阅读说明：本技术 制造鞍座的方法及相关鞍座 (Method for manufacturing a saddle and associated saddle ) 是由 里卡尔多·佩罗托 朱塞佩·比戈林 于 2020-10-16 设计创作，主要内容包括：一种制造包括壳体(14)和衬垫(22)的鞍座(12)的方法,包括以下步骤：(a)将以热塑性聚合物制成的壳体(14)布置在模具(16)内用于注射成型,该模具包括凹模(18)和凸模(20、32)；所述壳体(14)包括支承表面(17)和在使用中面向所述衬垫(22)的支撑表面(15)；所述支承表面(17)耦接至所述凹模(18)或所述凸模(20、32)的内壁,所述支撑表面(15)形成成型腔的壁；(b)使模具(16)闭合；(c)通过在所述壳体(14)上、在所述支撑表面(15)和所述模具(16)之间对热塑性聚合物进行注射成型来制成衬垫(22)。本申请还提供一种由上述方法制造的鞍座(12)。(A method of manufacturing a saddle (12) comprising a shell (14) and a pad (22), comprising the steps of: (a) arranging a shell (14) made of a thermoplastic polymer in a mould (16) for injection moulding, the mould comprising a female mould (18) and a male mould (20, 32); the shell (14) comprising a bearing surface (17) and a support surface (15) facing, in use, the pad (22); -said bearing surface (17) is coupled to the inner wall of said matrix (18) or of said punch (20, 32), said support surface (15) forming the wall of a forming cavity; (b) closing the mould (16); (c) -producing a gasket (22) by injection moulding a thermoplastic polymer on the shell (14) between the support surface (15) and the mould (16). The present application also provides a saddle (12) manufactured by the above method.)

1. Method of manufacturing a saddle (12) comprising a shell (14) and a pad (22), comprising the steps of:

(a) arranging a shell (14) made of a thermoplastic polymer in a mould (16) for injection moulding, the mould comprising a female mould (18) and a male mould (20, 32); the shell (14) comprising a bearing surface (17) and a support surface (15) facing, in use, the pad (22); -said bearing surface (17) is coupled to the inner wall of said matrix (18) or of said punch (20, 32), said support surface (15) forming the wall of a forming cavity;

(b) closing the mould (16);

(c) -producing a gasket (22) by injection moulding a thermoplastic polymer on the shell (14) between the support surface (15) and the mould (16).

2. Saddle (12) in accordance with claim 1, characterised in that the polymer used in step (c) is a thermoplastic elastomer (TPE).

3. Saddle (12) according to any one of the preceding claims, characterised in that the polymer used in step (c) is SBS rubber.

4. Saddle (12) according to any one of the preceding claims, characterised in that said pad (22) is made by co-injection moulding: a coating (28) forming an outer coating of the liner (22) and being in contact with a surface of the shell (14); and an inner core (30) having a reduced hardness.

5. Method for manufacturing a saddle (12) according to the preceding claim, wherein the hardness of said coating (28) is between 5 and 60 Shore A and the hardness of said inner core (30) is between 0 and 5 Shore A, preferably 0 Shore A.

6. Saddle (12) according to any one of the preceding claims, characterised in that said shell (14) is made by injection moulding in a mould (22) comprising said male die (20) and a second female die (24).

7. Saddle (12) manufacturing method according to any one of claims 1 to 5, characterised in that said shell (14) is made by injection moulding in a dedicated mould and is subsequently placed in said mould (16).

8. Saddle (12) according to any one of the preceding claims, characterised in that it comprises the following steps: the housing (14) is manufactured by injection molding during the molding of the frame (26).

9. Saddle (12) according to any one of the preceding claims, characterised in that said shell (14) is made of copolymer polypropylene loaded with glass fibres in a percentage between 5% and 15%, preferably about 10%.

10. A saddle (12) comprising a shell (14) and a pad (22); the shell is made of a thermoplastic polymer, the shell comprising a bearing surface (17) and a support surface (15) facing, in use, the gasket (22) being made of a thermoplastic polymer by direct injection molding onto the support surface (15) of the shell (14).

