BICYCLING CUSHION AND METHODS OF MAKING THE SAME

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority under 35 USC § 119(3) to U.S. Provisional Application Serial Nos. 61/841,021, filed June 28, 2013, entitled "Seat Pad for Cyclists," which is incorporated herein by this reference in its entirety.

FIELD OF INVENTION

This disclosure relates to a cushion for a lower body cycling garment, more particularly, to a cushion for a pair of cycling pants. The cushion is configured for interconnecting about the groin area of the cycling pants. More specifically, the cushion is configured for positioning about the buttocks, perineum region, and hypogastric and pubic regions of a person wearing cycling pants containing the cushion.

BACKGROUND OF THE INVENTION

While bicycling, a substantial portion of the bicyclist's body weight is supported by a bicycle saddle, and when peddling the bicycle, portions of the cyclist's body undergo considerable movement relative to the bicycle saddle. Such movement can generate frictional forces between portions of the cyclist's body and one or both of the bicycle saddle and cycling pants or shorts. Furthermore, substantial heat and moisture from perspiration can accumulate about portions of the bicyclist's body supported about the bicycle saddle. The increased popularity of bicycling has resulted in demand for high quality cycling apparel that effectively comforts the bicyclist by eliminating or reducing these sources of irritation experienced by bicyclists during sustained periods of bicycling.

Typically, a cushion is affixed to the inside crotch area of bicyclist shorts/pants. The cushion is designed to provide comfort to the cyclist when seated on the bicycle saddle, and more importantly during peddling or cycling for extended periods of time. However, cushions affixed to the bicycle saddle or to the inside or outside of the bicyclist's pants are typically bulky and can accumulate moisture and heat about the portions of a cyclist's body in contact with, or adjacent to, the cushion. Accordingly, such cushions can actually exacerbate the bicyclist's discomfort during use. Thus, there is a need for an effective and comfortable cushion for bicyclist pants. SUMMARY OF THE INVENTION

These and other needs are addressed by the various embodiments and configurations of the cushions of the present disclosure.

In one aspect, this disclosure provides a cushion for a bicycling garment, the cushion including a sheet comprising a sheet thickness and a sheet bulk modulus and at least one void, at least one support insert positioned in the at least one void in the sheet, the at least one support insert comprising a support insert thickness and a support insert bulk modulus, wherein the support insert bulk modulus is greater than the sheet bulk modulus, and wherein the support insert thickness is greater than the sheet thickness.

In one or more embodiments the sheet comprises a foam or a gel. Similarly, in one or more embodiments the at least one insert comprises a foam or a gel. In certain embodiments, the sheet and the at least one insert consist of an open cell foam.

In one or more embodiments, the support insert bulk modulus is between about 1% and about 15% greater than the sheet bulk modulus. In one or more embodiments the support insert thickness and the sheet thickness differ by no more than about 5%.

In certain embodiments, the sheet comprises two arm elements joined to one stem element with the two arm elements extending from a common end of the stem element, and configured to generally resemble the letter "Y". In one or more of these embodiments, each of the two arm elements and the one stem element comprises a void having at least one support insert positioned in the void. In certain embodiments, the support inserts comprise a reticulated foam. In certain embodiments, the support insert thicknesses and the sheet thickness differ by no more than about 2%. In certain embodiments, the arm element bulk modulus is between about 1% and about 25% greater than the sheet bulk modulus. Certain embodiments further comprise opposing body-facing and garment-facing sheets positioned on opposing sides of the sheet comprising the at least one support insert.

In one or more embodiments, the body-facing and garment-facing sheets are elastomeric. In certain embodiments, the body-facing sheet comprises a textile layer comprising at least one of a woven or a knit textile. In certain embodiments, the body- facing sheet further comprises a body-facing sheet foam layer adhered to one side of the body-facing sheet. In certain embodiments, the body-facing sheet foam layer has a thickness between about 0.04mm and about 2.0mm. similarly, in certain embodiments the garment-facing sheet has a thickness between about 0.05 and about 0.5 mm.

In one or more embodiments, the body-facing sheet is adhered to the garment- facing sheet by at least one of adhesive bonding, stitching, and welding. In one or more embodiments, the cushion is adhered to both of the garment-facing and body-facing sheets.

In certain embodiments, the combined thickness of the body-facing sheet foam layer, body-facing sheet textile layer, and garment-facing sheet is between about 0.8mm and about 2.8mm. Similarly, in certain embodiments a thickness of a center region of the stem element is between about 5.0mm and about 9.0 mm, and a thickness of a peripheral portion of the stem element is between about 0.5mm to about 3.0 mm.

Similarly, in certain embodiments, a thickness of a center region of the stem element is between about 5.0mm and about 9.0 mm, and a thickness of a portion of the cushion located between the two stem elements is between about 1.5 and about 2.5 mm.

In another aspect, this disclosure provides a bicycle garment containing a cushion, including a pair of pants containing a sheet comprising a sheet comprising a sheet thickness and a sheet bulk modulus and at least one void, at least one support insert positioned in the at least one void in the sheet, the at least one support insert comprising a support insert thickness and a support insert bulk modulus, wherein the support insert bulk modulus is greater than the sheet bulk modulus and, wherein the support insert thickness is greater than the sheet thickness.

In another aspect, this disclosure provides a process for making a bicyclist seat cushion, including, providing a sheet with one or more void(s) and, positioning a support insert in each of the one or more voids of the sheet.

The preceding is a simplified summary of the invention to provide an

understanding of some aspects of the invention. This summary is neither an extensive nor exhaustive overview of the invention and its various embodiments. It is intended neither to identify key or critical elements of the invention nor to delineate the scope of the invention but to present selected concepts of the invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below. BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present invention(s). These drawings, together with the description, explain the principles of the invention(s). The drawings simply illustrate preferred and alternative examples of how the invention(s) can be made and used and are not to be construed as limiting the invention(s) to only the illustrated and described examples.

