CROSS-REFERENCE TO RELATED APPLICATIONS

[0081] This application is a continuation-in-part of parent application Serial No. 13/624,905 titled "Molded Seat ^' " filed September 22, 2012, the same being incorporated herein by reference and claims priority thereto.

BACKGROUND OF THE INVENTION

FIELD OF THE INVENTION

[0002 j This invention pertains generally to seat bottoms and seat bottom construction, but may have more general applicability to overall seat construction design and techniques. More specifically, the invention pertains to a moided seat bottom which incorporates and has been moided around an insert or inserts shaped in particular ways, having particular characteristics, comprised of particular materials chosen to impart desirable characteristics to the seat, including heating elements, and/or methods and systems for producing seats of this type,

DESCRIPTION OF THE RELATED ART

|0 03| Pofyurethane, produced by combining monomers including isocyanate functional groups and hydroxyl groups, is a known material for forming resilient seating of ali types, including motorcycle seals. The combination process typically requires a catalyst and, for applications similar to those of interest in the instant invention, a mold of some type, in this process, li uid isocyanate and resin are blended at a specific ratio, and the reacting liquid is dispensed into the mold and allowed to cure, then the finished part is demolded. Typically, in high volume manufacturing applications, a dispensing unit is used to combine and dispense the reacting liquid into the mold used in forming the finished piece in a process commonly known as reaction injection molding ("RIM"). J0004] Examples of prior art patents that may be found to have teachings rele vant to the invention are:

(1) U.S. Patent No. 3,787,278 for a "Molded Multiple Density Pol urethane Foam" issued January 22, 1974. to Ready et a!., describing molded, multiple density polyurethane foams and a process for their preparation.

(2) U.S. Patent No. 4,572,856 for a "Composite Molded Article and Process Using Self-Positioning Laminated Stiffener" issued February 25, 1986, to Gembinski, describing a stiffener insert incorporated into a molded composite article such as an automobile dashboard by inserting the stiffener insert between a pre-formed plastisol skin forming opposing mold walls.

However, there is a continuing need for devices providing new and improved features in the field of the invention. Further, there are no prior art devices possessing the unique features and advantages inherent in my invention. SUMMARY OF THE INVENTION

{0005] The instant invention teaches a seat having inserts) or ^* 'mat(s)" incorporated therein intermediate its upper and lower surfaces so as, in most cases, to be generally parallel to the upper surface of the seat (i.e., the surface on which the posterior of the user wiH rest). The primary embodiments of an insert/mat described herein are comprised of material that conforms to the contours of the user's body over a period of time, has certain "rebound" properties (or spring-like performance), and features areas adapted to underlie the perineum and/or ischiums of a user seated on the seat, which areas are softer than the rest of the insert either by virtue of included gap(s) in the insert or by- virtue of a softer material filling said gap(s). In another embodiment of the invention, the msert(s) is/are adapted and shaped to underly, e.g.. the perineum or ischiums of a user and is/are comprised of a softer materia! than the surrounding foam. Other insert embodiments may include heating elements. Materials for use in forming such inserts may include a variety of materials including gei-like materials, gel packets, air packets (which may be made adjustable in terms of pressure), and foams.

