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Title:
SPORT APPAREL SEAT PAD AND METHODS OF MAKING THE SAME
Document Type and Number:
WIPO Patent Application WO/2016/149459
Kind Code:
A1
Abstract:
A method of making a sport apparel seat pad including die cutting a laminated top face sheet and a laminated pad portion, skiving the pad portion to achieve a desired contour, and affixing the pad portion to the top face sheet. The sport apparel seat pads may be used as a cycling chamois and for similar applications.

Inventors:
BARBER THEODORE W (US)
FURFARO DEMIS (IT)
Application Number:
PCT/US2016/022785
Publication Date:
September 22, 2016
Filing Date:
March 17, 2016
Export Citation:
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Assignee:
DASHAMERICA INC D/B/A PEARL IZUMI USA INC (US)
International Classes:
A41D1/084; A41D13/015; A41D13/05; A41D27/00; A41D27/26; A41D27/28
Foreign References:
EP0643929A11995-03-22
US6093468A2000-07-25
US20050223478A12005-10-13
US20070174953A12007-08-02
US20080229488A12008-09-25
Attorney, Agent or Firm:
BOSCHERT, Tyler, J. (1560 BroadwaySuite 120, Denver CO, US)
Download PDF:
Claims:
What is claimed is:

1. A method of making a sport apparel seat pad, comprising:

laminating together a first fabric and a first foam to form a top face sheet;

laminating together a second fabric and one or more layers of a second foam to form at least one pad portion;

die cutting each of the top face sheet and the at least one pad portion;

skiving the at least one pad portion to achieve a desired contour; and

affixing the at least one pad portion to the top face sheet to form the sport apparel seat pad.

2. The method of claim 1, wherein the first foam is perforated.

3. The method of claim 1, wherein at least one of the layers of the second foam is perforated.

4. The method of claim 1, wherein the at least one pad portion is affixed to the top face sheet by being sewn around at least a part of a circumference of the pad portion.

5. The method of claim 4, wherein the at least one pad portion is affixed to the top face sheet by being sewn around the entire circumference of the pad portion.

6. The method of claim 1, wherein the sport apparel seat pad comprises at least two pad portions.

7. The method of claim 1, further comprising disposing the sport apparel seat pad within a cycling garment as a cycling chamois.

8. A sport apparel seat pad, comprising:

a laminated, die cut top face sheet having a first fabric and a first foam; and at least one laminated, die cut, skived pad portion, affixed to the top face sheet, having a second fabric and one or more layers of a second foam.

9. The sport apparel seat pad of claim 8, wherein the first foam is perforated.

10. The sport apparel seat pad of claim 8, wherein at least one of the layers of the second foam is perforated.

11. The sport apparel seat pad of claim 8, wherein the at least one pad portion is sewn to the top face sheet around at least a part of a circumference of the pad portion.

12. The sport apparel seat pad of claim 11, wherein the at least one pad portion is sewn to the top face sheet around the entire circumference of the pad portion.

13. The sport apparel seat pad of claim 8, further comprising at least a second pad portion.

14. The sport apparel seat pad of claim 8, wherein the sport apparel seat pad is adapted to be disposed within a cycling garment as a cycling chamois.

15. A method of making a sport apparel seat pad, comprising:

skiving a laminated, die cut pad portion comprising a fabric and one or more layers of a foam to achieve a desired contour; and

affixing the pad portion to a laminated, die cut top face sheet.

16. The method of claim 15, wherein at least one of the layers of the foam is perforated.

17. The method of claim 15, wherein the pad portion is affixed to the top face sheet by being sewn around at least a part of a circumference of the pad portion.

18. The method of claim 17, wherein the pad portion is affixed to the top face sheet by being sewn around the entire circumference of the pad portion.

19. The method of claim 15, wherein the sport apparel seat pad comprises at least two pad portions.

20. The method of claim 15, further comprising disposing the sport apparel seat pad within a cycling garment as a cycling chamois.

Description:
SPORT APPAREL SEAT PAD AND METHODS OF MAKING THE SAME

FIELD OF THE INVENTION

This disclosure relates to a seat pad, apparatus for distributing a user's weight while cycling, and methods of making the same.

