Seat pad for a sport cycling garment

DESCRIPTION

Field of the invention

The invention relates to the field of sport cycling clothing and more in particular to a seat pad of a cycling garment.

Prior art

Specialised cycling shorts typically include a padded seat pad positioned in the area known as the crotch or saddle area. This seat pad serves to cushion and make the seat more comfortable even during intense and prolonged use.

The seat pad is typically made with a suitably shaped panel, also known as cover, which in turn may have a multi-layered structure, and a plurality of pads stitched or otherwise attached to the cover. The cover is then attached inside the shorts typically with a seam along the contour of the cover.

As it can be easily understood, the seat pad is largely responsible for the performance and comfort of the shorts. In fact, the seat pad is in direct contact with the body and essentially determines the comfort of the seat on the saddle. In addition, the seat pad must be light and adapted to the pedalling movement without constituting a hindrance. For these reasons, the seat pad has been and still is the subject of continuous attempts of improvement.

Prior art pads can be stitched or attached to the cover using another technique (e.g. an adhesive); another technique that can be used to make a seat pad is thermoforming. It has also been proposed to make the pad of the seat pad entirely by using a 3D printing technique, which enables to obtain a desired micro-architecture of the pad. The disadvantage of this technique, however, is that the structure obtained by 3D printing, designed to bear the weight resting on the saddle, is rather rigid and worsens the comfort. In addition, a common defect that afflicts cycling garments is that, as they are highly optimised for the riding position, result less comfortable and somewhat bulky when getting off the bike, for instance during stops.

IT 2019 0001 6949 discloses a seat pad with a sandwich structure comprising a layer of foamed material and a component with a complex structure which may be realized by 3D-printing.

Summary of the invention

The object of the invention is to further improve the technique of seat pads for cycling garments.

The applicant has found that 3D-printed element sandwiched with conventional foam material does not fully exploit the advantages of the 3D- printing technique. A sandwiched structure does not fully overcome the disadvantages of the conventional foamed pads such as the tendency to absorb sweat and limited durability.

The invention comes from the understanding that 3D-printed elements should actually replace the conventional foamed material in strategically selected portions of the seat pad. The number and location of said portions may depend on the intended use, i.e. on the sport discipline for which the seat pad is specifically designed and the resulting position assumed by the cyclist.

Accordingly, the object of the invention is achieved by a seat pad according to the claims.

The seat pad has a cover, a first region which is padded by one or more foamed padding elements made of a piece of foamed material, a second region which is padded by one or more 3D-printed padding element, wherein said first region and said second region are separate regions which do not overlap. As a consequence, the padding function, at each padded location of the seat pad, is given by one of the foamed material element(s) or 3D-printed element(s). Hence the seat pad has no sandwich of conventional foamed pads and 3D-pads.

The idea underlying the invention is to make a hybrid seat pad in which the 3D printing technique is selectively used for a specific padding region. The padding of a remaining region is made using a conventional technique of padding elements made of a foamed material. The invention makes combines the advantages of the two techniques, in particular the comfort that can be achieved with conventional pads made of foamed material and the enhanced support that can be achieved with a structure made by 3D printing.

The invention arises from the consideration that the pressure on the saddle is typically concentrated on a limited portion of the seat pad, depending on the use. This portion is the most critical being highly stressed by the weight and exposed to the attack of sweat. The design by 3D printing makes it possible to create a micro-structure suitable for cushioning the weight and for faster drying, which can be strategically located in said critical part of the seat pad. in the remaining parts, a soft and comfortable padding made of foamed material can be used.

The 3D-printed padding may include one or more elements. For example 3D- printed padding elements may be places symmetrically with respect to a longitudinal (front-rear) axis of the seat pad.

Generally, the 3D-printed padding is preferably located essentially or exclusively at the rear part of the seat pad, as the rear part is typically highly stressed by weight and sweat. However, for some disciplines such as time trials or Triathlon, the cyclist shifts the weight forward and for such applications a structure with front 3D printed padding may be preferred.

