A bicycle saddle includes a stack of fiber fabrics, a braided fiber bundle including two bundle segments, and a cured member. The cured member includes a first cured portion and a second cured portion. The first cured portion is configured to embed the stack of fiber fabrics therein to form a shell having a front nose portion and a rear widened portion. The second cured portion is bonded to and integrally formed with the first cured portion, and is configured to embed the braided fiber bundle therein to form two rails which respectively have the bundle segments therein. A method for making the bicycle saddle is also disclosed.

The present invention regards a moulding unit for producing a support element for the human body, such as a vehicle seat.

A method of making a saddle having a shell and a padding involves arranging the shell in thermoplastic polymer inside a mould for injection moulding having a die and a punch, the shell having a support surface, which in use faces the padding, and a supporting surface coupled to an inner wall of the punch or of the die, the support surface forming a wall of the moulding cavity; closing the mould; and making the padding by injection moulding a thermoplastic polymer over the shell, between the support surface and the mould.

A method for making a bicycle saddle includes the steps of placing a cover onto a mold cavity of a female mold; pouring a pressure-loading layer of a temper Foam material into the mold cavity; placing a first male mold into the mold cavity for defining a first closed portion and maintaining the mold in such closed condition a first period of time for foaming the temper foam material into the pressure-loading layer; removing the first male mold; pouring a supporting layer of an ordinary foam material into the mold cavity; closing the mold cavity by the second male mold with a shell coupled thereon for defining a second closed portion and maintaining the mold in such closed condition a second period of time for foaming the ordinary foam material into the supporting layer, and removing the second male mold to extract a finished bicycle saddle.

The present invention relates to a male component or punch for a mould unit for producing a vehicle saddle.

In some embodiments, a method of forming a bonded assembly includes: providing a first object comprising a first surface having a plurality of locking orifices formed therein, each of the plurality of locking orifices including an opening on the surface of the object and a cavity extending in the first object; positioning an adhesive on at least one of the first surface of the first object and a second surface on a second object; positioning the first surface of the first object on the second surface of the second object with the adhesive between the first and second surfaces; and curing the adhesive to form the bonded assembly.

Mould for making a support element for the human body, such as a bicycle saddle or a motorcycle saddle, wherein the mould includes a first component or matrix, which it is provided with a cavity open at the top, and at least one second component or false-male, in which the second component or false-male has a through opening, the cavity of the first component or matrix and the through opening of the second component or false-male determine a cavity, which has a conformation in use matching the conformation and/or the bulk and/o to the outer surface of the support element for the human body or the saddle; method for obtaining the support element for the human body and support element for the human body.

Mould for making a support element for the human body, such as a bicycle saddle or a motorcycle saddle, wherein the mould includes a first component or matrix, which is provided with a cavity open at the top, and at least one second component or false-male, in which the second component or false-male has a through opening, the cavity of the first component or matrix and the through opening of the second component or false-male determine a cavity, which has a conformation in use matching the conformation and/or the bulk and/or to the outer surface of the support element for the human body or the saddle; method for obtaining the support element for the human body and support element for the human body.

Disclosed herein are expanded thermoplastic polyurethane beads polymerized from an isocyanate, an isocyanate-reactive compound having a molecular weight between 500 and 10 000 g/mol and a chain extender, wherein customary adjuvants may be additionally present, and the thermoplastic polyurethane has a hard phase fraction ranging from 0.1 to 0.95 and the hard phase fraction is defined by:

[00001]$\mathrm{Hard}.Math..Math.\mathrm{phase}.Math..Math.\mathrm{fraction}=\frac{\underset{x=1}{\overset{k}{.Math.}}.Math.\left(\left(\frac{m_{\mathrm{KVx}}}{M_{{\mathrm{KV}}_x}}\right).Math.M_{\mathrm{Iso}}+m_{\mathrm{KVx}}\right)}{m_{\mathrm{ges}}}$

where M.sub.KVx represents a molar mass of chain extender x in g/mol, m.sub.KVx represents a mass of chain extender x in g, M.sub.Ixo represents a molar mass of isocyanate in g/mol, m.sub.ges represents a total mass of all starting materials without adjuvants, and k represents a number of chain extenders. Also disclosed herein are processes for producing expanded thermoplastic polyurethanes and processes for producing molded parts therefrom.

A bicycle saddle manufacturing method includes the steps of expanding a foamable material to form the foamable material into a semi-finished saddle body, and performing a thermoforming process to form the semi-finished saddle body into a saddle in a forming mold. As a result, the bicycle saddle manufacturing method of the present invention can avoid waste of material and environmental pollution.