Fig. 1 depicts a cyclist positioned on a bicycle;

Fig. 2A depicts a male pelvis;

Figs. 2B and 2C depict a female pelvis;

Fig. 3 depicts a cushion according to the present disclosure;

Figs, 4 and 5 depict side elevation views of a cushion according to the present disclosure;

Fig. 6 depicts a top elevation view of a cushion according to the present disclosure;

Fig. depicts a bottom elevation view of a cushion according to the present disclosure;

Fig. 8 depicts a front elevation view of a cushion according to the present disclosure;

Fig. 9 depicts a rear elevation view of a cushion according to the present disclosure;

Fig. 10 depicts an exploded view of a cushion according to the present invention;

Figs. 11A and 11B depict cross-sectional view according to Figs. 6 and 7;

Figs. 12A and 12B depict cross-sectional views according to Figs. 6 and 7;

Fig. 13A depicts the contour pattern of the ridge and groove design of a prior art seat cushion s marketed by SUGOI™;

Fig. 13B depicts the contour pattern of the ridge and groove design of a prior art seat cushion s marketed by CATELLI™;

Fig. 14 A depicts the contour pattern of the ridge and groove design of a prior art seat cushion s marketed by PEARL IZUMI™;

Fig. 14B depicts the contour pattern of the ridge and groove design of another prior art seat cushion marketed by PEARL IZUMI™; Fig. 15 is a chart showing the decreased moisture retention of a cushion of the present invention compared to seat cushions of the prior art;

Fig 16 is a chart showing the decreased heat retention of a cushion of the present invention compared to seat cushions of the prior art;

Fig. 17 depicts a process for making a bicyclist seat cushion assembly according to the present disclosure;

Fig. 18 depicts a process for making a cushion according to the present disclosure; and,

Fig. 19 depicts a process for making a lower body cycling garment according the present disclosure.

DETAILED DESCRPTION OF THE INVENTION

The present invention is drawn to cushions that effectively reduce a cyclist's discomfort in sitting on a bicycle saddle and bicycling. The cushions of this disclosure substantially reduce the interference with peddling a bicycle or accumulation of moisture experienced with many prior art cushions.

With reference to Fig. 1, when seated on a bicycle 103, a substantial portion of a cyclist's 101 mass is supported by bicycle saddle 102, which results in pressure exerted about the cyclist's perineum and ramus of ischium 105 and ischial tuberosity 106 portions of the cyclist's pelvis 104 (further illustrated in Figs. 2A-2C). A cyclist can wear a lower body garment 10 (Fig. 3) containing a cushion 20 fixed about the crotch area of the lower body garment 10. The cushion 20 is configured to reduce pressure about one or more of the perineum and the ramus of ischium 105 and ischial tuberosity 106 of the buttock's area. The lower body garment 10 can be a cycling short, bib, or speedsuit.

Figs. 4-9 depict top plan (Fig. 6), bottom plan (Fig. 7), front perspective (Fig. 8), rear perspective (Fig. 9) and side (Figs. 4-5) views of cushion 20. The cushion 20 is configured to conform to the three-dimensional geometry of one or more of a cyclist's hypogastric, pubic regions, perineum, and buttocks, when the cushion 20 is located in a garment worn by a bicyclist when the bicyclist is positioned on a bicycle seat. The perineum area can extend from coccyx 109 to one or both of the hypogastric and pubic regions. As is shown in Figs. 4, 5 and 7, the cushion 20 has a longitudinal direction (x- direction), lateral direction (y-direction) and a vertical direction (z-direction).

The cushion 20 has opposing body-facing 10 and garment-facing 9 sides. The body-facing side 10 generally has a convex-shaped surface. The garment-facing side 9 generally has a concave-shaped surface. As depicted in Figs. 4, 5, 8 and 9, together, the body-facing 10 and garment-facing 9 sides generally resemble an arch. The cushion 20 is generally shaped with the garment-facing side 9 adapted to drape over a top surface 92 of a bicycle saddle 102. In certain embodiments, the cushion 20 is shaped to conform to and drape over the top surface 92 of a road racing bicycle saddle 102. By having the cushion 20 generally shaped to conform and/or drape over the top surface 92 of the bicycle saddle 102, one or both of abrasion and chaffing of at least one of the user's buttocks, perineum, and thighs while bicycling are substantially reduced.

Referring to Fig. 6, in one embodiment, the cushion 20 has arm elements 63 extending from stem element 60. The arm elements 63 are joined to first distal stem end 61 of the stem element 60. The cushion 20 generally has two arm elements 63. Moreover, the cushion 20 is shaped to generally resembling the letter "Y."

The arm elements 63 are disposed on opposing sides of longitudinal axis 31. The two arm elements 63 are configured to substantially align with a portion of the buttocks of a bicyclist sitting on the cushion 20. Specifically, the arm elements 63 are configured to align with the ramus of ischium 105 and ischial tuberosity 106 portions of the user's pelvis 104. Together, the arm elements 63 form a body-facing arm surface 64 (Fig. 4). The body-facing arm surface 64 typically has a convex shape. It will be appreciated that the arm elements 63 may be configured differently for males and females, as the ramus of ischium 105 and ischial tuberosity 106 portions of the pelvis differ for men and women. More particularly, the pubic symphysis arch is wider in females 13 (Fig. 2B) than males 12 (Fig. 2A). Due to the wider pubic symphysis arch in females, females generally have the ramus of ischium and ischial tuberosities separated by a greater distance than males. Moreover, the distribution and density of nerves and blood vessels differ in males and females about the pubic symphysis, ramus of ischium, and ischial tuberosity.

The first distal stem end 61 is positioned between second distal stem end 62 and the arm elements 63. The stem element 60 is configured to substantially align with the perineum of a bicyclist sitting on the cushion 20. The stem element 60 has a body-facing stem surface 65 (Figs. 11A and 11B). The body-facing stem surface 65 can have a convex shape. Similar to the arm elements, it will be appreciated that the stem element 60 is configured differently for males and females, as the perineum of men and women differ. Due to the wider pubic symposia arch in females than males, females generally have the ramus of ischium and ischial tuberosities separated by a greater distance than males. Moreover, the distribution and density of nerves and blood vessels differ in males and females about the pubic symphysis, ramus of ischium, ischial tuberosity and perineum.

