more, as does a thinner branch. On the contrary, smaller cells or with thicker or larger branches offer more resistance to compression.

[0057] Considering, for example, the saddle 1, it may comprise more yielding areas positioned at and supporting the soft tissues of the body of the user, for example at the front portion FP of the saddle 1, and more sustained and / or more resistant and / or more supportive areas, for example at the perineal-ischial area of the user, for example at the rear portion RP of the saddle 1.

[0058] Preferably, the padding component 3 is made of a thermosetting or thermoplastic material.

[0059] Such thermosetting or thermoplastic material may comprise, for example, at least one of the following materials or resins: a polyurethane (PU), a thermoplastic polyurethane (TPU), a thermoplastic resin, at least one component of the thermoplastics family, preferably TPU, other polymers, etc.

[0060] As for the manufacturing techniques of the padding component 3, the latter is advantageously produced by DLP (Digital Light Processing) or DLS (Digital Light Synthesis).

[0061] Optionally, the vehicle saddle 1 may also comprise a fork or rail component FC, which can connect the support component 2 to the bicycle frame itself. The fork or rail component FC may be made, for example, of steel and / or carbon and / or composite materials.

[0062] Returning to the padding component 3, it defines an external surface 3a configured to be turned, during use, towards the body of a user. According to at least one version of the invention, the external surface 3a is designed, at least in part, to come into contact with the body of a user.

[0063] The external surface 3a may delimit a plurality of zones Zl, Z2, Z3, for example, separated by at least one separation cord or section 3b defined by said padding component 3, preferably integrally made with the plurality of cells 4 of the padding component 3 and, thus, by three-dimensional printing.

[0064] In particular, in at least one preferred version of the invention, such separation cord or section 3b serves to cover or delimit the transition from a cell with a certain geometry to another with a different geometry and / or to cover or delimit the transition from one zone Zl, Z2, Z3 to another.

[0065] This results in the formation of different densities or of a different material response under load. Such a transition between one cell zone Zl, Z2, Z3 and another may occur without interruption, and in such a case the separation cord or section 3b is purely aesthetic.

[0066] Alternatively, the separation cord or section 3b may be absent.

[0067] Preferably, the separation cord or section 3b is continuous along its development and may branch on the external surface 3a so as to delimit the plurality of zones Zl, Z2, Z3.

[0068] According to the non-limiting embodiment of the saddle illustrated in figures 1 to 4, the separation cord or section 3b has a first and a second length 3b 1, 3b2, which extend from opposite positions of the rear portion RP in a direction from the rear R to the front F of the saddle 1, which lengths 3b 1, 3b2 converge, for example so as to form a U, substantially at the front portion FP of the saddle 1.

[0069] Advantageously, the separation cord or section 3b may also comprise a connecting length 3b3, optionally with a curved or at least partially curved course, which joins the two lengths 3b 1, 3b2, for example at the intersection of a plane orthogonal to the main lying plane of the saddle 1 passing through the widest portion of the latter with the two segments 3b 1, 3b2, so as to delimit or separate a first functional zone Zl from a second functional zone Z2.

[0070] In particular, the external surface 3a may comprise a first zone or rear zone Z1 defined at the rear portion RP, a second zone or central zone Z2, extending centrally and longitudinally, i.e., in a direction from the rear R to the front F of the saddle 1 or of the padding component 3, from the rear portion RP to the front portion FP, configured to reduce, during use, the pressure of the saddle 1 on the perineal-ischial area of a user, and in particular comprises a third zone or lateral zone Z3 extending longitudinally, i.e., in a direction from the rear R to the front F of the saddle 1 or of the padding component 3, from a right lateral part and from a left lateral part of the rear portion RP up to substantially the front portion FP.

[0071] The third zone or lateral zone Z3 runs alongside the second zone or central zone Z2 and optionally surrounds it at the front portion FP.