DESCRIPTION OF THE RELATED ART

When riding bicycles, motorcycles, etc., a large proportion of a rider's body weight is supported on the rider's pelvis and perineum. Properly designed and manufactured padding can distribute this force such that the associated pressure is distributed to the pelvis and correct tissue of the perineum. This padding can also prevent chronic damage of nerves and blood vessels caused by pressure, vibration, and impacts. Recent improvements in pad design provide reduction of sitting pressure by distributing loads across the pelvis, absorbing road vibration and shock, and moving with the rider to prevent friction and abrasion.

One commonly used method for manufacturing seat pads uses heated compression molds to raise the temperature of fabrics, adhesives, and foamed polymers to permanently deform and bond them. While this method produces the correct shapes, it also reduces the fabric elongation, causes an increase in the foam polymer density, and necessitates the addition of extra layers of fabric.

Another commonly used production method uses machines to cut 3D contours in polymer foams. This method has the advantage of being extremely rapid, on the order of thirty seconds per seat pad. This process can be mostly automated, and requires very little human labor. However, when utilized over the entire area of the pad, this process generates large volumes of waste material that must be removed. Generally, manufacturers have no use for this scrap material and must dispose of it in a way that generates no value.

A third commonly used production method uses automated sewing machines to secure die cut foam pad portions to a top sheet. The foam pad portions do not have 3D contouring, and although the pad portions may have a constant thickness prior to sewing, the sewing thread compresses the edge of the foam, resulting in areas of higher density near the edge of the pad portion. These areas of higher density near the edge of the pad are undesirable because less effective padding and weight distribution are provided thereby, and such areas can cause discomfort for the user. The lack of contouring and the variation in the density of the foam result in areas that may cause restriction or loss of circulation and/or nerve damage. These methods are commonly used by makers of high-end cycling chamois.

Various methods have been designed in an attempt to balance desirable material properties, economy of resources, pad shape and contour, and uniformity of pad thickness. U.S. Pat. No. 6,565,702 to Forsyth et al. ("Forsyth '702"), the entirety of which is hereby incorporated by reference, discloses a method of making a chamois for cycling pants wherein the chamois can be formed into a single unit by the use of a bonding agent, and/or by the application of heat and pressure that operates to fuse the various pieces of the chamois together into a single unit. In particular, Forsyth '702 discloses that a unitary chamois can be formed of the various members by providing a heat-melting plastic ribbon that extends along the edges or borders of the various members, such that the use of a heat press operates to melt the plastic ribbon and form a unitary chamois from the various chamois members. Further, Forsyth '702 discloses that the application of heat and pressure to the chamois can operate to form the chamois into a three-dimensional shape that generally matches the pelvic girdle of a male or a female.

U.S. Pat. No. 6,687,917 to Forsyth et al. ("Forsyth '917"), the entirety of which is hereby incorporated by reference, discloses a method of making a chamois for cycling pants wherein the chamois can be formed into a single unit by the use of a bonding agent, and/or by the application of heat and pressure that operates to fuse the various pieces of the chamois together into a single unit. In particular, Forsyth '917 discloses that a unitary chamois can be formed of the various members by providing a heat-melting plastic ribbon that extends along the edges or borders of the various members, such that the use of a heat press operates to melt the plastic ribbon and form a unitary chamois from the various chamois members. Further, Forsyth '917 discloses that the application of heat and pressure to the chamois can operate to form the chamois into a three-dimensional shape that generally matches the pelvic girdle of a male or a female.

U.S. Pat. Pub. No. 2005/0066423 to Hogan ("Hogan"), the entirety of which is hereby incorporated by reference, discloses a method of making a chamois for bicycle shorts in which various layers of the chamois are sewn together. Top and bottom layers are sewn together and surround or envelop a padded layer. The padded layer is not sewn or adhered to the top layer or the bottom layer. In this way, the padded layer moves, to the extent possible, independently from, and within an envelope formed by, the top and bottom layers. The chamois is attached to the bicycle shorts using stitching that fastens the envelope to the shorts. Hence, the padded layer is not fastened to the chamois or the bicycle shorts.