11. Saddle (12) according to the preceding claim, wherein said shell (14) is made of copolymer polypropylene loaded with glass fibres in a percentage between 5% and 15%, preferably about 10%.

12. Saddle (12) according to any one of claims 10 to 11, wherein said pad (22) is made of a thermoplastic elastomer TPE, preferably SBS rubber.

13. Saddle (12) according to any one of claims 10 to 12, characterized in that said pads comprise: a coating (28) forming an outer coating of the liner (22) and being in contact with a surface of the shell (14); and an inner core (30) having a reduced hardness.

14. Saddle (12) according to the preceding claim, wherein the hardness of said coating (28) is between 5 and 60 Shore A and the hardness of said inner core (30) is between 0 and 5 Shore A, preferably 0 Shore A.

Technical Field

The present invention relates to a method for manufacturing a saddle and to a saddle associated therewith. In particular, the present invention relates to a method of manufacturing a bicycle saddle.

Background

In this discussion, particular reference will be made to bicycle saddles; however, the principle of the invention can be applied in the same way to saddles intended for different uses.

As is known, bicycle saddles essentially comprise a frame, a shell, a liner and an outer coating.

The frame is usually made of metal or composite material, the function of which is to allow the saddle to be attached to the saddle post and to act as a mechanical support for the housing. The shell, made of a plastic material that is both rigid and hard, is the element that gives the saddle rigidity and acts as a support surface for the pad.

A cushion, typically made of polyurethane foam, is included between the shell and the outer coating.

As is known, the method of manufacturing saddles of this type comprises a first step of preparing the coating material inside a mould comprising an inverted surface with respect to the support surface of the saddle.

Once the coating material is positioned, it must be brought into contact with the counter-surface of the mould in a manner as adherent as possible, so that it reproduces in a precise manner the surface of the mould itself. In this connection, it is known to use means suitable for generating a vacuum (with a certain residual pressure) between the surface of the mould and the coating material, so as to cause the latter to adhere to the surface of the mould.

The shell is positioned on the second half of the mould that reproduces, on the opposite side, the lower surface of the shell, so that the inner side of the shell that will face the pad in use is visible.

Subsequently, a liquid foam material (e.g., polyurethane) is poured onto the first half of the mold and thus onto the inside of the coating material.

The mold is then closed and the polyurethane cured. In this case, the polyurethane foam acts as a cushion and at the same time as an adhesive between the shell and the coating material.

The time required to cure the polyurethane foam is about six minutes. Once curing is obtained, the mould can be opened and the saddle can be removed from the mould itself.

In this regard, a generally manual operation may be required to trim the excess edges of the coating material.

Alternatively, the foam pad may be manufactured separately using a method similar to the previous method, and then the various components are secured together using a particular adhesive or glue.

The above-mentioned background, although widely appreciated, still has drawbacks from the point of view of its production and from the point of view of the comfort of the user.

The background art process requires a very long cycle time of at least about six minutes, which is the time required for the polyurethane foam to cure. For this cycle time, it is also necessary to increase the time required for the recovery device to be used for the production of the next saddle.

Furthermore, this method involves multiple interventions by the operator, since most of the steps are managed and performed by a dedicated operator.

Moreover, the use of glues or adhesives to fix the various components to each other has an adverse effect on the environmental impact, both in terms of the use of these substances per se and in terms of the possible recyclability of the various materials used for manufacturing the saddle.

From the point of view of comfort of the saddle, polyurethane is inherently unable to respond to tangential stresses, since the reaction of polyurethane to the stresses applied is a simple compression. It is therefore not particularly suitable for accompanying the user's pelvic/ischial translation in an integral manner during use.

Disclosure of Invention

Accordingly, there is a need to address the shortcomings and limitations mentioned above with reference to the background.

It is therefore desirable to provide a method of manufacturing a saddle which allows a very short cycle time compared to the methods of the background art.

Furthermore, there is a need for a method of manufacturing a saddle which requires limited manual operations by the operator.