[0072] The saddle 1 according to the present invention then comprises at least one covering element 5, optionally referred to as cover, adapted to cover at least part of the external surface 3a of the padding component 3. The at least one covering element 5 is constrained or adhered at least at the third zone or lateral zone Z3, optionally also at the first zone or rear zone Zl. According to one version of the invention, the covering element 5 is not adhered or constrained at the second zone or central zone Z2.

[0073] Optionally, the covering element 5 may be superimposed, for example constrained and / or adhered, at least in part onto the separation cord or section 3b, so as to obtain a solid and stable constraint on its preferably continuous surface.

[0074] Preferably, the covering element 5 comprises or is made of a film or layer of plastic material, for example thermoplastic.

[0075] Optionally, such plastic material is thermoplastic polyurethane or, alternatively, polyvinyl chloride (PVC), a thermoplastic elastomer (TPE), a thermoplastic vulcanizate rubber (TPV), or any other fabric or synthetic material coupled with a fabric.

[0076] In at least one version of the invention, the material is preferably TPU because, being from the same family as the material from which the padding component 3 is made, the adhesion between such materials is better.

[0077] Preferably, the covering element 5 has a constant thickness along its extension.

[0078] Alternatively, the covering element 5 may have a variable thickness along its extension so as to further stiffen some specific areas of the external surface 3a of the padding component 3 and / or of the at least one third zone or lateral zone Z3.

[0079] For example, the covering element 5 may have a thickness between 0.1 mm and 1 mm, for example about 0.3 mm.

[0080] According to a further version of the invention, several covering elements 5 with different thicknesses may be positioned on the same padding component 3, for example positioned in different zones of the padding component itself.

[0081] The covering element 5 is capable of preventing the entry of dirt or dust into the cells of the padding component 3 and of regulating the adhesion or grip and / or the comfort of the user at the main contact areas of its body with the saddle 1 during riding or use, i.e., for example, the third zone or lateral zone Z3 and, optionally, the first zone or rear zone Zl.

[0082] Advantageously, the covering element 5 may have different finishes, for example a smooth and / or wavy and / or striped and / or wrinkled finish, in order to reduce or increase the adhesion or grip, optionally only in certain desired zones where the covering element 5 is applied (see, for example, the enlargement illustrated in figure 4, where the covering element 5 has a wavy and / or striped finish so as to increase the adhesion or grip in the third zone or lateral zone Z3).

[0083] Optionally, the zones Zl, Z2, Z3 each delimit a respective group Gl, G2, G3 of cells 4 which have different mechanical and / or elastic properties between them, for example different density and / or shape and / or size and / or stiffness.

[0084] With reference to this latter aspect, the variation or transition of density between the groups Gl, G2, G3 of cells 4 of the padding component 3 may occur in discrete zones or continuously along the entire extent of the saddle 1 and / or of the padding component 3.

[0085] In the latter case, the groups Gl, G2 and G3 of cells 4 are joined or interconnected to one another without interruption, i.e., in a gradual and continuous manner along the entire extent of the padding component 3.

[0086] Subject-matter of the present invention is also a method for making a saddle 1 for vehicles, such as bicycles or motorcycles, or at least a part thereof, defining the procedure for applying a covering element 5 to a padding component 3 of a saddle 1 for vehicles, such as bicycles or motorcycles.

[0087] The method according to the present invention comprises a step of providing at least one padding component 3 that defines an external surface 3a configured to be turned, during use, toward a user.

[0088] The step of providing a padding component 3 comprises a step of making, for example by three-dimensional printing, a honeycomb structure that includes a plurality of cells 4.

[0089] The method according to the present invention then comprises the steps of providing a covering element or cover 5 and positioning the covering element 5 on the external surface 3a of the padding component 3, in particular at the third zone or lateral zone Z3.

[0090] The step of applying the at least one covering element 5 onto the padding component 3 thus provides a compression or thermal compression step so as to secure or adhere the at least one covering element 5 on at least part of the external surface 3a of the padding component 3, obtaining the finished saddle 1 and / or its finished padding component 3.