U.S. Pat. No. 4,961,233 to Black ("Black"), the entirety of which is hereby incorporated by reference, discloses cycling pants having a chamois made of a laminate of a synthetic leather-like material ("Ultrasuede") and a knitted polyester fleece. The Ultrasuede and polyester fleece are bonded in web form by a suitable adhesive. The laminate is heat-formed to a body-conforming shape by holding a sheet cut from the laminate along its edges in a suitable tenter frame, heating the sheet to a temperature above its softening but below the melting point, and, while it is hot, molding it between molding dies having shapes conforming to the desired final shape. The softened laminate is stretched and deformed by the dies and is held in the dies long enough to allow the fabric to cool to a temperature below the softening point of the synthetic fibers. The formed chamois element is then cut from the fabric piece and over-edge stitched along the margin to stabilize the edge.

U.S. Pat. No. 7,007,356 to Cudney et al. ("Cudney"), the entirety of which is hereby incorporated by reference, discloses a method of forming a cushioning pad wherein a first web of material, a second web of material, and a component are heated. The component is compressed between the first web and the second web, causing the component to spread laterally and the first and second webs to contact one another and encircle the component. Due to the heat and pressure, the first web is bonded to the second web at the encirclement of the component.

U.S. Pat. No. 7,707,659 to Africa et al. ("Africa"), the entirety of which is hereby incorporated by reference, discloses a chamois for athletic shorts. The chamois has a buttocks region and an abdominal region. The buttocks region has a plurality of buttocks support areas defined by seams. The seams may be embossed seams, welded seams, bonded seams, adhesive seals, stitched seams, or a combination thereof.

U.S. Pat. Pub. No. 2011/0271425 to Furfaro ("Furfaro"), the entirety of which is hereby incorporated by reference, discloses a process of making a bottom lining for cycling shorts. The bottom lining comprises two layers made of synthetic fabric, between which a thicker layer and a thinner layer of sponge or foam. The thicker layer is made of a foam of high density, for example 80 kilograms per cubic meter, and has a thickness of, for example, 8 millimeters. The thinner layer is made of a foam of lower density, for example 60 kilograms per cubic meter, and has a thickness of, for example, 3 millimeters. The total thickness of the bottom lining is uniform, and transitional "zones" or "corners" of higher or lower thickness or density are not present. A bend is formed along a longitudinal axis of the bottom lining to develop a saddle wrapping effect that could otherwise be obtained only by cut-and- stitch or a weakening along the axis. The desired shape of the bottom lining can be determined by manufacturing casts for different types of persons in order to envisage a shape having a perfect conformability between the person's body and a saddle and develop padding having modulated levels at support points by means of foams having a gradual pattern.

U.S. Pat. No. 5,271,101 to Speth et al. ("Speth"), the entirety of which is hereby incorporated by reference, discloses cycling shorts with an anatomical seat pad. The seat pad has a top covering layer, a middle cushioning layer, and a backing layer. These layers are adhered together in a conventional manner, and then attached to a body portion by stitching to an inside surface or, preferably, by being laminated directly to the inside surface. The top covering layer may be made from Suedemark, the middle cushioning layer is constructed from a four-millimeter-thick polyurethane foam pad, and the backing layer is made from a nylon tricot. The seat pad also includes a plurality of embossed break lines formed by heat molding the seat pad in a flat position, without utilizing stitching or sewn seams which can cause abrasion to the cyclist.

There is a need in the art for a method of manufacturing a sport apparel seat pad that preserves the desirable material properties of the foam pad portion, minimizes wasted material, and achieves the desired pad shape and engineered contouring of the pad portion after the seat pad has been constructed.

SUMMARY

The present disclosure relates to methods of manufacturing a sport apparel seat pad that preserve the desirable material properties of the foam pad portion, minimize wasted material, and achieve the desired pad shape and contouring of the pad, as well as to sport apparel seat pads made by this method. The contour of the pad provides improved padding and weight distribution and characteristics, and thus improved comfort for the rider, as compared to the sewing and heat forming processes of the prior art which produce pads of constant thickness. In particular embodiments, methods of manufacturing a cycling chamois are provided. The method maximizes the stretch of fabrics and foams used in fabrication of the cycling chamois, creates a desired 3D contour of padding, controls the density and resilience of the foams, minimizes the quantity of scrap material to control costs and environmental impacts, and reduces labor costs. The method has improved economy of resources over the methods of the prior art and may be used to produce a seat pad that moves with the user's body and reduces sitting pressures and impact loads.

