Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-07-06
2001-09-18
Silbaugh, Jan H. (Department: 1732)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S290000, C156S308400, C264S257000, C264S263000, C264S266000, C264S267000
Reexamination Certificate
active
06290794
ABSTRACT:
The present invention relates to bicycle saddles and more specifically relates to a cushioned bicycle saddle with an embossed fabric surface and method of manufacturing same.
Most modem high performance bicycle saddles consist of pliable or semi rigid molded shell with a leather, plastic, vinyl or fabric cover fitted thereover. The use of lightweight, durable materials in modem saddles has resulted in a lighter, more durable and more appealing saddle than those earlier designed.
Modem design of bicycle seat covers includes a variety of decorative elements, company logos, and multiple color applications. Such decorative elements are typically comprised of decals or embroidery. Decals on a bicycle saddle which are exposed to repetitive physical contact with the rider tend to fade quickly. Embroidery, on the other hand, which may be more visually appealing and longer lasting than most decals, tends to be costly to apply to the saddle during the manufacturing process, and thus saddles including such embroidery will tend to be more costly to consumers. In addition, embroidery on the seat surface, though sometimes considered a safeguard against slippage from the saddle, may be considered uncomfortable to some riders who prefer a smoother seat.
Conventional bicycle saddles may also include protective elements, such as scuff guards and bumpers, to protect the saddle from abrasion and damage resulting from falls. In addition, light reflectors may be included on a saddle for the protection of the rider. All of these types of protective elements are typically applied by sewing, bolting or gluing these items to the perimeter of the covered shell. Finally, modem saddles now often include internal elements, such as gel inserts or other padding for enhancing rider comfort.
Unfortunately, when all of these desirable elements, i.e. decorative elements, bumper guards and padding, are incorporated into a bicycle seat, the manufacturing process requires a multitude of separate steps, which include, inter alia, sewing of different colored fabric panels together, insertion of padding, the sewing or adhesion of logos and protective elements to underlying fabric, in addition to the conventional stretching of the cover over the shell. Needless to say, the increase in manufacturing steps results in a decrease in affordability for many purchasers.
The present invention provides a padded bicycle saddle having an attractive embossed fabric surface and sturdy, scuff-proof bumper guards, and an economical method of manufacturing same.
SUMMARY OF THE INVENTION
Accordingly, a bicycle saddle is provided and a method of manufacturing same. A method in accordance with the present invention generally comprises the steps of providing a bicycle saddle shell and providing a mold having a molding surface defining, a desired contour for a seat of the bicycle saddle. The shell may comprise a frame structure defining openings therethrough.
The method of the present invention further comprises cutting a fabric, film or the like, to a size and shape suitable for covering at least a top surface of the shell and sealing the fabric to the shell, preferably along a perimeter of the shell.
Next, the shell, having the fabric sealed thereto, is disposed into the mold such that the fabric faces the molding surface. A gelable medium, such as a gel or foam, is injected in fluid form between the shell and the fabric in order force the fabric away from. the shell and into intimate contact with the molding surface.
The contoured seat of the bicycle saddle is molded by allowing the gelable medium to gelate and bond with the fabric while the shell is disposed in the mold. In order to expedite the cooling process and prevent the gelable medium from permeating the fabric, means for cooling the mold may be provided.
Finally, the shell, having the desired contoured seat bonded thereto, is removed from the mold.
In another embodiment of the present invention, the step of providing a mold comprises the step of forming a mold having a molding surface defining a desired pattern to be embossed or imprinted in the bicycle saddle and the step of contouring comprises the step of embossing or imprinting the desired pattern into the fabric by allowing the gelable medium to gelate and bond with the fabric while the shell is disposed in the mold.
For the sake of simplicity, the term “embossing” will hereinafter refer to both embossing and imprinting. In other words, “embossing” is defined herein as a design raised in relief from a surface, or a design impressed in relief from a surface. Thus, as will be described hereinafter, the step of embossing a design in the fabric may result in either a raised design or an impressed design, depending upon the molding surface.
Preferably, the step of sealing the fabric to the shell is comprised of heat sealing the fabric, along a perimeter thereof, to the shell by heat bonding methods or by ultrasonic heat sealing, as known to those skilled in the art. Preferably, conventional adhesives are avoided.
In one embodiment of the invention, the fabric is sized to cover only a top surface of the shell, thus leaving the sides of the shell exposed to function as scuff resistant bumpers.
The present invention may also comprise the step of disposing a resilient material, such as a flexible shoe or a foam pad between the shell and the fabric before the step of sealing the fabric to the shell. When used in conjunction with the openings in the shell, the flexible shoe provides orthotic, hammock-like support to a cyclist seated on the saddle. Furthermore, the orthotic shoe may include a plurality of or a combination of different hardnesses. For example, the shoe may be softest and most resilient along the horn portion of the saddle and of a lower resilience along the seat portion.
The present invention further comprises a bicycle saddle made in accordance with the method briefly outlined above.
REFERENCES:
patent: 4955909 (1990-09-01), Ersek et al.
patent: 5108076 (1992-04-01), Chiarella
patent: 6017407 (2000-01-01), Yates
Hackler Walter A.
Silbaugh Jan H.
Staicovici Stefan
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