[0091] The compression step may be performed so that the adhesion or constraining of the covering element 5 occurs by means of an element acting as a press (hereinafter referred to as pressure mold or counter-mold 12, 22) and which is actuated by applying pressure from the outside or, preferably, acts by its own weight or gravity on the components to be constrained together.

[0092] The thermal compression step may correspond to the aforementioned compression step, to which is added a step of heating the involved elements.

[0093] In particular, the method according to the invention may thus comprise a step of providing a mold base 11, 21 and a pressure mold or counter-mold 12, 22.

[0094] In particular, the mold base 11, 21 defines a cavity I la, 21a configured to house the padding component 3.

[0095] The cavity I la, 21a preferably has a shape that substantially matches that of the padding component 3. In other words, the padding component 3 is preferably insertable or houseable in a fitted manner inside the cavity 1 la, 21a.

[0096] Subsequently, before or after the step of positioning the covering element 5, a step of positioning the padding component 3 inside the cavity I la, 21a of the mold base 11, 21 is included.

[0097] Furthermore, a step of positioning the pressure mold or counter-mold 12, 22 on the mold base 11, 21 or in any case on the padding component 3 so as to press (for example, by lowering the pressure mold or counter-mold 12, 22 onto the mold base 11, 21 and applying pressure or letting these elements act by weight or gravity) the covering element 5 against the padding component 3 is comprised.

[0098] Subsequently, a step of heating at least the pressure mold or counter-mold 22 (or also the mold base 21) or of heating in an oven the assembly comprising the mold base 11, padding component 3, covering element 5 and pressure mold or counter-mold 12, and waiting for a specific time so as to constrain or adhere the covering element 5 to the padding component 3 may be provided.

[0099] Finally, the method according to the present invention may include a step of extracting from the mold and / or from the oven the padding component 3 with the covering element 5 secured or constrained to the external surface 3a.

[0100] According to the non-limiting embodiment of the method illustrated in figures 5 to 10, before the step of positioning the covering element on the external surface 3a of the padding component 3, there is a step of providing a guide plate 13 comprising at least one shaped pass-through zone TZ for housing the at least one covering element 5, and a step of positioning the guide plate 13 on the mold base 11 with the padding component 3 already positioned in the cavity I la of the mold base 11 so as to delimit at least a portion of the padding component 3, corresponding to the at least one pass-through-zone TZ, on which at least part of the at least one covering element 5 will be positioned.

[0101] If desired, before the step of positioning the covering element 5, a pre- cutting phase of the same can be provided, so as to speed up and facilitate its positioning on the padding component 3. Preferably, the covering element 5 is pre-cut so as to assume a configuration substantially corresponding to the configuration of the at least one shaped pass-through zone TZ.

[0102] The guide plate 13 may comprise a base 13a which may include at least one protruding portion 13b that departs from the base 13a within the shaped pass- through zone TZ to define a portion of a padding component 3 that will not be covered with a covering element or cover 5.

[0103] Preferably, the protruding portion 13b departs within the shaped pass- through zone TZ in a direction from the rear to the front of the guide plate 13 itself.

[0104] Optionally, the shaped pass-through zone TZ can be composed of a first space SI delimited at the rear of the guide plate 13, and a second space S2 formed by a right lateral part and a left lateral part that extend longitudinally and laterally to the protruding portion 13b so as to run alongside it and, if desired, wrap it at a terminal portion proximal to the front of the guide plate 13.

[0105] The first space SI can be configured so as to substantially trace the first zone or rear zone Z 1 of the padding component 3.

[0106] The second space S2, instead, can be configured so as to trace the third area or lateral zone Z3 of the padding component 3.

[0107] As can be understood, the pass-through zone TZ of the guide plate 13 allows the at least one covering element 5 to be correctly positioned on the corresponding area of the external surface 3 a of the padding component 3.

[0108] Similarly, the covering element 5 can also have a configuration substantially corresponding to the second space S2 and / or the first space SI.