It is one aspect of the present disclosure to provide a method of making a sport apparel seat pad. The method makes use of new manufacturing techniques that maintain material properties such as fabric elongation, foam density, and compression rate while producing complex contours necessary to achieve desired comfort and performance requirements. In preferred embodiments, the method maximizes the stretch of fabrics and foams used in fabrication of a cycling chamois, creates a desired 3D contour of padding, controls the density and resilience of the foams, minimizes the quantity of scrap material to control costs and environmental impacts, and reduces labor costs. The method has improved economy of resources over the methods of the prior art and may be used to produce a seat pad that moves with the user's body and reduces sitting pressures and impact loads.

Although these seat pads may be used for cycling, embodiments of the disclosure may be used in any application where irritation and injury to one or more of the nerves, bones, and blood vessels in the pelvic or perineal region caused by prolonged pressure applied against the pelvic or perineal region is a common problem. Such applications include activities that involve prolonged or intense pressure, vibration, or impact on a user's pelvis or perineum, or that require a user to support a substantial proportion of his or her body weight on the pelvis or perineum for an extended period of time. Such other applications include, but are not limited to, motocross riding, motorcycle riding, equestrian sports, horse racing, rodeo, and any application where placing weight or pressure on the pelvis or perineum is required.

By way of providing additional background and context, the following references are described for the express purpose of explaining the nature of sport apparel seat pads and their methods of manufacture, and to further describe the various tools and other apparatus commonly associated therewith.

U.S. Pat. Pub. No. 2014/0250567, the entirety of which is hereby incorporated by reference, describes cycling shorts comprising a pad affixed to an inner surface of the shorts, the pad comprising a composite, multi-layered device. The internal layers of the pad are preferably formed of molded silicone rubber for flexibility and may be secured to one another by one or more of a number of conventional sealing processes such as gluing or fusion. U.S. Pat. Pub. No. 2005/0223478, the entirety of which is hereby incorporated by reference, describes a body support for placement within cyclists' shorts or trousers, assembled by joining an intermediate cushion or padding layer to a bottom layer, preferably with stitching that runs at or near the outer periphery of the intermediate layer. The bottom layer is then stitched near the edges of its front and back portions to corresponding edges of the top layer, with a top surface of the intermediate layer facing toward a bottom surface of the top layer.

U.S. Pat. No. 6,460, 186, the entirety of which is hereby incorporated by reference, describes a sports garment comprising an external flap extending from a curved lower seam, the external flap partially overlapping an internal flap extending from a curved upper seam, the internal and external flaps being joined to one another by at least two spaced apart holding seams extending obliquely between the curved upper seam and curved lower seam without the help of any fastening means, wherein the curved upper seam and the curved lower seam are concavely stitched relative to one another.

U.S. Pat. No. 6,928,665, the entirety of which is hereby incorporated by reference, describes cycle pants comprising a breathable cushion which generally includes a base sheet and a cover sheet each sharing a common periphery and sealed together along the periphery.

U.S. Pat. No. 5,978,970, the entirety of which is hereby incorporated by reference, describes a crotch cushion for a bicycle rider which can be fabricated from almost any semi-ridged material that exhibits some degree of flexure. The crotch cushion has padding on upwardly facing surfaces, which can be fabricated from any material having suitable cushioning properties.

U.S. Pat. No. 6,393,618, the entirety of which is hereby incorporated by reference, describes a process of manufacturing a seat pad for mounting into the inside crotch portion of a cyclist pant, comprising molding the seat pad with an ultrasound gun so as to shape the seat pad conformingly to the crotch portion of the cyclist pant, and permanently compressing selected areas of an intermediate layer of the seat pad by heat stamping, wherein thin hinge lines are formed by bringing together and merging top and bottom layers of the seat pad.

U.S. Pat. No. 6,817,037, the entirety of which is hereby incorporated by reference, describes stretchable athletic pants comprising one or more panels connected by at least one overlapping bonded seam formed at overlapping edges of the panel(s), in some embodiments providing a substantially flat seam. U.S. Pat. No. 8,042, 197, the entirety of which is hereby incorporated by reference, describes cyclist trousers made at least partially from elasticized material and comprising at least two shaped protection pads positioned in the area of the trousers intended to rest on a saddle of a bicycle seat and symmetrically with respect to a median crotch line, and a substantially unstretchable portion placed to mutually connect at least a portion of the shaped pads.

