Method for making an anatomical multilayer bicycle-type seat

• US 4,999,068 A
• Filed: 11/14/1988
• Issued: 03/12/1991
• Est. Priority Date: 02/24/1986
• Status: Expired due to Fees

• Current Assignee: Vetta West, Inc.
• Original Assignee: Michele A. Chiarella
• Inventors: Chiarella, Michele A.
• Primary Examiner(s): Dawson, Robert A.
• Application Number:
  US07/270,968
• Time in Patent Office: 848 Days
• Field of Search: 5/449, 5/481, 156/78, 156/145, 156/146, 156/70, 156/245, 156/292, 264/45.1, 264/248, 264/279, 264/279.1, 297/214, 297/DIG. 1, 297/DIG. 2, 428/71, 428/76, 428/320.2, 428/322.7
• US Class Current: 156/78
• CPC Class Codes: B62J 1/18 Covers for saddles or other seats; Paddings
• CPC Class Codes: Y10S 297/01 Foam
• CPC Class Codes: Y10S 297/02 Molded
• CPC Class Codes: Y10T 428/233 Foamed or expanded material encased
• CPC Class Codes: Y10T 428/239 Complete cover or casing
• CPC Class Codes: Y10T 428/249994 Composite having a component wherein a constituent is liquid or is contained within preformed walls [e.g., impregnant-filled, previously void containing component, etc.]
• CPC Class Codes: Y10T 428/249999 Differentially filled foam, filled plural layers, or filled layer with coat of filling material

Abstract

An anatomical multilayer seat for use on a bicycle or the like. The seat comprises a formed substantially rigid shell covered by a flexible cover sheet and having a layer of soft encapsulated gel material provided between the cover shell and the seat shell. The encapsulated gel layer is constrained against any appreciable lateral movement while permitting only limited deflection of the gel during use by a lower formed foam layer provided between the shell and the cover sheet to produce a controlled graduated support for the rider. If desired, a second upper layer of a resilient material can be advantageously provided between the gel layer and the cover sheet of the seat for encapsulating the gel layer. The invention also includes a method for making the anatomical multilayer seat.

Claims

1. A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of:

(a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface;

(b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface;

(c) forming a mold cavity with said first and second mold surfaces;

(d) forming a cured foam or rubber-like material layer in said mold having a central cavity;

(e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; and

(f) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, whereby said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection.

2. The method according to claim 1, further comprising the step of placing a layer of resilient material above the encapsulated gel layer before attaching the flexible cover sheet.

3. A method for constructing an anatomical multilayer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated soft, resilient gel layer between said shell and said flexible outer cover sheet, said method comprising the steps of:

(a) providing a first mold half;

(b) placing a resilient layer on the first mold half;

(c) placing said gel layer on said resilient layer;

(d) placing said rigid shell, acting as a second mold half above the first mold half to form a cavity;

(e) injecting a foam or rubber-like material into said cavity;

(f) curing the foam material;

(g) removing the first mold half; and

(h) attaching a flexible cover sheet firmly to the periphery of said shell;

whereby the gel layer is constrained on at least two edges by said foam material against substantial lateral movement and is permitted only limited up-and-down vertical deflection by at least said shell and said cover sheet.

4. The method according to claim 3 wherein said resilient layer is adhered to said injected foam or rubber-like material at least at the edges of said gel layer.

5. The method according to claim 4 including the step of disposing said gel layer above a mesh substrate before placing said gel layer on said resilient layer.

6. A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of:

(a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface;

(b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface;

(c) forming a mold cavity with said first and second mold surfaces;

(d) forming a cured foam or rubber-like material layer in said mold having a central cavity;

(e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; and

(f) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, wherein said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection wherein steps (c), (d), (e) and (f), comprise;

first placing said gel layer on the upper surface of said shell acting as said first mold surface;

placing said second mold surface above said first mold surface to form a cavity therebetween;

injecting said foam or rubber-like material into said cavity between said mold surfaces;

curing said foam or rubber-like material; and

removing subsequently said second mold surface.

7. A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of:

(a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface;

(b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface;

(c) forming a mold cavity with said first and second mold surfaces;

(d) forming a cured foam or rubber-like material layer in said mold having a central cavity;

(e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement;

(f) placing a layer of resilient material above the foam-encapsulated gel layer;

(g) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, wherein said gel layer is constrained against substantial lateral movement and is permitted only limited vertical defection; and

wherein steps (c), (d), (e) and (g), comprise first placing said gel layer on the upper surface of said shell acting as said first mold surface;

placing said second mold surface above said first mold surface to form a cavity therebetween;

injecting said foam or rubber-like material into said cavity between said mold surfaces;

curing said foam or rubber-like material; and

removing subsequently said second mold surface.

8. A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of:

(a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface;

(b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface;

(c) forming a mold cavity with said first and second mold surfaces;

(d) forming a cured foam or rubber-like material layer in said mold having a central cavity;

(e) including a soft resilient gel layer in said central cavity so as to escape at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; and

(f) placing a layer of resilient material above the foam-encapsulated gel layer;

(g) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, wherein said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection, wherein steps (c), (d), (e) and (g) comprise;

placing said resilient layer on said second mold surface;

placing said gel layer on top of said resilient layer;

placing said mold surface above said second mold surface to form a cavity therebetween;

injecting a foam material into said cavity and curing the foam material; and

removing said second mold surface.

9. A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of:

(a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface;

(b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface;

(c) forming a mold cavity with said first and second mold surfaces;

(d) forming a cured foam or rubber-like material layer in said mold having a central cavity;

(e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement;

(f) placing a layer of resilient material above the foam-encapsulated gel layer;

(g) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, whereby said gel layer is constrained against substantial lateral movement, wherein steps (c), (d), (e) and (g) comprise

placing said first mold surface above said second mold surface to form a cavity therebetween;

injecting said foam or rubber-like material into said cavity;

curing said foam material;

removing said second mold surface; and

placing a gel packet into said depression.

10. A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of:

(a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface;

(b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface;

(c) forming a mold cavity with said first and second mold surfaces;

(d) forming a cured foam or rubber-like material layer in said mold having a central cavity;

(e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement;

(f) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, whereby said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection, and wherein said layer of resilient material is placed prior to attaching of the flexible cover sheet, wherein said steps (c), (d), (e) and (f) comprise;

providing said second mold surface with a downward projection shaped to form a depression corresponding to the desired shape of said gel layer;

placing said first mold surface above said second mold surface to form a cavity therebetween;

injecting said foam or rubber-like material into said cavity;

curing said foam or rubber-like material;

removing said second mold surface; and

placing a gel packet into said depression.