The arm elements 63 and stem element 60 are configured for positioning about a user's buttocks, perineum, and thighs. The one or both of the body-facing arm surface 64 and body-facing surface 65 (Figs. 11A and 11B) are substantially free of ridges, troughs, channels, voids, apertures, pimples, or the like, which could contribute to abrasion and chaffing of one or more of the user's buttocks, perineum, and thighs. It will be appreciated that one or both of the body-facing surface 64 and body-facing stem surface 65 may be positioned differently for male and female user's to reduce and/or eliminate abrasion and chaffing of one or more of the user's buttocks, perineum, and thighs.

As depicted in Fig. 6, the second distal stem end 62 is configured to substantially align with one or both of the hypogastric and pubic regions of a user sitting on the cushion 20. The body-facing arm surface 64 and body-facing stem surface 65 are oriented on the body-facing side 10 of the cushion 20. It can be appreciated that the second distal stem 62, body-facing arm surface 64 and body-facing stem surface 65 are configured differently for males and females, as the pubic regions of men and women differ.

Cushion 20 generally comprises a pad assembly 110 positioned between a body- facing sheet 150 and a garment-facing sheet 140 (see Figs. 10, 11A, 11B, 12A and 12B). One or both of the body-facing 150 and garment-facing 140 sheets can be elastomeric. It is believed that the elastomeric nature of one or both of the body-facing 150 and garment-facing 140 sheets can substantially reduce one or both of abrasion and chaffing of one or more of the user's buttocks, perineum, and thighs.

The pad assembly 110 can comprise one or more sheet(s) 120, which may comprise a gel or foam material. In some embodiments, the gel or foam material may have one or both of open cell and reticulated structures. In one or more embodiments, the sheet 120 comprises an open cell foam. In certain embodiments, the sheet 120 consists of an open cell foam. The pad assembly components have a bulk modulus (K), which can be formally defined by the equation:

K=-V(dP/dV)

where P is pressure, V is volume, and dP/dV denotes the derivative of pressure with respect to volume. Equivalently,

l<= p (dP/d p)

where p is density and dP/dp denotes the derivative of pressure with respect to density. The inverse of the bulk modulus gives a component's compressibility, and therefore, the pad assembly components also have a compressibility value. These values (bulk modulus and compressibility) can be measured using methods well known in the art, including, for example, powder diffraction under applied pressure and specified temperature.

Other moduli describe the material's response (strain) to other kinds of stress: the shear modulus describes the response to shear, and Young's modulus describes the response to linear stress. For a fluid, only the bulk modulus is meaningful.

The sheet 120 can have one or more voids 125. The sheet 120 can have any number of voids 125. Typically, the sheet 120 has from one to seven voids 125, more typically from one to five voids, and even more typically from one to three voids.

In some configurations, the sheet 120 has a single void 125. The single void 125 can be configured such that when the single void 125 is positioned adjacent to the user of the bicycling garment containing the pad assembly, the single void 125 is positioned about the user's perineum area and about one or both of the ramus of ischium 105 and ischial tuberosity 106 of the user's buttocks area.

In some configurations, the sheet 120 has two voids 125. One or both of the two voids 125 can be configured such that when the two voids 125 are positioned adjacent to the user of the bicycling garment containing the pad assembly, one of the two voids 125 is positioned about the user's perineum area and the other of the two voids 125 is positioned about one or both of the ramus of ischium 105 and ischial tuberosity 106 of the user's buttocks area.

In some configurations, the sheet 120 has three voids 125. The three voids 125 can be configured such that when the three voids 125 are positioned adjacent to a user of the bicycling garment containing the pad assembly, some of the three voids 125 are positioned about the user's perineum area and the other of the three voids 125 are positioned about one or both of the ramus of ischium 105 and ischial tuberosity 106 of the user's buttocks area. In some configurations, one of the three voids 125 is positioned about the user's perineum area and the remainder of the voids 125 are positioned about one or both of the ramus of ischium 105 and ischial tuberosity 106 of the user's buttock area.

A support insert 130 can be positioned in each of the one or more voids 125. The support insert 130 can be a gel or foam material. The gel or foam material of the support insert 130 can be the same as, or different from the gel and/or foam material of the pad assembly 110 and/or sheet 120. The support insert 130 can comprise one or both of open cell and reticulated structures. In one or more embodiments, the support insert 130 comprises an open cell foam. In certain embodiments, the support insert 130 consists of an open cell foam.

The sheet 120 and each of the support inserts 130 can have substantially the same thickness. It is believed that when the support inserts 130 and the sheet 120 have substantially the same thickness, one or both of pressure points and raised edges of cushion 20 are substantially reduced and/or eliminated. The substantial reduction and/or elimination of one or both of pressure points and edges can substantially reduce one or both of abrasion and chaffing of one or more of the user's buttocks, perineum, and thighs while the cushion is in use by a bicyclist.

Commonly, the thicknesses of the support insert 130 and the sheet 120 differ by no more than about 15%, or by no more than about 13%, or differ by no more than about 12%, or differ by no more than about 11%, or differ by no more than about 10%, or differ by no more than about 9%, or differ by no more than about 8%, or differ by no more than about 7%, or differ by no more than about 6%, or differ by no more than about 5%, or differ by no more than about 4%, or differ by no more than about 3%, or differ by no more than about 2%, or differ by no more than about 1%.

The sheet 120 and each of the support inserts 130 can have different bulk modulus. It is believed that when the support inserts 130 have a bulk modulus greater than the bulk modulus of the sheet 120, pressure points of cushion 20 are substantially reduced and/or eliminated. The substantial reduction and/or elimination of pressure points can substantially reduce one or both of abrasion and chaffing of one or more of the user's buttocks, perineum, and thighs while the cushion is in use by a bicyclist.

Commonly, the bulk modulus of the support insert 130 is greater than the bulk modulus of the sheet 120 by about 15%, or by about 13%, or by about 12%, or by about 11%, or by about 10%, or by about 9%, or by about 8%, or by about 7%, or by about 6%, or by about 5%, or by about 4%, or by about 3%, or by about 2%, or by about 1%.

