DESCRIPTION

FIELD OF APPLICATION

The present invention concerns a method to make a chamois pad for cycling shorts and the corresponding chamois pad for cycling shorts obtained by means of said method.

BACKGROUND OF THE INVENTION

The chamois pad is an element applied to cycling shorts, comprising a covering, that is, a fabric coupled with a 1 to 5 mm layer of polyurethane foam that comes into contact with the cyclist’s skin and occupies the entire extension surface of the chamois pad, and at least one padding, typically made of a polyurethane foam, having variable thicknesses, disposed in correspondence with the central portion of the covering, to protect the areas of the cyclist’s body in contact with the saddle of the bike.

Therefore the chamois pad is responsible for the comfort and hence the performance of the cyclist while pedaling.

More and more, the design of the chamois pad obviously aims to increase its performance, also paying attention to the smallest details that can negatively affect the cyclist’s comfort.

It is therefore necessary to identify the optimal solution that is able to reconcile the needs of comfort, anatomy, lightness and also production costs.

The current solutions in the state of the art are unable to satisfy these requirements in an optimum manner.

PRESENTATION OF THE INVENTION

There is therefore a need to resolve the disadvantages and limitations mentioned in reference to the state of the art.

This need is satisfied by a method to make a chamois pad for cycling shorts in accordance with claim 1.

DESCRIPTION OF THE DRAWINGS

Other characteristics and the advantages of the present invention will become clearer from the following description of some preferred and non-limiting example embodiments, wherein: fig. la shows a plan view of the lower detail of a stitching and/or gluing template, in accordance with various embodiments of the present invention; fig. lb shows a section view of the lower detail (on which the padding rests) of the stitching and/or gluing template of fig. 4a, along section plane I-I; fig. 2a shows a plan view of the intermediate detail (which clamps the padding) of the stitching and/or gluing template, in accordance with various embodiments of the present invention; fig. 2b shows a section view of the stitching and/or gluing template of fig. 4a, along section plane I-I; fig. 3a shows a plan view of the upper detail of the stitching and/or gluing template in accordance with various embodiments of the present invention; fig. 3b shows a section view of the stitching and/or gluing template of fig. 4a, along section plane I-I; fig. 4a shows a plan view of a stitching and/or gluing template consisting of the details la, 2a, 3a, in accordance with various embodiments of the present invention; fig. 4b shows a section view of the stitching and/or gluing template of fig. 4a, along section plane I-I; fig. 5 shows the enlarged detail V indicated in fig. 4b, with an indication of an attachment tooth for the padding that runs along the entire perimeter of the seating; figs. 6a-6b-6c show perspective views of stitching and/or gluing templates of the present invention, in successive opening/closing steps; figs. 7a, 7b, 7c, 7d show successive steps to make a chamois pad in accordance with a possible embodiment of the present invention, in the event a flat covering is used; figs. 8a, 8b, 8c show details of the steps of inserting paddings into corresponding windows in the manufacturing process shown in figs. 7a-7d; figs. 9a, 9b, 9c, 9d, 9e show perspective views of successive steps of manufacturing the covering of a chamois pad in accordance with another embodiment of the present invention; figs. 10a, 10b, 10c, lOd show steps that follow those shown in figs. 9a, 9b, 9c, 9d respectively, to make a chamois pad in accordance with another possible embodiment of the present invention; figs. I la, l ib, 11c show details of the steps of inserting paddings into corresponding windows in the manufacturing process shown in figs. 10a- lOd; fig. 12a shows a perspective view of a chamois pad of the state of the art, comprising a central seam; fig. 12b shows a perspective view of a chamois pad in accordance with another embodiment of the present invention; figs. 13a, 13b, 13c, 13d, 13e show perspective views of successive steps of manufacturing a chamois pad in accordance with another embodiment of the present invention.

Those elements, or parts of elements, that are common in the embodiments described below are indicated with the same reference numbers.

DETAILED DESCRIPTION

With reference to the drawings above, the number 4 generally indicates an overall schematic view of a chamois pad for cycling shorts according to the present invention.

In particular, the chamois pad 4 for cycling shorts comprises a covering 8 on which at least one pair of paddings 12, 16 is applied. Embodiments comprising several pairs of paddings 12, 16 are possible.

In accordance with one possible embodiment, the covering 8 is made of a fabric coupled with a 1-5 mm layer of polyurethane foam.

The paddings 12, 16, in accordance with one possible embodiment, are in turn made of a polyurethane foam, with thicknesses varying between 4mm and 15mm. In the final configuration, the covering 8 is used to fix the chamois pad 4 to an associable cycling short, not shown.

Furthermore, in the final configuration, the paddings are positioned in correspondence with the ischial and perineal bones of the user, which in turn rest on the saddle of a bicycle.

The paddings are positioned on opposite sides and symmetrical with respect to a center plane M-M of the chamois pad 4.