U.S. Pat. No. 6,990,693, the entirety of which is hereby incorporated by reference, describes a seat element for being inserted into a pair of cycling pants, comprising a seat pad for padding a seat surface in a bottom region of a person wearing the seat element, a bowl-shaped protective element for protecting a male genital region connected with the seat pad, and an outside of the seat element provided with an adhesive coating.

U.S. Pat. Pub. No. 2008/0092273, the entirety of which is hereby incorporated by reference, describes convertible athletic running pants preferably including a chamois type pad comprised of gel, foam, or other applicable material, allowing for increased comfort during cycling.

U.S. Pat. No. 4,805,243, the entirety of which is hereby incorporated by reference, describes a protective pants garment for athletic use comprising multiple pads preferably formed from a synthetic, resilient foam material of cellular foam, such as neoprene foam or vinylnitril foam, permitting the user to select the most effective padding thickness.

U.S. Pat. Pub. No. 2012/0076985, the entirety of which is hereby incorporated by reference, describes a support element for a cycling glove comprising a padding structure constructed of a plurality of interconnected spherical shaped structures together defining a pliable support element.

U.S. Pat. No. 8,087,097, the entirety of which is hereby incorporated by reference, describes a method for manufacturing and pre-forming a protection seat for cyclist trousers, comprising shaping the seat with a front portion and a rear portion, making a longitudinal, median, substantially V-shaped notch with an open end on the front portion to obtain two opposite flaps, and joining at least a portion of the opposite flaps, obtaining a longitudinal joint and forming a shell-shaped concave region in the front portion of the seat.

U.S. Pat. No. 6,618,860, the entirety of which is hereby incorporated by reference, describes athletic gloves having palm pads, each of which includes a relatively thin bonding film or layer that operates to bond the palm pad to a palm of the glove in the absence of a securing means such as stitching, a relatively thick intermediate padding layer, and a relatively thin surface layer. The palm pad may be devoid of stitching and the like and may be secured or welded to the palm of the glove by the operation of a heat- activated adhesive by forming permanent depressed lines around and within each of the palm pads by the application of heat and line pressure.

One aspect of this disclosure provides methods for manufacturing a sport apparel seat pad that protects against or mitigates nerve, bone, and blood vessel injury or irritation by providing a pad portion that is placed so as to spread out and diffuse loading of the pelvic and perineal regions and protects a user against pressure, vibration, and impacts. A pad portion may be manufactured that has a uniform density and thickness to provide even and consistent protection across the entirety of a user's pelvic and perineal regions. The pad portion may be skived to a desired contour to provide a close fit to a user's pelvic and perineal regions.

The phrase "method" is used herein to indicate an inventive method as herein disclosed. The phrases "device" and "apparatus" are used herein to indicate an inventive device as herein disclosed.

These methods may include laminating together a first fabric and a first foam to form a top face sheet, laminating together a second fabric and one or more layers of a second foam to form a pad portion, die cutting each of the top face sheet and the pad portion, skiving the pad portion to achieve a desired contour, and affixing the pad portion to the top face sheet to form a sport apparel seat pad. The first foam may be perforated. At least one of the layers of the second foam may be perforated. The pad portion may be affixed to the top face sheet by being sewn around part or all of a circumference of the pad portion. These methods may further comprise disposing the sport apparel seat pad within a cycling garment as a cycling chamois. The pad portion may have two or more layers of the second foam. The top face sheet may have two or more layers of the first fabric, and/or the pad portion may have two or more layers of the second fabric. More than one pad portion may be affixed to the top face sheet. Either or both of the top face sheet and the pad portion(s) may be heat formed prior to the affixing step. The sport apparel seat pad may be heat formed after the affixing step.

In a preferred embodiment of the disclosure, the device is a sport apparel seat pad, comprising a laminated, die cut top face sheet having a first fabric and a first foam; and a laminated, die cut, skived pad portion, affixed to the top face sheet, having a second fabric and one or more layers of a second foam. The first foam may be perforated. At least one of the layers of the second foam may be perforated. The pad portion may be affixed to the top face sheet by being sewn around part or all of a circumference of the pad portion. The sport apparel seat pad may be adapted to be disposed within a cycling garment as a cycling chamois.