The sheet 120 and each of the support inserts 130 can also have different compressibility. It is believed that when the support inserts 130 have a compressibility that is less than the compressibility of the sheet 120, pressure points of cushion 20 are substantially reduced and/or eliminated and as noted above, the substantial reduction and/or elimination of pressure points can substantially reduce one or both of abrasion and chaffing of one or more of the user's buttocks, perineum, and thighs while the cushion is in use by a bicyclist.

Commonly, the compressibility of the support insert 130 is less than the compressibility of the sheet 120 by about 15%, or by about 13%, or by about 12%, or by about 11%, or by about 10%, or by about 9%, or by about 8%, or by about 7%, or by about 6%, or by about 5%, or by about 4%, or by about 3%, or by about 2%, or by about 1%.

Referring to Figure 10, the sheet 120 can have one or more arm elements 111 joined to at least one stem element 112. As depicted in Figure 10, the sheet 120 typically has two arm elements 111 joined to one stem element 112. The arm elements 111 correspond to the arm elements 63 of cushion 20. The stem element 112 corresponds to stem element 60 of cushion 20. Each of the arm elements 111 generally has a shape resembling an ellipse. The stem element 112 also typically has an elliptical shape. In some configurations, the stem element has a generally "tear-drop" shape. Moreover, the sheet 120 can have a shape generally resembling the letter "Y" with the two arm elements 111 extending from a common end of the stem element 112. It can be appreciated that the pad assembly 110 typically resembles the shape of the sheet 120.

Accordingly, the pad assembly 110 has a shape generally resembling the letter "Y" with the two arm elements (111 and 63) extending from the stem element (112 and 60).

The stem element 112 and each of the two arm elements 111 of the sheet 120 can contain one or more voids 125. Each of the arm elements can contain an arm void 125a and the stem element 112 can contain a stem void 125s. Each of the arm element voids 125a contains an arm element support insert 130a. The arm element support inserts 130a typically comprise a reticulated foam. The sheet 120 and each of the arm element support inserts 130a can have substantially equal thicknesses. It is believed that when the sheet 120 and each of the arm element support inserts 130a have substantially equal thicknesses, one or both of pressure points and raised edges of cushion 20 are substantially reduced or eliminated. The substantial reduction and/or elimination of one or both of pressure points and edges in the cushion 20 can substantially reduce one or both of abrasion and chaffing of one or more of the user's buttocks, perineum, and thighs. More particularly, it is believed that the substantial reduction and/or elimination of one or both of pressure points and edges about the two arm elements 63 of cushion 20 can substantially reduce one or both of abrasion and chaffing about the user's buttocks. Furthermore, it is believed that the substantial reduction and/or elimination of one or both of pressure points and edges about the two arm elements 63 of cushion 20 can substantially reduce pressure about one or both of the ramus of ischium 105 and ischial tuberosity 106 of a user of the cushion while bicycling. The reduction of pressure about the ischium 105 and ischial tuberosity 160 can substantially reduce pressure on one or both of the blood vessels and nerves about ramus of ischium 105 and ischial tuberosity 106 portions of the user's buttock and/or pelvic region during bicycling. In particular for a user, the reduction of pressure about the ischium 105 and ischial tuberosity 160 can substantially reduce pressure on one or both of the blood vessels and nerves about the ramus of ischium 105 and ischial tuberosity 106 portions of a user's buttock and/or pelvic region.

Commonly, the thicknesses of the arm element support inserts 130a and the sheet 120 differ by no more than about 15%, or no more than about 13%, or no more than about 12%, or no more than about 11%, or no more than about 10%, or no more than about 9%, or no more than about 8%, or no more than about 7%, or no more than about 6%, or no more than about 5%, or no more than about 4%, or no more than about 3%, or no more than about 2%, or no more than about 1%.

The stem void 125s can contain a stem element support insert 130s. The stem element support insert 130s typically comprises a reticulate foam. The sheet 120 and the stem element support insert 130s can have substantially equal thicknesses. It is believed that when the sheet 120 and each of the stem element support insert 130s have substantially equal thickness, one or both of pressure points and raised edges of cushion 20 are substantially reduced or eliminated. The substantial reduction and/or elimination of one or both of pressure points and edges in cushion 20 can substantially reduce one or both of abrasion and chaffing of one or more of the user's buttocks, perineum, and thighs, while bicycling. More particularly, it is believed that the substantial reduction and/or elimination of one or both of pressure points and edges about the stem element 60 of the cushion 20 can substantially reduce one or both of abrasion and chaffing about the user's perineum, while bicycling. Furthermore, it is believed that the substantial reduction and/or elimination of one or both of pressure points and edges about the stem element 60 of cushion 20 can substantially reduce pressure about one or both of perineum blood vessels and perineum nerves of the user. In particular, for a user, the reduction in pressure about the perineum can substantially reduce pressure on one or both of the blood vessels and nerves of a user's perineum.

Commonly, the thicknesses of the stem element support insert 130s and the sheet 120 differ by no more than about 15%, by no more than about 13%, by no more than about 12%, by no more than about 11%, by no more than about 10%, by no more than about 9%, by no more than about 8%, by no more than about 7%, by no more than about 6%, by no more than about 5%, by no more than about 4%, by no more than about 3%, by no more than about 2%, or by no more than about 1%.

The support insert 130 has support insert bulk modulus and sheet 120 has sheet bulk modulus. The support insert bulk modulus can be about equal to, greater than, or less than the bulk modulus of the sheet 120. In some configurations, the support insert 120 has a bulk modulus greater than bulk modulus of the sheet 120. In other

configuration, at least one of the support inserts 120 has a bulk modulus greater than the bulk modulus of the sheet 120 and the remainder of the support inserts 120 have a bulk modulus no greater than the bulk modulus of the sheet 120. It is believed that when the support insert bulk modulus is greater than the sheet bulk modulus, pressure points can be substantially reduced about one or both of the user's buttocks and perineum, during use of the support insert while in use by a bicyclist.