[0109] According to this embodiment, the padding component 3 is made of thermoplastic or thermosetting material and / or is made by three-dimensional printing and is positioned in the cavity 1 la of the mold base 11 in a reactive or not fully polymerized state (for example, just removed from the 3D printing bed, after being cleaned of the various debris or 3D printing residues and / or the various supports) so as to facilitate the constraint or adhesion of the covering element 5.

[0110] Preferably, the mold base 11 (as visible, for example, in figure 5) delimits a plurality of through openings TO1 configured to allow the passage of hot air during the heating step in the oven.

[0111] Similarly to the mold base 11, the guide plate 13 and / or the pressure mold or counter-mold 12 also advantageously delimit a plurality of through openings TO3, TO2 configured to allow the passage of hot air during the heating step in the oven, for example a forced convection oven.

[0112] This plurality of through openings TO1, and / or TO2, and / or TO3 allows for uniform polymerization of the padding component 3, for example with evaporation of the solvent present in the material, for example in the resin, which constitutes the padding component 3.

[0113] In this version, the counter-mold 12, by force of weight or gravity, inside the oven, holds the covering element 5 pressed downwards against the padding component 3. Once the oven cycle is completed and therefore the polymerization of the assembly is complete, the padding component 3 on which the covering element 5 has been adhered and / or constrained is removed from the mold and the whole is left to cool.

[0114] According to the non-limiting embodiment of the method illustrated in figures 11 to 15, before the step of positioning the covering element or cover 5 on the external surface 3 a of the padding component 3, a step of applying to the padding component 3, made of already polymerized (and therefore finished) thermosetting or thermoplastic material, a layer of adhesive material configured to promote the constraint or adhesion of the covering element on the padding component 3, may be included. This adhesive material may be, for example, hot melt, if desired a hot-melt glue.

[0115] With reference to the step of applying the possible layer of adhesive material, before such a step a step of sanding at least part of the external surface 3a of the padding component 3 can also be provided as well as a step of applying a preparation layer for gluing or primer. As an alternative to the step of applying the possible adhesive layer, a plasma treatment step could be provided for the external surface 3 a of the padding component 3 before the application of the covering element 5.

[0116] All this is used to prepare the surface of the padding component 3 for the gluing and adhesion and / or constraint step of the covering element 5.

[0117] In this version, the covering element 5 and the padding component 3 are heated and both are coupled manually.

[0118] Finally, the mold of fig. 11 at room temperature presses the padding component 3 and the covering element 5 to bond everything together and / or constrain them to each other.

[0119] In addition or alternatively, the method may comprise a step of providing the covering element 5 with a heat-adhesive layer or surface at the surface of the component 5 itself suitable for contacting the external surface 3a of the padding component 3.

[0120] The method according to this embodiment may provide the step of positioning the padding component 3 at the cavity 21a before or (preferably) after the application of the at least one covering element 5 on the padding component 3.

[0121] Again according to this example, the step of positioning the pressure mold or counter-mold 22 on the mold base 21 or in any case on the padding component 3 so as to press or compress the covering element 5 against the padding component 3 can take place using a press configured to apply pressure on the pressure mold or counter-mold 22.

[0122] Optionally, after the extraction step or after the heating step, a step of waiting or cooling the padding component 3 with the covering element or cover 5 bound or adhered to the external surface 3a is included.

[0123] With particular reference to the non-limiting embodiment of the method illustrated in figures 11 to 15, the optional heating step may serve to activate the adhesive material (or glue) and ensure the necessary bonding or adhesion between the padding component 3 and the covering element 5, and / or the cooling step may take place during the pressing step of the pressure mold or counter-mold 22 on the covering element 5 so as to accelerate the bonding time of the adhesive layer, if present. Alternatively, the padding component 3, after being removed from the mold and / or from the oven, may be transferred to a suitable work surface and cooled to solidify or crystallize the adhesive layer, if present.