In a preferred embodiment of the disclosure, the method comprises skiving a laminated, die cut pad portion comprising a fabric and one or more layers of a foam to achieve a desired contour; and affixing the pad portion to a laminated, die cut top face sheet. At least one of the layers of the foam may be perforated. The pad portion may be affixed to the top face sheet by being sewn around part or all of a circumference of the pad portion. The method may further comprise disposing the sport apparel seat pad within a cycling garment as a cycling chamois.

These methods may produce a sport apparel seat pad having a pad portion of uniform density. The pad portion is free of areas that have been compressed so as to have greater density and lesser thickness, particularly near edges of the pad portion, i.e. near the points where the pad portion is affixed to the top face sheet.

The pad portion laminating step of these methods may comprise laminating together a fabric and at least one layer of each of two or more different foams. By way of non-limiting example, one of the foams may be a relatively low-density foam for cushioning a user's pelvic and perineal regions and provide comfort to the user, and another of the foams may be a relatively high-density foam for distributing pressure, vibration, and impact loads away from, or to appropriate portions of, the user's pelvic and perineal regions. Suitable foams for use in the pad portion laminating step include, but are not limited to, polymeric foams, such as polyurethane foam, polyester foam, polyvinyl chloride foam, polyimide foam, silicone foam, and microcellular foam.

The above-described benefits, embodiments, and characterizations are not necessarily complete or exhaustive, particularly as to the patentable subject matter disclosed herein. Other benefits, embodiments, or characterizations of the present disclosure are possible as set forth above, as described in the accompanying figures, and as in the description herein below. However, the Detailed Description of the Invention, the drawing figures, and the claims set forth herein, taken in conjunction with this Summary, define the invention.

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and, together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is an illustration of a previously known method of making a cycling chamois using a sewing process;

Figure 2 is an illustration of a cycling chamois made by the sewing process of the prior art;

Figure 3 is an illustration of a previously known method of making a cycling chamois using a skiving process;

Figure 4 is an illustration of a previously known method of making a cycling chamois using a skiving process;

Figure 5 is a bottom view of a cycling chamois made by the skiving process of the prior art;

Figure 6 is an illustration of a method of making a sport apparel seat pad according to embodiments of the present disclosure;

Figure 7 is an illustration of a sport apparel seat pad according to embodiments of the present disclosure;

Figure 8 is a bottom view of a pad portion of a sport apparel seat pad according to embodiments of the present disclosure; and

Figure 9 is a bottom view of an assembled sport apparel seat pad according to embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure relates to methods of manufacturing a sport apparel seat pad, used in any application where irritation and injury to the nerves, blood vessels, or bones of the pelvic and perineal regions are common problems. Such applications include athletic activities that require a user to support his or her weight on the pelvic region or perineal region for prolonged periods of time. One such application is bicycling. The method involves skiving a pad portion to a desired contour and subsequently affixing the pad portion to a top face sheet.

The method produces a sport apparel seat pad with a pad portion of uniform density and engineered contour. Particularly, as compared to sport apparel seat pads made by other methods, the areas of the pad portion near its edges, i.e. near the points where the pad portion is affixed to the top face sheet, are compressed to a lesser degree. The change in the thickness and density of the edges of the pad portion when the pad portion is affixed to the top face sheet is therefore reduced to a minimum. Thus, sport apparel seat pads produced by the methods of the present disclosure effectively reduce average and peak pressure, vibration, and impact loads across all regions of a user's pelvic and perineal regions. Furthermore, skiving the pad portion prior to affixing the pad portion to the top face sheet reduces the labor costs associated with manufacturing sport apparel seat pads and minimizes material waste, thus reducing the material cost and environmental impact of the method.

Figure 1 illustrates a previously known method of making a cycling chamois using a sewing process 100. This method combines a top sheet-making submethod 110 and a pad-making submethod 120. In the top sheet-making submethod 110, a fabric layer 111 and a first foam layer 112 are laminated together in a laminating step 113 to form a top sheet 114. In the pad-making submethod 120, a second foam layer 121 is die cut to form a foam pad 122. The top sheet 114 and the foam pad 122 are then sewn together in a sewing step 130 to form the cycling chamois 131.

Figure 2 illustrates the cycling chamois 131 made by the sewing process 100 illustrated in Figure 1. The foam pad 122 is of a uniform thickness (A) before the sewing step 130, but is compressed (B) when sewn to the top sheet 114.