Moreover, the stem element support insert 130s and arm element support inserts

130a, respectively, have a stem element bulk modulus value and an arm element bulk modulus value. The arm element bulk modulus value can be about equal to, greater than, or less than the stem element bulk modulus value. In some configurations, the arm element bulk modulus value is greater than the stem element bulk modulus value. In other configurations, the arm element bulk modulus value is substantially equal to the stem element bulk modulus value. The arm element bulk modulus value, in some configurations, is no greater than the stem element bulk modulus value. Moreover, the arm element bulk modulus can be greater than the bulk modulus of one or both of the sheet 120 and stem element support insert 130s bulk moduli further reducing pressure about one or both of the user's buttocks and perineum. It is believed that the reduction in pressure about the perineum can substantially reduce pressure on one or both of the blood vessels and nerves of a user's perineum. Furthermore, the reduction in pressure about one or both of the ramus of ischium 105 and ischial tuberosity 106 portions of a user can substantially reduce pressure on one or both of the blood vessels and nerves about ramus of ischium 105 and ischial tuberosity 106 portions of a user's buttocks and/or pelvic region.

Generally, the arm element bulk modulus value is greater than the bulk modulus values of one or both of the sheet 120 and stem element support insert 130s. More generally, the arm element bulk modulus is no more than about 1% greater than the sheet 120 bulk modulus, no more than about 2.5% greater, no more than about 5% greater, no more than about 7.5% greater, no more than about 10% greater, no more than about 15% greater, no more than about 25% greater, no more than about 50% greater, no more than about 100% greater, no more than about 200% greater, or no more than about 500% greater than the sheet 120 bulk modulus value. Thus, in one or more embodiments, the arm element bulk modulus value is between about 1% and about 200% greater than the bulk modulus values of one or both of the sheet 120 and stem element support insert 130s.

Typically, the arm element bulk modulus is no more than about 1% greater than the stem element support insert 130s bulk modulus, no more than about 2.5% greater, no more than about 5% greater, no more than about 7.5% greater, no more than about 10% greater, no more than about 15% greater, no more than about 25% greater, no more than about 50% greater, no more than about 100% greater, no more than about 200% greater, or no more than about 500% greater than the stem element support insert 130s bulk modulus.

In some configurations, the stem element support insert 130s has a bulk modulus value greater than the bulk modulus value of the sheet 120. Commonly, the stem element bulk modulus value is no more than about 1% greater than the stem element support insert 130s bulk modulus, no more than about 2.5% greater, no more than about 5% greater, no more than about 7.5% greater, no more than about 10% greater, no more than about 15% greater, no more than about 25% greater, no more than about 50% greater, no more than about 100% greater, no more than about 200% greater, no more than about 500% greater than the bulk modulus value of the sheet 120.

In some configurations, the support insert bulk modulus can be substantially less than the sheet bulk modulus. That is, the sheet 120 can be firmer, or less compressible, than the support inserts 130. It is believed that when the sheet bulk modulus value is greater than the support insert bulk modulus value, pressure points on cushion 20 can be substantially reduced about one or both of the user's buttocks and perineum while in use during bicycling. It is believed that this reduction in pressure about the perineum can substantially reduce pressure on one or both of the blood vessels and nerves of a user's perineum. Furthermore, the reduction in pressure about one or both of the ramus of ischium 105 and ischial tuberosity 106 portions of a user can substantially reduce pressure on one or both of the blood vessels and nerves about the ramus of ischium 105 and ischial tuberosity 106 portions of a user's buttock and/or pelvic region.

However, the support inserts 130 and the sheet 120 can have, in some configurations, substantially the same bulk modulus values. That is, the support inserts 130 and sheet 120 can have substantially the same compressibility.

The body-facing sheet 150 can have elastomeric properties in one or both of the x and y directions. The body-facing sheet 150 can be elongated commonly to more than about 25% of its pre-elongated length, or to more than about 100%, or to more than about 150%, or to more than about 200% of its pre-elongated length. Furthermore, the elastomeric body-facing sheet 150 has a recovery level after being elongated from about 50% of its pre-elongation length, typically of more than about 95%, or more than about 98%, or more than about 99%. As used herein, recovery indicates the percent of the fabric's shape retained after a 12 mm sample is stretched to a 50% elongation at 508 mm per minute after 3 cycles.

Generally, the body-facing sheet 150 has a recovery level of greater than about 97% after being elongated by more than about 50% of its pre-elongation length. The elastomeric properties and recovery level of the body-facing sheet 150 can substantially reduce one or both of abrasion and chaffing of the cushion 20 about one or more of the user's buttocks, perineum, and thighs while in use during bicycling.

The body-facing sheet 150 can comprise a body-facing sheet textile layer 152. The body-facing sheet textile layer 152 can be one of a woven or knit textile. The body- facing sheet textile layer 152 can comprise one of polyester, nylon, elastane (such as, but not limited to LYCRA™ from Invista or DORLASTAN™ from Bayer), and blends thereof. The body-facing sheet textile layer 152 generally has a thickness from about 0.05 to about 0.2 mm, or about 0.08 to about 0.12 mm, or about 0.09 to about 0.11 mm.

The body-facing sheet 150 can optionally include a body-facing sheet foam layer 153. The body-facing sheet foam layer 153 is generally adhered to the body-facing sheet textile layer 152. Moreover, the body-facing sheet foam layer 153 can comprise one or both of open-cell and reticulated foams. The body-facing sheet foam layer 153 generally has a foam layer thickness of no more than about 3 mm, no more than about 2 mm, no more than about 1 mm, no more than about 0.5 mm, no more than about 0.2 mm. The foam layer thickness is typically from about 0.04mm to about 2.0 mm, or about 0.5 to about 1.5 mm, or about 0.8 to about 1.1 mm, or about 0.08 to about 1.0 mm. The body- facing sheet 150 is positioned on the pad assembly 110. Generally, some of the body- facing sheet layer 153 is in contact with the pad assembly 110.