The term 3D printing denotes a three-dimensional printing technique, typically of the additive type such as additive manufacturing. The preferred material for the 3D printed element or elements is an elastomeric material.

The invention benefits, in any case, from the advantages of 3D printing such as reduced material waste (scrap) if compared to conventional techniques. However, this technique is only used where it provides the greatest advantages and benefits, i.e. in the pad region that undergoes the greatest load. The applicant has found that this hybrid structure provides the best compromise between performance and comfort.

Description of the invention

In the following, references to padding element or padding elements, irrespective of singular or plural form, shall be understood to one or more padding element(s).

The 3D-printed padding elements have preferably a different resistance to compression compared to the foamed padding elements. The foamed padding elements are conventionally made of foamed material, for example cut from a piece of foamed material of a suitable thickness. The 3D-printed elements, in a preferred embodiment, may have a lattice structure. In some embodiments the 3D-printed elements may be internally hollow with a 3D-printed surface structure.

The 3D printed elements can be made with any suitable technique for 3D printing including, for example, fused deposition modelling (FDM) or selective laser sintering (SLS). In a preferred embodiment, the seat pad is not made by thermoforming. Although thermoforming is deemed attractive for making seat pads of a complex shape, the applicant has found that stitching the padding elements to the seat pad still provides the best performance.

In certain embodiments, a 3D-printed padding elements can be fitted within a foamed padding element, so that the 3D-printed element replaces the foamed material over a portion of said foamed element. For example, a 3D-printed element may form a core portion of a foamed element.

In certain embodiments, the 3D-printed elements may fit into the foamed material of foamed elements or into the material of the layer, like pieces of a puzzle. For example a 3D-printed element may have a padding portion and one or more attachment portions which extend from the padding portion to fit into the material of the cover or into the foamed material of one or more foamed padding element located around said 3D-printed element.

The following are preferred techniques for attaching a 3D-printed element to the cover of the seat pad: a 3D-printed padding element may be stitched directly to the cover of the seat pad or may be attached to the cover by means of an additional sheet of fabric; in an embodiment said additional sheet encases the 3D-printed element and is attached to the cover of the seat pad; in another embodiment said sheet of fabric is placed between the padding element and the cover.

The above techniques for attaching a 3D printed element to the cover may be used for different 3D-printed elements of the same seat pad, or alternatively all 3D-printed elements of the seat pad may be attached with the same technique.

An additional sheet of fabric placed between the padding element and the cover may have the additional function of stabilizing the seat pad. In an embodiment, said additional sheet of fabric connects two 3D-printed elements on opposite sides of the seat pad and opposes to a lateral deviation of the 3D- printed elements from their design position.

The preferred location for the 3D-printed padding elements may include any of: the prostate area of a male user, the location of ischial bones of a user, the front portion of the seat pad, the rear portion of the seat pad. The location of said anatomical parts shall mean the portion of the seat pad wherein the anatomical part rests during the use (i.e. the bicycle riding activity).

One or more 3D-printed element may be located in the front portion and7or in the rear portion of the seat pad. In certain embodiments the 3D-printed elements are located only in the front portion or only in the rear portion of the seat pad.

The invention relates also to a cycling garment comprising a seat pad according to any one of the above embodiments, the seat pad being positioned in the saddle area to cushion the seat on the saddle while using the garment.

In an embodiment, a 3D-printed padding element is a U-shaped pad and is oriented longitudinally with respect to the seat pad. Said U-shaped element may have arms projecting towards the front part or, preferably, towards the rear part of the seat pad. Said U-shaped pad advantageously extends into the middle or centre-rear part of the seat pad.

In an embodiment provides, the 3D-printed elements include a pair of shaped pads which are positioned in the central-rear area of the seat pad and are symmetrical with respect to a front-rear longitudinal axis of the seat pad.

The 3D-printed elements advantageously have differentiated density and/or pliability with respect to the conventional foamed elements. In general, padding regions made by 3D printing, or with the contribution of elements made by 3D printing, have less pliability than conventional parts made of foamed material.