{0006J in the preferred embodiments taught herein, the aforesaid inserts are completely encapsulated and enclosed by the foam materials making up the seat with this being advantageously accomplished by molding the seat around the inserts. This is made possible, in accordance with the teachings of the invention, by providing means for suspending inserts within the mold used in forming the scat so as to be in proper spaced relationship to the upper surface of the seat (on which the user will be seated) and the lower surface of the seat (facing away from the seated user) when formed in the mold. Thus, my invention is enabled to provide a more comfortable seat for the user with— even in the most basic embodiments discussed— enhanced abilities to conform to the user's bodv and enhanced springiness, while limiting pressure o the perineum, in addition, the ""integrated or molded in" aspect of the invention maintains the integrity of the exterior foam seat surfaces, in particular the upper surface of the seat/foam, fn this manner, the essential "mechanics" or "workings" of my invention (as provided by said insert(s)) are "hidden" inside the foam making up the seat; protected thereby from wear, weather and the elements; and creating little or no interruption of the top surface in terms of aesthetics or the look/feel of upholstery fit, etc. Further, carefully selecting and designing the properties of the various foams, gels and/or other materials involved, i.e., insert materials, perineal gap materials, ischial gap materials, heating insert materials, and surrounding foam, provides the ability to control the overall suspension effect with zone density control, to better adapt the final composite to the human anatomy and pressures for various applications, and to provide a heated seat with elements hidden from view and protected from wear and weather. f 0007] Thus, as opposed to simply addi ng the same (or a sim ilar) pad on top of the molded ibam (which might be an obvious approach), "embedding" or "in-molding" creates a subtle transition between the generally firm areas of the foam and the softer pressure relief areas, it creates soft spots and/or springy areas deep within the foam. Also, simply adding a foam pad on top (consisting of soft, springy and/or firm sections), would result in too abrupt a transition between areas of varying characteristics and density, as opposed to the more "blended" transitions achieved by the instant invention. Another potential problem that adding a pad on top would create (consisting of presumably bonded oam composite of varying densities), is the potential for delammation of the pad composite due to wear and sheer forces. By molding foam around the pad, all of the above issues are solved, and we have created a foam cushion composite with incredibly strong construction and gentle transitions between areas of firm support and soft areas.

[0008] These goals and others are ail accomplished in an efficient and economical manner using the method 1 have developed for molding the seat around an insert or inserts including and providing the characteristics described.

BRIEF DESCRIPTION OF THE DRAWINGS

{00091 FIG. 1 provides a schematic perspective view of a mold and dispenser for forming an exemplary poly rethane seat in accordance with the teachings of prior art. f00010J FIG. 2 provides a schematic perspective view of a preferred embodiment of a seat insert in accordance with the teachings of my invention.

[00011] FIG. 3 provides a schematic perspective view of the preferred embodiment of a seat insert illustrated in FIG. 2, wherein the perinea! gap therein is filled with an insert which may be comprise, e.g., gel-like materials, gel packets, air packets (which may be made adjustable in terms of pressure), and soft foams or other similar†iller{s). j 00012] FIG. 4 provides a schematic perspective view of the moid and dispenser of FIG. 1 as adapted for placement and support of a seat insert therein by inclusion of appropriately spaced and configured support pegs in accordance with the teachings of my invention.

[00013] FIG. 5 provides a schematic perspective vie of the moid and dispenser including appropriately spaced and configured support pegs as illustrated in FIG. 4 with the seat insert appropriately mounted thereon in accordance with the teachings of my invention.

(0001 1 FIG. 6 provides another schematic perspective view of the mold and dispenser including appropriately spaced and configured support pegs as illustrated in FIG. 4 with the seat insert appropriately mounted thereon in accordance with the teachings of my invention.

(00015 j FIG. 7 provides a schematic perspective view of the moid and dispenser including appropriately spaced and configured support pegs as illustrated in FIG. 4 with another preferred seat insert embodiment appropriately mounted thereon in accordance with the teachings of my invention .

[00016] FIG. 8 provides a schematic cross-sectional perspective view of an exemplary motorcycle seat with integral seat insert of the types previously illustrated included therein, al l formed in accordance with the teachings of my invention.

[00017] FIG. 9 provides a schematic perspective view of the mold and dispenser including appropriately spaced and configured support pegs for and with a perineal insert appropriately mounted thereon in accordance with the teachings of my invention.

(00018] FIG. 10 provides a schematic cross-sectional perspective view of an exempJary motorcycle seat with integral perineal insert formed in accordance with the teachings of my invention.

[00019] FIG. 11 provides a schematic perspective view of an exemplary heating e lement pad/Insert in accordance with the teachings of my invention.

(00020] FIG. 12 provides a schematic perspective view of the mold and dispenser including appropriately spaced and configured support pegs with seat insert and heating element pad/insert appropriately mounted thereon in accordance with the teachings of my invention.