The method to make a chamois pad in accordance with the present invention comprises the steps of cutting the outline of the covering 8 and cutting the outline of a pair of paddings 12, 16 to be associated with the covering 8.

The paddings 12, 16 can be the same as each other; however, they can also be different from each other: the specific geometry (often dictated by comfort and/or size requirements) has no relevance for the purposes of the present patent application.

The step of cutting the outline of the covering 8 typically occurs by means of punching from a sheet made according to the material and the final layering of the covering.

The step of cutting the outline of the paddings 12, 16 also occurs preferably by means of punching from a sheet made of material corresponding to the paddings to be applied to the covering.

The outline of the covering 8, after being punched from a flat sheet, can possibly be thermoformed. This is a pre-forming operation that consists in giving the covering, at least partly, the saddle-like configuration that the final chamois pad will have to assume.

The saddle-like configuration provides in particular that the chamois pad 4 has a concave back 20 from which two symmetrical lateral portions 24, 28 extend, disposed on opposite sides to the back 20. The lateral portions are intended to support the paddings 12, 16.

The outline of the paddings 12, 16, after being punched from a flat sheet, can possibly be thermoformed. This is a pre-forming operation that consists in giving the paddings, at least partly, the arched configuration that the final chamois pad will have to assume and/or a flattening of the edges to facilitate the subsequent thermoforming of the paddings 12, 16 on the covering 8, as better described below.

Then follows the step of associating the paddings 12, 16 with the covering 8 by means of stitching and/or gluing and/or thermoforming.

The step of associating the paddings 12, 16 with the covering 8 is extremely important and delicate since it determines a reciprocal deformation of the paddings 12, 16 and/or of the covering 8 in such a way as to obtain, during the assembly of the paddings, a chamois pad 4 having the desired final curvature.

The paddings 12, 16 are joined to the covering 8 by means of stitching through a stitching and/or gluing template 32 applied on the covering 8. The stitching and/or gluing template 32 is equipped with a pair of windows 36, 40 able to delimit the area of application of the paddings 12, 16.

In other words, the windows 36, 40 delimit the outlines that the paddings 12, 16 will have after being applied on the covering 8.

Thanks to the presence of the windows 36, 40 of the stitching and/or gluing template 32 it is possible to stably associate the paddings 12, 16 on the covering 8 exactly in the pre-established position, in such a way as to obtain the final desired shape, that is, the final curvature, of the chamois pad during the application of the paddings.

This application, thanks to the stitching and/or gluing template 32, can provide the stitching and/or gluing.

Usually, stitching is preferred, as long as it is of the perimeter type and as long as it does not involve portions of the covering adjacent to the center plane M-M, since in this position the seams would be bothersome and uncomfortable for the user.

In any case, it is also possible to carry out an at least partial gluing of the paddings 12, 16 onto the covering 8, preferably alongside the stitching and not as a total replacement thereof.

According to one embodiment of the present invention, the outline of each of the paddings 12, 16 is different with respect to the corresponding window 36, 40 of the stitching and/or gluing template 32.

This difference can be in terms of shape and/or in terms of overall area or extension.

Preferably, the area of the outline of the paddings 12, 16 can be slightly larger than the area of each corresponding window 36, 40 of the stitching and/or gluing template 32.

For example, the area of the outline of the paddings 12, 16 is up to 10% larger than the area of each corresponding window 36, 40 of the stitching and/or gluing template 32.

Preferably, the paddings 12, 16 are deformed manually in order to be inserted in the respective windows 36, 40 of the stitching and/or gluing template 32.

According to one possible embodiment, a profile or contour of the outline of the paddings 12, 16 has at least one internal concave portion 44, facing the center plane M-M of the associable covering 8, and at least one external convex portion 48, opposite the center plane M-M with respect to the internal concave portion 44.

Preferably, the internal concave portion 44 has a radius of curvature not smaller than 50 mm.

Preferably, the internal concave portion 44 and/or the external convex portion 48 have respective radii of curvature that are smaller than the corresponding arcuate portions of the windows 36, 40 of the stitching and/or gluing template 32.

As mentioned above, the outline of the covering 8 can be flat before the application of the stitching and/or gluing template 32.

The outline of the covering 8 can also be pre-formed, through thermoforming, before the application of the paddings 12, 16.

According to another possible embodiment, the paddings 12, 16 are thermoformed and then applied by thermoforming on the outline of the covering 8: in this way the entire chamois pad 4 is obtained by means of thermoforming, without seams.

In this solution, which provides the integral thermoforming of the chamois pad, it is not necessary to use any stitching and/or gluing template 32.

The covering 8 can be punched from a flat sheet in such a way as to directly have the definitive outline (as described above) or it is possible to punch a covering equipped with corresponding straps 52.

The straps 52 have the function of allowing an easier attachment/fixing of the covering on a specific frame 56 of the corresponding mold 60 for thermoforming. In particular, a frame 56 is provided on which the outline of the covering 8, not yet formed, is fixed.