Furthermore, there is a need for a process that does not involve the use of glues and adhesives, and thus can be an ecologically sustainable process using fully recyclable materials.

In addition, there is a need for a saddle that is more comfortable than current saddles made of polyurethane foam.

In particular, the saddle more effectively accompanies the user's pelvic/ischial translation in an integrated manner when in use.

Such a requirement is at least partially met by a method of manufacturing a saddle, and a related saddle, according to exemplary embodiments of the present application.

Drawings

Other characteristics and advantages of the invention will become better understood from the following description of a preferred embodiment thereof, given by way of non-limiting example, in which:

figure 1 schematically shows a perspective view of a saddle according to the present invention;

figure 2 schematically shows a rear view of a saddle according to the present invention;

figure 3 schematically shows a perspective view of two parts of a saddle according to the present invention;

figure 4 schematically shows a cross section of the mould and of the saddle portion during a step of the method for manufacturing a saddle according to the present invention;

figure 5 schematically shows a cross section of the mould and of the saddle during a step of the method for manufacturing a saddle according to the present invention;

figure 6 schematically shows a cross section of the mould and of the saddle during a step of the method for manufacturing a saddle according to the present invention; and

figures 7 and 8 schematically show two saddle portions according to two possible embodiments of the invention.

In the following, the same elements or components in the described embodiments will be indicated with the same reference numerals.

Detailed Description

The method of manufacturing a saddle 12 comprising a shell 14 and a pad 22 according to the invention comprises the following steps:

(a) a housing 14 made of a thermoplastic polymer is arranged for injection molding in a mold 16 comprising a female (die) 18 and a male (punch) 20, 32; the shell 14 comprises a support surface 15 and a bearing surface 17, the support surface 15 facing, in use, said gasket 22, the bearing surface 17 being coupled to the inner wall of the punch 20, 32 or the die 18, the support surface 15 forming the wall of the forming cavity.

(b) Closing the mold 16;

(c) the liner 22 is manufactured by injection molding a thermoplastic polymer on the shell 14 between the support surface 15 and the inner surface of the mold 16.

The polymer used in step (c) may be a thermoplastic elastomer TPE.

According to a possible embodiment, the thermoplastic polymer used for the gasket may be SBS rubber (styrene-butadiene-styrene rubber).

According to a possible alternative embodiment, the thermoplastic material used for the gasket may beThermoplastic materials under the name.

According to the first embodiment of the present invention, the gasket has a uniform hardness. For example, the pad 22 may have a hardness between 5 and 60 shore a.

Thus, in other words, the liner 22 may be made of a single thermoplastic polymer, as shown in the example of fig. 8.

According to a possible embodiment, the pad 22 may comprise an outer coating 28 having a hardness of between 5 and 60 shore a, and an inner core 30 having a lower hardness relative to the coating 28.

Advantageously, the hardness of inner core 30 may be between 0 and 5 shore a. Preferably, the hardness of inner core 30 may be around 0 shore a.

In this case, the gasket 22 is made by co-injection molding:

a coating 28 forming an outer coating 28 of the liner 22 and also forming a contact with the surface of the shell 14, an

An inner core 30 having a reduced hardness.

In other words, the liner 22 may be made of the coating 28 and the inner core 30 having a lower hardness.

The thermoplastic polymer used to make the outermost layer of the gasket, in both cases corresponding to a material with a hardness between 5 and 60 shore a, allows the gasket material to be fixed directly to the casing 14 by chemical bonding.

In the case of providing an inner core 30 having a reduced hardness, in particular below 5 shore a, the coating 28 allows to effectively fix the polymer forming the inner core 30. In other words, the thermoplastic polymer with a higher hardness allows fixation to the shell 14, but also to the core 30, and therefore can exploit its mechanical properties.

Furthermore, the coating 28 made of a thermoplastic polymer, in particular SBS rubber with a shore a hardness of 5 to 60, allows to obtain:

wear resistance (e.g., determined by rubbing against the user's clothing),

-impermeability;

surface friction control, which may be varied according to specific requirements, for example by adding additives.