Figures 3 and 4 illustrate a previously known method of making a cycling chamois using a skiving process 300. In this process, a fabric 301 and one or more layers of foam 302 are laminated together in a laminating step 310. The laminated fabric and foam are die cut to form a pad shape 321 in a die cutting step 320. The pad shape 321 is then placed into a mold 410 that has a cavity 411 and a core 412 shaped to deflect the pad shape 321 out of plane in a skive contour step 330. In most cases, the mold 410 is designed so that the material of the pad shape 321 is not compressed. During the skive contour step 330, the mold 410 is placed through a straight knife 420, which may be a continuous band (e.g. a band saw) or reciprocating, to form a contoured pad 331. After passing through the knife 420, the mold 410 is opened and the contoured pad 331 returns to a flat configuration with a new contour 332 on the cut side. The contoured pad may then be formed by heat and/or pressure in a forming step 340 to form the cycling chamois 341.

Figure 5 illustrates the cycling chamois 341 made by the skiving process 300 illustrated in Figures 3 and 4. A large quantity of waste material 510 remains after the skiving process 300, both overlying the skived contour 332 and surrounding its circumference. This waste material 510 must be removed before the cycling chamois 341 is ready for use. Figure 6 illustrates a method 600 of making a sport apparel seat pad by a skiving/sewing process, according to embodiments of the present disclosure. The method 600 comprises a top face sheet-making submethod 610 and a pad-making submethod 620. In the top face sheet-making submethod 610, a top face sheet 614 is formed by laminating together a first fabric 611 and a foam 612 in a laminating step 613. The foam 612 of the top face sheet 614 may be perforated. In the pad-making submethod 620, a pad portion 624 is formed by laminating together a second fabric 621 and one or more layers of foam 622 in a laminating step 623. The foam 622 of the pad portion 624 may be perforated. The top face sheet 614 and the pad portion 624 are then each separately die cut. The pad portion 624 is skived to achieve a desired skive contour 625. Finally, the pad portion 624 is affixed to the top face sheet 614 in an affixing step 626 to form the sport apparel seat pad 630. By way of non-limiting example, the pad portion 624 may be partially sewn or completely sewn to the top face sheet 614 in the affixing step 626.

Figure 7 illustrates a sport apparel seat pad 630 according to embodiments of the present disclosure. As compared to the waste material 510 of the cycling chamois 341 illustrated in Figures 3 and 5, the quantity of waste material 710 surrounding the circumference of the pad portion 624 is greatly reduced, and only the small amount of waste overlying the skive contour 625 remains to be removed.

Figure 8 illustrates a bottom view of a pad portion 624 of a sport apparel seat pad 630 according to embodiments of the present disclosure. As compared to the waste material 510 of the cycling chamois 341 illustrated in Figures 3 and 5, the quantity of waste material 710 surrounding the circumference of the pad portion 624 is greatly reduced.

Figure 9 illustrates a bottom view of an assembled sport apparel seat pad 630 according to embodiments of the present disclosure. The pad portion 624 illustrated in Figure 8 has been affixed to a top face sheet 614. Unlike with the foam pad 122 illustrated in Figure 2, the pad compression at the edge of the pad portion 624 is reduced to a minimum and the pad portion 624 retains a uniform density throughout. Although in Figure 9 the pad portion 624 has been affixed to the top face sheet 614 by being sewn around parts of the circumference of the pad portion 624, one of ordinary skill in the art would understand that it may be affixed by any of several known methods, including but not limited to being sewn around the entire circumference of the pad portion 624.

While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and alterations of these embodiments will occur to those skilled in the art. It is to be expressly understood that such modifications and alterations are within the scope of the present disclosure, as set forth in the following claims.

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, or embodiment or embodiments, disclosed herein. In the foregoing Detailed Description, various features of the disclosure are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are incorporated into this disclosure, with each claim standing on its own as a separate preferred embodiment of the disclosure.

Moreover, though the present disclosure has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the disclosure, as may be within the skill and knowledge of those skilled in the art after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable, or equivalent structures, functions, ranges, or steps to those claimed, whether or not such alternate, interchangeable, or equivalent structures, functions, ranges, or steps are disclosed herein, and without intending to dedicate to the public any patentable subject matter.