[0124] Subject-matter of the present invention is also a mold for making a saddle 1 equipped with a covering element 5 adhered or constrained to a padding component 3 of the saddle 1 itself.

[0125] The mold according to the present invention comprises, as mentioned above, a mold base 11 that defines a cavity I la configured to house a padding component 3.

[0126] Structurally, the mold base 11 may have a plate-like configuration.

[0127] Optionally, the cavity I la may be delimited by a peripheral rim 11b protruding from the main upper surface of the mold base 11.

[0128] Said peripheral rim 1 lb, if present, may define along its length a plurality of recesses or notches 11c, for example spaced evenly from one another. These recesses 11c, if present, improve both the flow of hot air during oven heating and the evaporation of any solvent contained in the material of the padding component 3.

[0129] The mold also comprises a guide plate 13 configured to be positioned on the mold base 11, wherein said guide plate 13 defines at least one shaped pass- through zone TZ for housing a covering element 5, and a pressure mold or counter-mold 12, which defines a pressing portion 14 having a configuration that substantially corresponds to or matches that of the at least one shaped pass- through zone TZ.

[0130] In particular, the pressure mold or counter-mold 12 is movable between an open or rest position and a closed or working position in which it is coupled with the guide plate 13 and the mold base 11 so that, during use of the mold, the pressing portion 14 presses on a covering element 5 positioned at the shaped pass- through zone TZ to facilitate, for example following oven heating, its constraining or adhesion to the padding component 3 positioned in the cavity I la of the mold base 11.

[0131] Preferably, the mold base 11 and / or the pressure mold or counter-mold 12 and / or the guide plate 13 define a plurality of through openings TO1, TO2, TO3 configured to allow the passage of hot air during oven heating of the mold.

[0132] If present, the through openings TO1 in the mold base 11 may, for example, have a circular configuration and, optionally, variable sizes.

[0133] Preferably, the through openings TO1 are distributed over the entire extent of the cavity I la, i.e., not localized only in one area.

[0134] Advantageously, the guide plate 13 comprises a base 13a on which the shaped pass-through zone TZ is defined. The base 13a may also comprise at least one protruding portion 13b extending from the base 13a within the shaped pass- through zone TZ to define a portion of a padding component 3 that will not be covered with a covering element 5.

[0135] Preferably, the protruding portion 13b extends within the shaped pass- through zone TZ from the rear toward the front of the guide plate 13 itself.

[0136] According to the non-limiting embodiment of the mold illustrated in figures 5 to 10, the shaped pass-through zone TZ may consist of a first space SI defined at the rear of the guide plate 13, and a second space S2 formed by a right lateral part and a left lateral part extending longitudinally and laterally alongside the protruding portion 13b, optionally wrapping around it at a terminal portion near the front of the guide plate 13.

[0137] The first space SI may be configured to substantially match the first zone or rear zone Z 1 of the padding component 3.

[0138] The second space S2, on the other hand, may be configured to match the third zone or lateral zone Z3 of the padding component 3.

[0139] According to the embodiment of the mold shown in figures 5 to 10, the through openings TO3 of the guide plate 13, if present, are defined along the protruding portion 13b.

[0140] These through openings TO3 of the guide plate 13 may have, for example, a circular configuration and, optionally, different sizes. Preferably, the through openings TO3 are distributed along the entire length of the protruding portion 13b, i.e., not localized only in one area.

[0141] Optionally, the through openings TO3 arranged along the entire length of the protruding portion 13b may have decreasing diameters or widths from the rear toward the front of the guide plate 13.

[0142] With reference to the pressure mold or counter-mold 12, it may have, for example, a configuration that substantially matches at least part of the perimeter of cavity I la.

[0143] If present, the through openings TO2 of the pressure mold or counter-mold 12 may have, for example, a circular configuration and, optionally, different sizes.