{00021 J FIG. 13 provides a schematic perspective view of the mold and dispenser including appropriately spaced and configured support pegs with seat insert and heating element pad/insert appropriately mounted thereon in accordance with the teachings of my invention, wherein said inserts have appropriately spaced and configured perineum and ischium openings.

[00022] FIG. 14 provides a schematic perspective view of another version of the initial preferred embodiment of a seat insert in accordance with the teachings of my invention, but having both perineal and ischium openings which are filled with gel-tike materials, gel packets, air packets (which may be made adjustable i terms of pressure), and soft foams or other similar filler{s).

[00023] FIG. 15 provides a schematic cross-sectional perspective view of an exemplar motorcycle seat with inserts as iiiustrated in FIG. 14, all fonned in accordance with the teachings of my invention.

{00024} FIG. 16 provides a schematic perspective view of a mold and dispenser including appropriately spaced and configured support pegs for and with a perinea! insert and ischium inserts, all appropriately mounted thereon in accordance with the teachings of my invention.

[00025] FIG. 17 provides a schematic cross-sectional perspective view of an exemplary motorcycle seat with inserts as illustrated in FIG. 16, all formed in accordance with the teachings of my invention. DESCRIPTION

{00026} The process, construction and apparatus used in the instant invention can best be imderstood by careful and ordered review of the above-referenced drawin figures, beginning with FIG. 1, which illustrates a mold i having an upper mold part lA and a lower mold part IB, defining a hollow mold space 1C (in the desired shape of a motorcycle seat in this case) when closed together. (The motorcycle seat shown in the drawing figures provides an example of how the teachings of the invention can be applied in tins context, but should not be seen as limiting the scope of the inventive concept to this particular type of seating). As illustrated, and in accordance with the prior discussion of the reaction injection molding process, a dispensing unit 2 is used to combine and dispense the reacting liquid 30 into the mold 1 used in forming the finished piece, a poiyurethane motorcycle seat (not illustrated), in accordance with the teachings of prior art. Once an appropriate amount of liquid 30 is dispensed into mold space 1C, the mold is closed, and the reacting liquid 30 expands to fully fill the mold space IC, taking the desired form/shape of a motorcycle seat as defined by the shape of moid space IC,

[00027 J With the background previously provided, especially in regard to FIG. 1, the teachings and novelty of FIGS. 2 and 3 can be better appreciated. These drawing figures illustrate an initial preferred embodiment of a seat, insert 10 in accordance with the teachings of my invention. As will be noted, both versions illustrated feature foam dispersion and distribution openings ents ί 1 scattered across their surfaces, mounting peg openings 12, and a perineal opening S 3, with the version of the first embodiment illustrated in FIG. 3 varying from that in FIG. 2 by virtue of the inclusion of a sub- insert/perinea! insert 14 in perineal opening 13 which may be comprised of gel-like materials, gel packets, air packets, and soft foams or other similar tlller(s), such as super- light density foam. ( Where an air packet forms an insert or pad such as perineal insert 14, its pressure may be adjusted by means known in the art by the inclusion of a tube (not shown) leading from the packet to an activatable pump (not shown) or release valve (not shown) which can be used to adjust the pressure/firmness of the insert). Another embodiment is illustrated in FIG. 7, where perineal opening 13 forms a gap completely separating the two halves of seat insert 10. However, possible embodiments are not restricted to those including seat inserts 10. An embodiments using only a perineal insert 14 is illustrated in F GS. 9 and 10, while a still further variation, using only perineal inserts 14 and ischium inserts 1 is illustrated in FIGS. 36 and 17.