The foamed pads can be made from a polyurethane foam. Said pads may comprise one or more portions attached to the seat pad by a technique such as stitching, heat-sealing or equivalent.

A preferred embodiment provides for a front pad and a rear pad having a shape in plan that is substantially mirrored with respect to a front-rear median axis of the seat pad. More preferably, the front pad comprises at least two distinct portions, positioned respectively on opposite sides of said median axis.

The term front pad refers to the pad or pads located at the front of the seat pad; similarly, the term rear pad refers to the pad or pads located at the rear of the seat pad. Both the front pad and the rear pad can be formed in a single body or in several parts.

The rear pad, in particular, may be formed in a single structure forming two lobes, i.e. a right lobe and a left lobe, extending from opposite sides of said median axis. Preferably the two lobes are connected by a central bridge that maintains the continuity of the single structure.

In a preferred embodiment, the front pad comprises portions that diverge, moving away from each other, along the longitudinal direction and towards the rear pad. As a result of this divergent arrangement, said two portions of front pad leave a non-padded area with an increasing width as it approaches the centre of the seat pad.

The rear pad may have an essentially V-shaped front recess. Said recess essentially separates the front areas of the two lobes. Similarly, the rear pad may have a second rear recess, also V-shaped, wherein said second recess substantially separates the central and rear areas of the two lobes. It is understood that the divergence of the front pads and the said front recess of the rear pad form a central area free of pad. This means that said central area is free of added pads; it may however have a limited cushioning effect given by the cover of the seat pad. This non-padded region may be essentially drop or rhomboid-shaped.

The pad of the front part preferably extends in a central-front area of the seat pad, starting from a separation line between the two pads; similarly, the pad of the rear part preferably extends in a central-rear area of the seat pad, starting from said separation line.

The rear pad preferably extends over a predominant part of the length of the seat pad. Observing a seat pad plan view, preferably the front pad occupies a portion of the length of the seat pad, along the front-rear direction of the seat pad itself, between 30% and 40% of the total length; the pad of the rear part can consequently occupy a portion of the length of the seat pad between 60% and 70%.

A further aspect of the invention is to have seat pad portions having different densities. In particular, the front pad and rear pad may have a different density.

Advantageously, the front pad has a greater deformability than the rear pad. In other words, in the preferred embodiments a front pad more deformable than the rear one will be obtained. This means that, at equal load, the front pad undergoes greater crushing deformation. Said difference in deformability can be achieved as a function of the different material and/or thickness between the pads. For some cycling disciplines, the opposite solution may be preferred, i.e. with a front pad less deformable than the rear one.

The seat pad can be attached to a cycling shorts or garment of various shapes, for example a long or short pants or a cycling suit. In all the embodiments, the cover may include a single layer or a plurality of layers. In some embodiments the cover has a layer of foam material which provides an additional, albeit limited, padding effect.

Description of the figures

Fig. 1 is a top view of a seat pad for cycling shorts according to an embodiment of the invention.

Fig. 2 shows a seat pad according to a second embodiment.

Fig. 3 shows a seat pad according to a third embodiment.

Fig. 4 illustrates the positioning of a seat pad in a pair of cycling shorts.

Fig. 5 illustrates a simplified cross section of a seat pad with a 3D-printed pad attached to the cover in accordance with a preferred embodiment.

Fig. 1 illustrates a seat pad 101 comprising a cover 102 to which two shaped pads 103, 104 are attached. The shaped pads 103, 104 are made of conventional foamed material. A 3D-printed pad 105 is fitted in each of the pads 103, 104, so that the 3D-printed pad replaces the foam material over a portion of the pads.

In Fig. 1 , the 3D-printed pads 105 are in correspondence of the resting region of the ischial bones.

The pad 101 has a hybrid nature comprising regions where the padding is given conventionally by foamed material, and regions (in the example the zones of the pads 105) differentiated by components made by 3D printing.

Ventilation holes 106 are present in the front part of the seat pad. The cover 102 can be made in a single or multi-layered layer. The line 107 denotes a stabilizer sheet that may be interposed between the pads 103, 104 and the cover 102. Said sheet 107 opposes to a divergence of the pads 103, 104 from the design position, e.g. due to transversal forces which tend to move the pads laterally.