The frame 56 comprises a plurality of beams 58 which form fixing points for the ends or flaps of the covering 8, in such a way that the latter can be held firmly in position and sufficiently stretched so that it can then be thermoformed. For this purpose, the straps 52 are provided on the edges of the covering: these straps 52, for example in the number of five, allow to stretch the flaps of the covering 8 and to fix them in position on the beams 58 of the frame 56. The number of straps 52 can vary, for example from 2 to 7, as a function of the complexity of the covering. The frame 56, with the corresponding covering 8 applied and fixed thereon, is interposed between the mold 60 and a corresponding counter-mold 64 preformed according to a saddle-like configuration that is to be permanently applied to the covering 8.

After having carried out the thermoforming of the covering 8 it is possible to proceed with the application/fixing of the paddings 12, 16.

In the case of fixing by means of stitching and/or gluing only, the pre-formed covering is extracted from the mold 60, the stitching and/or gluing template 32 is applied and then the paddings 12, 16 are fixed in such a way as to further modify the shape of the covering and therefore of the chamois pad 4.

In the case of fixing by means of thermoforming, the paddings 12, 16 are thermoformed inside the same mold 60 and at the same time the covering 8 is thermoformed. In this case, the mold will preferably provide suitable seatings to accommodate the paddings 12, 16 to be thermoformed.

According to one possible embodiment (fig. 13b), it is possible to modify the counter-mold 64 by providing it with removable lateral blocks 66, typically a right block and a left block, which contain the seatings or windows 36, 40 for the insertion of the paddings in the case of a fully thermoformed chamois pad 4; according to another embodiment, the removable lateral blocks 66 can be smooth, in the case of thermoforming of the covering 8 only.

Fig. 12b shows an embodiment in which the covering 8 is made to pass, previously, over a flat thermoforming mold which forms two lateral wings 70, 72 disposed at approximately 90°; in this embodiment, the covering 8 does not require straps or even a loading/unloading frame because the covering 8 rests on the flat part of the counter-mold 64.

The frame 56 is specially designed in such a way as to allow rapid loading and unloading of the coverings 8 onto the mold 60. In fact, the covering 8 is loaded onto the frame 56 by attaching it in 4/5 points outside the thermoforming press while the machine is working, thanks to the straps 52. The same frame 56 is then loaded into the machine in the next thermoforming cycle after the one with the thermoformed covering has been unloaded. This allows to reduce the amount of time during which the thermoformer is idle at the end of a cycle, because the unloading of the frame 56 with the thermoformed covering 8 and the subsequent loading of the frame 56 with a new covering 8 to be thermoformed is very fast. Furthermore, this prevents the person in charge of the mold from having to attach the covering in 4/5 points inside the thermoformer, which is at 200° C with the risk of getting burned and corresponding waste of time.

As anticipated, after the step of thermoforming the covering 8, the subsequent operation occurs through the stitching and/or gluing template 32 which, according to one embodiment, provides an oblique attachment profile 68, preferably inclined at 45°, along the entire perimeter of the windows 36, 40 intended to accommodate the paddings 12, 16. The attachment profile 68 serves to hold the paddings 12, 16 inside the stitching and/or gluing template 32 which, otherwise, since they have a different geometry/conformation than the corresponding windows 36, 40, would tend to come out. For this purpose, the attachment profile 68 defines an interlocking edge 69 configured in such a way as to house the padding.

At the end of the extraction of the covering 8 from the mold 60, it is possible to proceed with the trimming, that is, the elimination of the straps 56. This operation can occur by positioning the chamois pad (or only the covering) folded in two (figs. 9e, 13e), on which a special punch is rested with a centering on the curvature of the covering 8.

As can be appreciated from what has been described, the present invention allows to overcome the disadvantages outlined in the state of the art.

In particular, the present invention allows to make available a solution that reconciles the requirements of comfort, anatomy, lightness as well as production costs of chamois pads for cycling shorts.

In particular, thanks to the fact that in the step of associating the paddings with the covering there is determined a reciprocal deformation of the paddings and/or of the covering, it is possible to obtain a chamois pad having a final desired curvature that is particularly ergonomic and without seams in the central part (which would be uncomfortable and unsightly for the user).

In this way, it is not necessary to pre-form the covering in a definitive manner in order to then apply the paddings to it, as occurs in the state of the art; instead, the final curvature of the chamois pad occurs only after the paddings have been applied to the covering. The latter can be flat or pre-formed but, in any case, the final or definitive curvature of the covering (and therefore of the chamois pad) is obtained thanks to the application of the paddings suitably pre-formed or shaped in such a way as to have a profile with respect to that of the corresponding stitching and/or gluing template. Thanks to this progressive deformation or pre-forming of the covering, it is possible to give the final product (chamois pad) the desired shape which proves to be particularly anatomical and comfortable for the user.

In order to meet contingent and specific requirements, a person of skill in the art will be able to make numerous modifications and variants of the solutions described above, all of which are in any case included within the scope of the invention as defined by the following claims.