[0144] Advantageously, in the closed or working position of the mold, two, three or more through openings TO3 of the guide plate 13, if present, are aligned with two, three or more through openings TO2 of the pressure mold or counter-mold 12, thereby allowing the passage of hot air during oven heating.

[0145] Preferably, the pressure mold or counter-mold 12 is a shaped element or body that has the pressing portion 14 configured to press the covering element 5, positioned at the shaped pass-through zone TZ or, more specifically, at the second space S2, against the padding component 3.

[0146] With reference to the non-limiting embodiment of the mold illustrated in figures 11 to 15, the mold base 21 has a plate-like configuration.

[0147] Optionally, the cavity 21a of the mold base 21 may define a raised portion 21b configured to facilitate centering of the padding component 3 during its positioning in the cavity 21a.

[0148] Optionally, the raised portion 21b may also assist in centering and / or positioning the covering element 5.

[0149] As for the pressure mold or counter-mold 22 shown in this embodiment in figures 11 to 15, it also has a plate-like configuration.

[0150] The pressure mold or counter-mold 22 may define, on its lower working surface, a cavity 22a that is specular or corresponding to the configuration of the cavity 21a defined on the mold base 21, so as to effectively press on the covering element 5 to constrain or adhere it to the padding component 3 positioned in the cavity 21a of the mold base 21.

[0151] It is specified that, advantageously, when the padding component 3 is positioned in the cavity 21a of the mold base 21, it partially protrudes from said cavity 21 so that, following placement of the pressure mold or counter-mold 22 over it, a clearance is defined between the mold base 21 and the pressure mold or counter-mold 22 to allow the pressure mold or counter-mold 22 to exert a pressing force on the covering element 5.

[0152] The saddle 1 for vehicles, such as bicycles or motorcycles, is capable of providing, during use, improved and / or adjustable grip for the user, thanks to the presence of the covering element 5 on localized portions of the external surface 3a, and / or thanks to the surface texture of the covering element 5 itself.

[0153] Moreover, the presence of the covering element 5 prevents the accumulation of dirt, dust, particles and moisture inside the cells 4 of the padding component 3 made by three-dimensional printing.

[0154] Furthermore, the covering element 5 is also capable of improving user comfort while using the saddle 1.

[0155] The method and mold for applying the covering element 5 to the padding component 3 are easy and quick to use, allowing for precise application and adhesion of the covering element 5, optionally only on specific areas of the padding component 3 of the saddle 1.

[0156] As is clear from the above description, the method and mold foresee, in at least one version of the present invention, that the padding component is produced and / or printed separately, for example in a dedicated mold or using a separate 3D printing machine. In this sense, the method and mold are specifically aimed at achieving the coupling between the covering element 5 and the padding component 3, thus producing a finished padding component 3.

[0157] The finished padding component 3 thus produced may then be ready to be applied and / or constrained to the support component 2. Should the method or mold also provide a constraining step of the support component 2, the present invention will also relate to a method and a mold for manufacturing a (complete) saddle for vehicles.

[0158] It has thus been seen how the invention fully achieves the proposed objects.

[0159] Modifications and variations of the invention are possible within the scope of protection defined by the claims.

Claims

CLAIMS1. Saddle (1) for vehicles, such as bicycles or motorcycles, which defines a rear portion (PP), a front portion (AP) and an intermediate portion (IP) connecting said rear portion (PP) and said front portion (AP), said saddle (1) comprising a support component (2) and at least one padding component (3) fixed to said support component (2), said padding component (3) comprising a honeycomb structure which includes a plurality of cells (4), said padding component (3) defining an external surface (3a) configured to be turned, during use, towards the body of a user, said external surface (3a) delimiting at least a third zone or lateral zone (Z3) extending longitudinally starting from a right lateral part and from a left lateral part of said rear portion (PP) substantially up to said front portion (AP), characterized by the fact that said saddle (1) includes a covering element or cover (5) constrained or adhered at least at said third zone or lateral zone (Z3), wherein said external surface (3a) delimits, in addition to said third zone or lateral zone (Z3) also at least a first zone or rear zone (Zl) defined at said rear portion (PP) and a second zone or central zone (Z2), extending centrally and longitudinally starting from said rear portion (PP) up to said front portion (AP), configured to reduce, during use, the pressure of said saddle (1) on the perineal- ischial area of a user, wherein said third zone or lateral zone (Z3) runs alongside said second zone or central zone (Z2), and / or wherein said zones (Zl, Z2, Z3) are separated by at least one separation cord or section (3b) defined by said padding component (3), and / or wherein said zones (Zl, Z2, Z3) each delimit a respective group (Gl, G2, G3) of cells (4) which have different mechanical or elastic properties between them. wherein said covering element or cover (5) is not placed at said second zone or central zone (Z2).