[00028 | In the embodiments having larger inserts 10, it is sometimes advantageous to include openings 1 1 so that reacting liquid 30 can freely move through and around the seat inserts 10 so that there are no unfilled gaps left in the molded seat 20. These holes/openings 1 1 may be of varying size, frequency of distribution or not included at all, depending on the flow characteristics and/or requirements of each particular mold/insert/seat. Thus, they are not shown in all illustrations, particularly those where open perineal openings 13 and/or ischium openings 19 provide alternate means of distribution which have been found sufficient by themselves for the aforesaid purpose without the inclusion of openings 1 1. However, the primary purpose of perineal openings 13 and/or ischium openings 19 is to create, include and incorporate a softer area or cushion below the perineum and/or ischiums of the person seated on seat 20.

[00029] Perineum/peri neal openings 13 are provided as the perineum is more sensitive than surrounding areas for many people. By leaving the perineal opening 13 unfilled (as illustrated in FIG. 2), this area wiii be filled with the somewhat softer polyurethane foam making up the remainder of seat 20. Alternately, as illustrated in FIGS. 3, 9 and 10, a sub-insert e ineal insert 14— which may be comprised of gel-like materials, gel packets, air packets (which may be made adjustable in terms of pressure), and soft foams or other similar filler(s), such as super-light density foam-provides an even softer substrate for this same purpose. Thus, in the version of seat insert 10 illustrated in FIG. 2 (and FIG. 7) openings 11 will generally be found to be unnecessary, but in the version of insert 10 illustrated in FIG. 3, they will serve a valuable purpose in allowing the complete and even spreading of reacting liquid 30 so that no gaps remain .

[00030] As will be appreciated from the drawing figures (and in accordance with their anatomical purpose of underlying the perineal regions of a user), perineal opening 13 and perineal inserts 14 are preferably elongate, which shape defines a long axis that will be aligned with the bilateral axis of the user when seated on seat 20, and serve to separate seat 20 and/or mat/insert 10 into two halves, each of which would support, anatomically, respective buttocks/thighs of the user.

[00031] Insert 10 is preferably formed from closed cell foam with characteristics important to the purposes of my invention, though other materials having similar characteristics or other chosen characteristics can be used for this purpose. One such characteristic is "Compression Set", a property that describes the fact that a permanent foam setting or deformation is achieved when a load is place on the seat insert 10 over a period of time. In the instant application this is advantageous because it allows the insert to form itself to the contours of the user's body over a period of time, adapting itself to the particular shape and configuration of the user for added user comfort. Vinyl nitrile foam has been found ideal for these purposes. Another important property of any such insert 10 is "rebound" (or spring-like performance), which is a property of vinyl nitrile foam by virtue of its closed cell construction. The inclusion and incorporation of insert 10 in molded seat 20 results in a final molded foam composite (seat 20) that is enhanced with these added properties derived from insert 10. However, as previously mentioned, other materials may be useful for this purpose, particularly other closed cell foam materials.

{00032} Rev iew of FIGS. 4 through 6 provide insight into the manner in which, and apparatus used, to adapt the mold 1 of FIG. 1 for placement and support of a seat insert 1 therein in a position intermediate upper mold half 1A and lower mold half IB. In this position it will be completely enveloped and surrounded by polyurethane foam as part of the reaction injection molding process previously described and thereby completely encapsulated in, enveloped by, and embedded in, the seat 20 formed thereby. (See, e.g., FIG. 8). T his i accomplished by the inclusion of appropriately spaced and configured support pegs 3 in mold space 1C, preferably via mounting/attachment of said pegs 3 to lower mold part 1 B as illustrated in FIG. 4.

[00033 j As will be noted, pegs 3 can be advantageously formed with a base portion 3A (adapted for insertion i a registering opening provided in mold base portion 3A), support portion 3B (which holds the insert 10 in place within the mold 1 in spaced relationship to the upper moid portion 1 A and lower mold portion I B when the mold 1 i closed), a ledge portion 3C (with a substantially conical shape providing direct support of the insert 30 from below while allowing the seat 20 to be withdrawn— due to its sloped portion— from the mold I when it is formed), a barrel section 3D (dimensioned in terms of diameter and length to fit the width of mounting peg openings 12 and the thickness of insert 10), and a substantially conical head 3E (adapted to push through the somewhat flexible material of insert 10 while holding the insert 10 in place from above). Thus, insert it 10 can be pressed onto the pegs 2 in mold 1 (as illustrated in FIGS. 5 and 6) so as to be positioned adjacent barrel section 3D so as to be held firmly in place between ledg portion 3C and head 3E through the molding process, and both insert 10 and seat 20 can be freed from pegs 3 and pulled out of moid 1 ( .<?., easily de-molded), when the molding process is complete. When removed, as illustrated in FIG. 8, the seat 20 of the invention will feature a completely embedded and encapsulated insert 10 having the features previously described. Similarly, FIGS. 9 and .10 illustrate the aforesaid teachings and techniques as applied to a perineal insert 14, when used without a seat insert 10.