Fig. 2 shows a seat pad 201 , which in this case comprises a cover 202, a central-rear pad 203 made by 3D printing and a pair of lateral-rear pads 204, 205 made conventionally of foamed material. The pad 203 has a U-shape or horseshoe shape arranged longitudinally. In the figure the arms of the II- shaped pad 203 face towards the rear part of the seat pad; in other embodiments, the orientation of the II may be mirrored with respect to Fig. 2 i.e. with the forward facing arms.

The embodiment of Fig. 2 with a differentiated support given by the 3D-printed pad 203 in the middle position is particularly suitable for a triathlon seat pad.

Fig. 3 illustrates a seat pad 301 comprising: a cover 302, a pair of front pads 303 and 304, a rear pad 305.

The cover 302 may be made with a multi-layered structure, for example comprising an inner layer (facing the user's body), an outer layer (facing the garment) and an intermediate layer of soft material. The latter can also give the cover a limited cushioning effect.

The two front pads 303, 304 are separate and have divergent portions 306 as shown in the figure. In particular, the front pads diverge as they extend towards the central part of the seat pad and towards the rear pad 305.

The rear pad 305 is a single piece having essentially a shape with two lobes 307, 308 connected by a narrow bridge portion 309. Accordingly, the rear pad 305 has an essentially V-shaped front recess 310 and a rear recess 311 also essentially V-shaped. The divergent areas 306 of the front pad and the front recess 310 of the rear pad 305 define a central region 312 of the cover that is free of added pads. Similarly, the region defined by the recess 311 between the two lobes 307 and 308 is free of pads. It can be noted by observing the figure that the pad is strategically located in the resting areas, avoiding padding the entire surface of the seat pad, which would increase weight and thickness.

A front-rear median axis A is also shown in the figure, which defines the commonly said longitudinal direction of the seat pad. As it can be seen, the pads are essentially specular in shape with respect to said axis A. In other words, it can be said that the seat pad is essentially symmetrical with respect to a plane identified by the A-axis (plane of symmetry perpendicular to the plane of Fig. 3).

The two front pads 303, 304 and the rear pad 305 are on opposite sides of a line B which can be considered as a separation line between the front and the rear part of the seat pad itself. Said line B is perpendicular to the longitudinal front-rear axis A.

The seat pad 301 has a hybrid structure due to the different technique with which the front and rear pads are made. The front pads are made of a foamed material, preferably a polyurethane foam. The rear pad 305, on the other hand, is made by 3D printing, using a technique such as fused deposition modelling (FDM) or selective laser sintering (SLS) or another known 3D printing technique.

A preferred material for the pad 305 is an elastomeric material suitable for lattice structures (“latex”). For instance, an exemplary material is EPU 41 elastomer from the manufacturer Carbon Inc. In other embodiments, the 3D technique may be used, by contrast, for the front pads 303 and 304 by making the rear pad 305 conventionally of foamed material.

The seat pad 301 is normally stitched inside the shorts along its perimeter, with a continuous or interrupted seam. Line 313 indicates a further seam line between the lobes of the rear pad that can be provided to stabilise the seat pad. It must be understood that, instead of stitching, another technique for anchoring the seat pad to the shorts may be used.

Fig. 4 shows the location of the seat pad 101 , 201 or 301 in a cycling garment 20.

Fig. 5 illustrates an example of a 3D-printed pad 503 fixed to a cover 502 of a seat pad by means of a fabric sheet 504. The fabric sheet 504 extends all over the pad 503 and edges 505 of the sheet 504 are stitched to the cover 502, that is they are attached with stitches 506, so that the pad 503 remains encapsulated within the sheet 504.

In a variant embodiment of Fig. 1 , the pads 103, 104 may be made entirely by 3D printing and may be attached to the cover 102 by means of the sheet 107. Accordingly, the sheet 107 may perform both functions of stabilizer and attachment for the 3D-printed pads.