2. Saddle for vehicles according to claim 1, wherein said covering element or cover (5) comprises or consists of a film or layer made of plastic or thermoplastic material.

3. Saddle for vehicles according to the preceding claim, wherein said plastic material of said film is thermoplastic polyurethane.

4. Saddle for vehicles according to any one of the preceding claims, wherein said padding component (3) is made by means of three-dimensional printing and / or is made of a thermosetting or thermoplastic material.

5. Saddle for vehicles according to the preceding claim, wherein said groups (Gl, G2, G3) of cells (4) are joined or juxtaposed with each other without interruption.

6. Saddle for vehicles according to any one of the preceding claims, wherein each cell of said plurality of cells (4) has a substantially three-dimensional lattice or open cell structure or conformation.

7. Method for making a saddle (1) for vehicles, such as bicycles or motorcycles, wherein said saddle (1) defines a rear portion (PP), a front portion (AP) and an intermediate portion (IP) connecting said rear portion (PP) and said front portion (AP), said saddle (1) comprising the steps of: providing at least one padding component (3), said padding component (3) comprising a honeycomb structure that includes a plurality of cells (4) and defining an external surface (3a) configured to be turned, during use, towards the body of a user, said external surface (3a) delimiting at least a third zone or lateral zone (Z3) extending longitudinally starting from a right lateral part and from a left lateral part of said rear portion (PP) substantially up to said front portion (AP), providing at least one covering element or cover (5), positioning said covering element or cover (5) on at least part of said external surface (3a) of said padding component (3), at least at said third zone or lateral zone (Z3), compressing or thermo-compressing said at least one covering element or cover (5) on said at least part of said external surface (3a), at least at said third zone or lateral zone (Z3), so as to constraint and / or make said at least one covering element or cover (5) adhere to said at least one padding component (3), wherein said method also includes the following steps:providing a mold base (11, 21) and a pressure mold or counter-mold (12, 22), said mold base (11, 21) delimiting a cavity (I la, 21a) configured to house said padding component (3), before or after said step of positioning said covering element or cover (5), positioning said padding component (3) in said cavity (I la, 21a) of said mold base (11, 21), positioning said pressure mold or counter-mold (12, 22) on said mold base (11, 21) so as to push or press said covering element or cover (5) against said padding component (3), thus creating said compression step, and / or extract said padding component (3) with said covering element or cover (5) constrained or adhered to said external surface (3a).

8. Method according to claim 7, comprising a step of heating at least said pressure mold or counter-mold (22) or a step of heating in an oven the assembly comprising mold base (11), padding component (3), covering element or cover (5) and pressure mold or counter-mold (12) and waiting a certain time to carry out said compression or thermo-compression step.

9. Method according to claim 7 o 8, comprising the steps of providing a support component (2) and constraining said at least one padding component (3) to said support component (2).

10. Method according to any one of claims from 7 to 9, comprising the following steps before the step of positioning said covering element or cover (5) on at least part of the external surface (3a) of said padding component (3): providing a guide plate (13) including at least one shaped pass-through zone (TZ) to house said covering element or cover (5), and positioning said guide plate (13) on said mold base (1) with said padding component (3) already positioned in said cavity (I la) of said mold base (11) so as to delimit at least a portion of said padding component (3) corresponding to at least said third zone or lateral zone (Z3) on which at least part of said covering element or cover (5) will be positioned.