[00034] FIGS. 1 1 through 13 provide further insights into the possibilities of my invention. In this case, illustrating the potential for including a heatable seat insert 16 as well as the previously mentioned ischium openings 1 in seat insert 10 and heatable insert 16. The heatable insert 16 can be made from materials suitable for embedding a heating element/wire 17, and can advantageously be electrically activated by leads 18 connected via a switch to a source of electrical power in accordance with techniques known in the electrical and mechanical arts. The heatable insert 16 is best placed under the seat insert .10 (as illustrated in FIGS. 1.2 and 13), which assists in buffering, spreading and diffusing the heat produced by the heatable in sert 16

[00035] The ischium openings 19 illustrated for both seat insert 10 and heatable insert 16 in FIG. 13 are provided because the ischium bones are primary weight supporting skeletal features for the human body when seated, and adjustment of density and seat response under these bones can greatly increase the comfort of a seat to a user. Thus, the ischium openings 19 can be left open as illustrated in regard to seat insert 10 in FIG. 13, or can accommodate an appropriately sized ischium insert 15 having qualities generally in accordance with those previously discussed with regard to perineal inserts 14 in the perineal opening 13. (See, e.g, FIGS. 14 and 15).

[00036} Alternatively, particularly with regard to the heatable insert 16, the size of the seat ischium openings 19 can be left open, but minimized as illustrated in FIG. 13, to allow for less interruption in the density of heating element/wires 17, and also allow for the same heatable insert 16 to be used in other applications with full heat wire coverage when no ischium opening 19 is desired. This can be done by closing off most of the ischium opening 19 with tabs 19A that can flex and give under the weight of a user (alternatively, it could be said that the opening 1 is comprised of "X" shaped slots that create such tabs 1 A).

{00037] PARTS AND FEATURES ILLUSTRATED IN DRA WING FIGURES:

1 Mold

1 A upper mold part IB lower mold part

2 Dispenser

3 Pegs

3A base portion 3B support portion 3C ledge portion 3D barrel section 3E conical head 10 Seat Insert

11 insert openings

12 Mounting peg openings 33 Perineal opening

14 Perinea! insert

15 ischium insert

16 Heatable insert

37 Embedded heating elements/wires

18 Lead wires for heating element

19 ischium opening

3 A Ischium opening tabs

20 Seat

20A upper surface of seat (molded by lower mold part I B) 20B lower surface of seat (molded by upper mold part I A)

21 Openings left in seat 20 by part 3 B

{00038] In view of the foregoing, it should be clear that numerous changes and variations can be made without exceeding the scope of the inventive concept outlined. Thus, though the preferred embodiment is illustrated in the context of a motorcycle seat, the teachings of the invention are not necessari ly restricted to such seats, indeed, potential applications range from seats for all. kinds of riders (horseback/motorcycle/ATV) to more mundane chairs and seats used in other applications. Further, though the preferred materials comprising the seat are specified, other materials with similar support and/or molding characteristics may certainly be substituted. In addition, though single layer mats/inserts are shown, the inventive concept does not preclude multiple mat/insert layers or furtJher subdivision of the mat insert in tenns of its constituent materials than those shown. Accordingly, it is to be understood that the embodiments) of the in vention herein described is are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiment(s) is not intended to limit the scope of the claims, which will themselves recite those features regarded as essential to the invention.