According to a possible embodiment of the invention, the shell 14 is made of a thermoplastic material with a high elastic modulus and a high hardness.

The housing 14 may be made of a thermoplastic material, such as a copolymer polypropylene.

The copolymer propylene used may be of the load (loaded, blended) type. In particular, the copolymer polypropylene may be loaded with a load of a type known per se, such as glass fibres, carbon and/or talc, etc.

Advantageously, the shell may be made of a copolymer polypropylene loaded with a percentage of glass fibres comprised between 5% and 15%, preferably about 10%.

In this case, the copolymer polypropylene loaded with about 10% of glass fibers may have an elastic modulus higher than 2000.

This copolymer polypropylene solution loaded with glass fibres in a percentage of about 10% allows to achieve an optimal anchoring of the thermoplastic elastomer making up the gasket, in particular in the case of SBS materials.

Fig. 4 shows a step of manufacturing the housing 14. According to a possible embodiment, the shell 14 can be manufactured by injection moulding in a mould 22 comprising a male mould 20 and a second female mould 24.

As can be seen in the figures, the male mold 20 may be formed with inserts 202, 204, 206 to form specific undercuts and allow removal of the shell from the mold. This type of device is known per se to the person skilled in the art and will therefore not be discussed further.

In the same way, the conduits for feeding the polymer into the mould cavity are not shown, since they are elements known per se to the person skilled in the art.

Once the shell 14 is made, the mold is opened and the second cavity 24 is replaced with the mold 18 to injection mold the liner 22. This mode is shown, for example, in fig. 5, in which it can be noted that the male mold 20 is identical, while the shape of the female mold 18, now having the inverse shape with respect to the liner 22, has been changed.

On the other hand, in fig. 6, an alternative embodiment is shown in which, once the shell 14 is made, it is removed from the mould 16 and placed in the second male mould 32, following which the second female mould 24 is prepared.

Thus, in this case, the shell 14 is made by injection moulding in a dedicated mould and is subsequently placed in a mould comprising a matrix 24 suitable for making the gasket 22.

From the point of view of the saddle being manufactured, these two methods are substantially equivalent. From a production point of view, the second method allows to divide the forming time on two machines and possibly to further reduce the production time and to create a certain number of frame-casing subset inventories, which are then formed on the other machine.

According to a possible embodiment, the housing 14 can be manufactured by injection molding during the molding of the frame 26.

Fig. 3 shows a possible embodiment of the frame 26. In particular, the frame 26 may include two rods 36, 38, which may be made of metal, thermoplastic material, and/or composite material.

Advantageously, the rod may be made of C40.

As can be seen in fig. 3, the rods 36, 38 may comprise tapered ends, arranged with radial projections, adapted to allow better adhesion to the thermoplastic material of the casing.

The advantages that can be achieved with the method of manufacturing a saddle and with the saddle in accordance with the present invention are therefore evident.

Firstly, the method and the materials used allow to improve the properties of the product, in particular in terms of comfort.

Furthermore, they allow an increase in the ecological sustainability and recycling of the materials used.

The operations required by the operator during the manufacture of the saddle are greatly reduced.

In addition, since the cycle time is significantly reduced, the production cost is significantly reduced.

In this connection, the time required for the cycle of forming the saddle 12, according to the method of the invention, is a very short time, of the order of one minute. The cycle time is therefore significantly lower than the cycle time of about six minutes required in the case of polyurethane gaskets.

Moreover, a method of manufacturing a saddle and a related saddle have been provided which allow to obtain a saddle that is more comfortable with respect to the saddles currently made of polyurethane foam. In particular, the saddle is adapted to accompany, in a unitary manner, the translation of the pelvis/ischia of the user during use.

Furthermore, a method has been provided in which, by modifying some of the additives used in the injection moulding process, it is possible to control the mechanical properties of the outer surface of the saddle without thus significantly modifying the properties of the material of which the inner core of the pad is made.

With regard to the above described embodiments, those skilled in the art will be able to change and/or replace the described elements with equivalent elements in order to meet specific requirements without departing from the scope of the appended claims.