11. Method according to any one of claims from 7 to 10, wherein said paddingcomponent (3) is made by means of 3D printing and / or in thermoplastic or thermosetting material and is positioned in said cavity (I la) of said mold base (11) in a reactive or incompletely polymerized state so as to facilitate the constraining or adhesion of said covering element or cover (5).

12. Method according to any one of claims from 7 to 11, wherein said mold base (11) delimits a plurality of through openings (TO1) configured to allow the passage of hot air during the heating step and / or wherein said guide plate (13) and / or said pressure mold or counter-mold (12) delimit a plurality of through openings (TO3, TO2) configured to allow the passage of hot air during the heating step.

13. Method according to claim 7, wherein before the step of positioning said covering element or cover (5) on the external surface (3a) of said padding component (3), at least one of the following steps is provided: applying on at least part of said external surface (3a) of said padding component (3), made of already polymerized thermosetting or thermoplastic material, an adhesive layer configured to promote the constraint or adhesion of said covering element or cover (5) on said padding component (3), sanding at least part of the external surface (3 a) of the padding component (3), applying a constraint preparation layer or primer, carrying out a plasma treatment of the external surface (3a) of the padding component (3).

14. Method according to any one of claims from 7 to 13, wherein after the extracting step or after the heating step there is included a step of waiting and / or cooling said padding component (3) with said covering element or cover (5) constrained or adhered to said external surface (3a).

15. Method according to any one of claims from 7 to 14, wherein said external surface (3a) delimits a first zone or rear zone (Zl) defined at said rear portion (PP), a second zone or central zone (Z2), extending centrally and longitudinally starting from said rear portion (PP) up to said front portion (AP), configured toreduce, during use, the pressure of said saddle (1) on the perineal-ischial area of a user, wherein said third zone or lateral zone (Z3) runs alongside said second zone or central zone (Z2), said plurality of zones (Zl, Z2, Z3) being separated by at least one separation cord or section (3b) defined by said padding component (3), wherein in the step of positioning said covering element or cover (5) on the external surface (3a) of said padding component (3), said covering element or cover (5) is positioned at least at said third zone or lateral zone (Z3) but not at said second zone or central zone (Z2).

16. Mold (30) for making a saddle (1) for vehicles, such as bicycles or motorcycles and / or to apply a covering element or cover (5) to a padding component (3) of a saddle (1) for vehicles, such as bicycles or motorcycles, comprising:- a mold base (11) which delimits a cavity (I la) configured to house a padding component (3),- a guide plate (13) configured to be positioned on said mold base (11) and defining at least one shaped pass-through zone (TZ) for housing a covering element or cover (5),- a pressure mold or counter-mold (12) which defines a pressure portion (14) which has a configuration substantially corresponding to that of said at least one shaped pass-through zone (TZ), wherein said pressure mold or counter-mold (12) is movable between an open or rest position and a closed or working position in which the same is coupled with said guide plate (13) and with said mold base (11) so that, during the use of said mold, said pressure portion (14) presses on a covering element or cover (5) positioned at said shaped pass-through zone (TZ) to facilitate, in use, its constraint or adhesion with a padding component (3) positioned in said cavity (1 la) of said mold base (11).

17. Mold according to the preceding claim, wherein said mold base (11) and / or said pressure mold or counter-mold (12) and / or said guide plate (13) delimit a plurality of through openings (TO1, TO2, TO3) suitable in use to allowthe passage of hot air during a possible heating step of said mold.

18. Mold according to claim 16 or 17, wherein said guide plate (13) includes a base (13a) on which said shaped pass-through zone (TZ) is delimited and at least one protruding portion which departs from said base (13a) within said shaped pass-through zone (TZ) to define in use a portion of a padding component (3) which will not be covered with a covering element or cover (5).

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