The garment-facing sheet 140 can be one of a woven or knit textile material. The garment-facing sheet 140 can comprise one of polyester, nylon, elastane (such as, but not limited to LYCRA™ from Invista or DORLASTAN™ from Bayer), and blends thereof. Moreover, the garment-facing sheet 140 has elastomeric properties in the x and y directions. The garment-facing sheet 140 can be elongated commonly to more than about 25% of its pre-elongated length, or to more than about 100%, or to more than about 150%, or to more than about 200% of its pre-elongated length. Furthermore, the garment-facing sheet 140 has a recovery level, after being elongated from about 50% to about 200% of its pre-elongation length, typically more than about 95%, or more than about 98%, or more than about 99% recovery. Generally, the garment-facing sheet 140 has a recovery level of greater than about 97% after being elongated by more than about 50% of its pre-elongation length. The stretch and recovery level of the garment-facing sheet 140 sheet can substantially reduce one or both of abrasion and chaffing of one or more of the user's buttocks, perineum, and thighs while in use during bicycling.

The garment-facing sheet 140 generally has a thickness of from about 0.05 to about 0.5 mm, or from about 0.1 to about 0.4 mm, or from about 0.15 to about 0.35 mm, or from about 0.2 to about 0.3 mm.

The garment-facing sheet 140 can have a garment-facing sheet plane shape substantially resembling the plane shape of the pad assembly 110. The garment-facing sheet has a garment-facing sheet perimeter 149 and the pad assembly 110 has a pad assembly perimeter 119. Generally, the garment-facing sheet perimeter 149 is greater than the pad assembly perimeter 119.

In some configurations, the garment-facing sheet perimeter 149 is offset from the pad assembly perimeter 119 by margin 115. Typically, the margin 115 is no more than about 3.0 cm, or no more than about 2.5 cm, or no more than about 2.25 cm, or no more than about 2.0 cm, or no more than about 1.75 cm, or no more than about 1.5 cm, or no more than about 1.25 cm, or no more than about 1.0 cm, or no more than about 0.75 cm, or no more than about 0.5 cm, or no more than about 0.25 cm.

The body-facing sheet 150 generally has a plane shape resembling the plane shapes of the pad assembly 110 and garment-facing sheet 140. However, the body- facing sheet 150 plane shape can differ from one or both of the plane shape of pad assembly 110 and garment-facing sheet 140. The body-facing sheet 150 can have a body-facing sheet head 154. The body-facing head 154 can extend beyond the portion of the body-facing sheet corresponding to the stem element 112.

Furthermore, the body-facing sheet 150 can have opposing body-facing sheet stem wings 155. The opposing body-facing sheet stem wings 155 can extend about a portion of the body-facing sheet corresponding to stem element opposing sides 114. Moreover, the body-facing sheet 150 can have buttocks wings 156. The buttocks wings 156 can extend beyond a portion of the body-facing sheet 150 corresponding to arm elements distal ends 116. The body-facing sheet 150 can be adhered to one or both of the garment-facing sheet 140 and pad assembly 110. The body-facing sheet 150 can be adhered to garment- facing sheet 140 by one of adhesive bonding, stitching, welding, or a combination thereof. Moreover, the body-facing sheet 150 can be adhered to garment-facing sheet 140 by one of adhesive bonding, welding, or a combination thereof.

Furthermore, the pad assembly 110 can be adhered to one or both of the garment-facing 140 and body-facing 150 sheets. The pad assembly 110 can be adhered to the garment-facing sheet 140 by one or both of adhesive bonding and welding. Similarly, the pad assembly 110 can be adhered to the body-facing sheet 150 by one or both of adhesive bonding or welding.

A feature of the cushion 20 resides in its low profile. The low profile of cushion 20 substantially decreases the bulkiness of the cushion 20. The decreased bulkiness can substantially reduce, or eliminate, the obstruction or impediment to the movement of the user while bicycling that is generally associated with the prior art cushions.

Furthermore, it is believed that the low profile of cushion 20 can substantially reduce or eliminate pressure points, raised edges, or both, which can substantially reduce abrasion and/or chaffing of one or more of the user's buttocks, perineum, and thighs while bicycling. In particular, the low profile can substantially reduce pressure on one or both of the blood vessels and nerves of a user's perineum.

Typically, the cushion 20 has a thickness of no more than about 10 mm, or no more than about 9 mm, or no more than about 8 mm, or no more than about 7 mm, or no more than about 6 mm, or no more typically no more than about 5 mm. Thus, the thickness of the cushion can be in the range between about 4mm and about 15mm.

Generally, the combined thickness of the body-facing sheet foam layer 153, body- facing sheet textile layer 152 and garment-facing sheet 140 is no more than about 2 mm, or no more than about 1.8 mm, or no more than about 1.6, or no more than about 1.4 mm, or no more than about 1.2, or no more than about 1.0 mm.

Commonly, the combined thickness of the body-facing sheet foam layer 153, body-facing sheet textile layer 152 and garment-facing sheet 140 is from about 0.5 to about 3.0 mm, more commonly from about 0.8 to about 2.8mm, more commonly from about 1.0 to about 2.7 mm, or more commonly from about 1.5 to about 2.5 mm.

Generally, the combined thickness of the elastomer body-facing sheet 150, the pad assembly 110, and the elastomeric garment-facing sheet 140 is from about 5.0 to about 9.0 mm, or from about 3.0 to 8.0 mm, or from about 4.5 to about 7.0 mm, or from about 4.0 to about 6.0 mm, or from about 3.0 to about 6.0 mm, or from about 2.0 to about 6.0 mm.

Another feature of the cushion 20 resides in its low stem element profile about stem element 60. Figs. 11A and 11B depict a cross sectional views of stem element 60 of cushion 20 about line 11A-B of Figs. 6 and 7. Line 11A-B bisects the stem element 60 of cushion 20. The low profile of the stem element 60 reduces or eliminates the bulk, moisture accumulation and heat generally associated with the prior art cycling cushions. Furthermore, it is believed that the low stem element profile can substantially reduce or eliminate pressure points or raised edges, which can substantially reduce abrasion and/or chaffing of the user's perineum and thighs. In particular, the low medial profile can substantially reduce pressure on the perineum blood vessels and perineum nerves of a user of the cushion 20. More particularly, the low medial profile can substantially reduce pressure on the perineum blood vessels and perineum nerves of a user of cushion 20.

Referring to Fig. 11, the stem element profile typically has three stem element thicknesses: stem medial thickness 163; first lateral stem thickness 162; and second lateral stem thickness 161. In some configurations, the first lateral thickness 163 and medial thickness 162 are substantially equal.

The second lateral stem thickness 161 comprises the body-facing sheet 150 and garment-facing sheet 140, Commonly, the first lateral stem thickness 161 is from about 0.5 to about 3.0 mm, or from about 0.8 to about 2.8mm, or from about 1.0 to about 2.7 mm, or from about 1.5 to about 2.5 mm.

The second lateral stem thickness 162 comprises the body-facing sheet 150, the sheet 120, and the garment-facing sheet 140. Typically, the second lateral stem thickness 162 is from about 5.0 to about 9.0 mm, or from about 6.0 to 8.8 mm, or from about 7.0 to about 8.6 mm, or from about 7.5 to about 8.5 mm, or from about 8.0 mm.

The medial thickness 163 comprises the body-facing sheet 150, the stem element support insert 130s, and the garment-facing sheet 140. Typically, the medial thickness 163 is from about 5.0 to about 9.0 mm, or from about 3.0 to 8.0 mm, or from about 4.5 to about 7.0 mm, or from about 4.0 to about 6.0 mm, or from about 3.0 to about 6.0 mm, or from about 2.0 to about 6.0 mm.

Yet another feature of the cushion 20 resides in its low lateral profile about arm elements 63. Figs. 12A and 12B depict cross-sectional views about line 12A-B of Figs. 6 and 7. Line 12A-B bisects the arm element 63 of cushion 20. The low profile of the arm elements 63 reduces or eliminates the bulk, moisture accumulation and heat generally associated with the prior art bicycling seat cushions. Furthermore, it is believed that the low arm element profile can substantially reduce or eliminate pressure points, raised edges, or both, which can reduce abrasion and/or chaffing of the user's buttocks. In particular, the low medial profile can substantially reduce pressure about the ramus of ischium 105 and ischial tuberosity 106 of a user of the cushion 20. More particularly, the low medial profile can substantially reduce pressure about one or both of the ramus of ischium 105 and ischial tuberosity 106 of a user of the cushion 20 by substantially reducing pressure on one or both of the blood vessels and nerves about the ramus of ischium 105 and ischial tuberosity 106 of a user's buttock and/or pelvic region.

Referring to Fig. 12A and 12B, the arm element profile generally has three arm element thicknesses: arm medial thickness 173; first lateral arm thickness 172; and second lateral arm thickness 171. In some configurations, the first lateral arm thickness 173 and medial arm thickness 172 are substantially equal.

The second lateral arm thickness 171 comprises the body-facing sheet 150 and garment-facing sheet 140. Commonly, the first lateral arm thickness 171 is from about 0.5 to about 3.0 mm, or from about 0.5 to about 3.0 mm, or from about 0.8 to about 2.8, or from about 1.0 to about 2.7 mm, or still from about 1.5 to about 2.5 mm.

The second lateral arm thickness 172 comprises the body-facing sheet 150, the arm element support inserts 130s, and the garment-facing sheet 140. Typically, the second lateral arm thickness 172 is from about 5.0 to about 9.0 mm, or from about 6.0 to 8.8 mm, or from about 7.0 to about 8.6 mm, or from about 7.5 to about 8.5 mm, or more typically about 8.0 mm.

The medial arm thickness 173 comprises the body-facing sheet 150, the pad assembly 110, and the support sheet 120. Typically, the medial arm thickness 173 is from about 0.5 to about 3.0 mm, or from about 0.8 to about 2.8mm, or from about 1.0 to about 2.7 mm, or from about 1.5 to about 2.5 mm. The low profile of cushion of the invention substantially reduces heat and moisture retention. More specifically, the low profile of cushion reduces the build-up of moisture in cushion about the regions of the user in contact with the cushion. In particular, the build-up of moisture is reduced about the perineum and the ramus ischium and ischial tuberosity of a user of the cushion while bicycling.

Four bicycle seat cushions of the prior art and a cushion of the present disclosure were subjected to comparison testing that included 30 minutes of peddling a bicycle under controlled conditions while wearing garments containing the different cushions. The moisture content of the seat cushions was determined after approximately 30 minutes of peddling. Fig. 15 is a chart showing the decreased moisture retention of a low profile cushion of the present invention (Fig. 15, "Present Invention") compared to seat cushions of the prior art (Fig. 15, "Prior Art" A-D). The seat cushions of the prior art retained from about 36% to about 14% moisture, compared to the water retention of a low profile cushion 20 of the present disclosure, which was about 11%. It will be appreciated that increased moisture content is generally associated with increased discomfort, abrasion and chaffing about the perineum, thighs, and buttocks of the user. The prior art seat cushions A-D have substantial steep edges and/or grooves. The ridge and groove design of the are shown in prior art seat cushions A-D are shown in Figs. 13A, 13B, 14A, and 14B, respectively. The steep ridge and deep groove designs of the prior art cushions are believed to contribute to increased moisture content and resulting discomfort reported by user's of these prior art seat cushions.

Fig. 16 is a chart showing the decreased heat retention of the low profile cushion 20 of the present disclosure (labeled "Present Invention" in Fig. 16) compared to seat cushions of the prior art (labeled "Prior Art" A-D) after approximately 30 minutes of peddling a bicycle under controlled conditions. The seat cushions of the prior art retained a greater amount of heat, measured as seat cushion surface temperature. The seat cushions of the prior art had surface temperature from about 30.8 to about 34.2 degrees Celsius compared to a surface temperature of about 30.6 degrees Celsius for a low profile cushion of the present disclosure. It will be appreciated that increased surface temperature is generally associated with increased discomfort, abrasion and chaffing about the perineum, thighs, and buttocks of a user. The seat cushions A-D of the prior art have substantial steep edges and/or thickness which are believed to contribute to increased heat content content and resulting discomfort reported by user's of the prior art seat cushions.

Figs. 17 and 18 depict processes 40 and 50 for making pad assembly 110 and cushion 20, respectively.

Process 40 comprises a method for making a pad assembly of the present disclosure comprising a support pad positioned in one or more voids of sheet. In step 42, a sheet is provided. The sheet can be provided with or without one or more void(s).

Optional step 44 comprises forming one or more voids in the sheet provided in step 42.

The voids may be made by any process known to those of ordinary skill in the art. Non- limiting examples of suitable processes for forming the one or more voids in the sheet include hot wire cutting, air knife cutting, die cutting, laser cutting, arc cutting, and hot die cutting to name a few.

In step 46, a support insert is positioned in each of the one or more voids of the sheet. The pad assembly is formed by the positioning of a support insert in each of the one or more voids of the sheet.

Step 46 can comprise a single step. That is, the support inserts can be positioned in the one or more voids substantially simultaneously. It can be appreciated that some, but not all of the support inserts can be positioned in some, but not all, of the one or more voids substantially simultaneously.

Alternatively , step 46 can comprise a series of steps carried out sequentially.

That is, support inserts can be positioned in each of the one or more voids sequentially.

The sequential positioning of the support inserts in the one or more voids can be carried out in any order.

Further, step 46 can comprise series of steps with some steps being conducted substantially simultaneously and others sequentially. For example, arm element support inserts can be positioned in the one or more voids substantially simultaneously. For example, with specific reference to Fig. 10, arm element support inserts 130a and stem element support insert 130s can be, respectively, positioned in voids 125a and 125s sequentially. It can be appreciated that the sequential positioning of arm and stem elements in voids 125 can be conducted in any order.

The support inserts 130 can be positioned in each of the one or more voids 125 by any method known to those of skill in the art. While not wanting to be limited by example, the support inserts 130 can be positioned in each void by a transfer sheet process, a mechanical process, a manual process, a robotic process, or a combination thereof. In some configurations, the positioning of the support insert in each void can include adhering the support insert to the sheet.

Process 50 comprises a method for making a cushion of the present disclosure.

The cushion produced by process 50 comprises a pad assembly positioned between a body-facing sheet and a garment-facing sheet. By this process, the body-facing and garment-facing sheets are adhered to one another.

In step 51, a pad assembly is provided, the pad assembly having opposing first and second pad assembly surfaces.

In step 53, a body-facing sheet and garment-facing sheet are provided. Step 53 can comprise a single step or additional sub-steps in preparing and providing the body- facing sheet and/or garment-facing sheet. For example, step 53 can include the single step of providing the body-facing sheet and garment-facing sheet at about the same time. Alternatively, step 53 can include providing the body-facing sheet and garment- facing sheet sequentially. In this instance, the body-facing sheet can be provided before or after the garment-facing sheet. For example, the body-facing sheet can be provided before the garment-facing sheet, or the body-facing sheet can be provided after the garment-facing sheet.

In step 55, one or both of the body-facing sheet and the garment-facing sheet are positioned adjacent to the pad assembly. The body-facing sheet is positioned adjacent to the first pad assembly surface and the garment-facing sheet is positioned adjacent to the second pad assembly surface. The positioning of the garment-facing sheet, and/or the body-facing sheet about the pad assembly may be conducted sequentially or about simultaneously. For example, step 55 can comprise sequential sub-steps of positing one of the body-facing and garment-facing sheets adjacent to the pad assembly before the other of the body-facing and garment-facing sheets. Step 55 can comprise positioning the body-facing sheet adjacent to the first pad assembly surface before or after positioning the garment-facing sheet adjacent to the second pad assembly surface. For example, in some configurations, the body-facing sheet can be positioned adjacent to the first pad assembly surface before the garment-facing sheet is positioned adjacent to the second pad assembly surface. While, in some configurations, the body-facing sheet can be positioned adjacent to the first pad assembly surface after the garment-facing sheet is positioned adjacent to the second pad assembly surface.

In step 57, the body-facing sheet and the garment-facing sheet are adhered together. The body-facing and garment-facing sheets can be adhered together by any methods known to one of ordinary skill in the art. For example, the body-facing and garment-facing sheets can be adhered together by one or more of an adhesive, thermal fusion bond, radio frequency bond, electro-bond, weld, or combinations thereof.

Similarly, step 57 can comprise adhering the body-facing sheet to the first pad assembly surface, which may also include, for example, one or more of an adhesive, thermal fusion bond, radio frequency bond, electro-bond, weld, or combinations thereof.

Step 57 can comprise a second sub-step of adhering the garment-facing sheet to the second pad assembly surface. The garment-facing sheet and the second pad assembly surface can be adhered together by methods known to one of ordinary skill in the art. While not wanting to be limited by example, the garment-facing sheet and the second pad assembly surface sheets can be adhered together by one or more of an adhesive, thermal fusion bond, radio frequency bond, electro-bond, weld, or a combination thereof. Step 57 can be conducted at about the same time as step 55 or step 55. Alternatively, in some configurations steps 53, 55 and 57 can be conducted sequentially.

Process 70 comprises a method for making a cycling garment comprising a cushion positioned about the crotch area of the garment. The garment may be cycling shorts, cycling pants, a cycling bib, a single-piece time-trial or speed suit, or the like. In process 70, the cushion is permanently interconnected to a crotch area of the cycling garment.

In step 72, a cushion is provided, and in step 74, the cycling garment is provided.

In step 76, the cushion is positioned in the crotch area of the garment. A garment-facing sheet on the cushion is positioned adjacent to the garment. A body- facing sheet is positioned in a crotch area of the garment such that the body-facing sheet is positioned adjacent to the crotch of a user of the garment.

In step 78, the cushion is permanently attached to the crotch area of the lower body garment. The cushion can be interconnected to the crotch area of the lower body garment by stitching. In some configurations, one or more of an adhesive, thermal fusion bond, radio frequency bond, electro-bond, weld, or combinations thereof, interconnects the cushion to the crotch area of the garment.

One of skill in the art will recognize that a number of variations and modifications of the disclosure can be used. For example, it would be possible to provide for some features of the disclosure without providing others.

The foregoing discussion of the disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the

embodiments, configurations, or aspects of the disclosure may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claims requires more features than are expressly recited in each claim. Rather, as the following claims reflect, aspects lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the presently herein disclosed.