Bicycle Saddle, Saddle Pad, and Method for Producing a Bicycle Saddle or Saddle Pad

Abstract

The invention relates to a bicycle saddle having a saddle shell, on the underside of which a frame is arranged. A saddle pad is arranged on the upper side of the saddle shell. According to the invention, the saddle pad has two padding elements for improved comfort, wherein in a preferred embodiment the inner padding element is made of TPU (thermoplastic polyurethane).

Claims

1. A bicycle saddle comprising a saddle shell, a saddle frame connected with a lower side of the saddle shell, and a saddle pad arranged on an upper side of the saddle shell, the saddle pad comprising at least two pad elements, wherein an inner pad element is enclosed at least in part by an outer pad element.

2. The bicycle saddle of claim 1, wherein the inner pad element is arranged on the upper side of the saddle shell.

3. The bicycle saddle of claim 1, wherein a lower side of the inner pad element is in surface contact with the upper side of the saddle shell.

4. The bicycle saddle of claim 1, wherein the inner pad element has protrusions in contact with the upper side of the saddle shell.

5. The bicycle saddle of claim 1, wherein the inner pad element comprises at least one retaining protrusion extending into a recess of the saddle shell.

6. The bicycle saddle of claim 5, wherein the recess is formed as a passage opening in the saddle shell.

7. The bicycle saddle of claim 5, wherein the retaining protrusion extends through the passage opening.

8. The bicycle saddle of claim 5, wherein the retaining protrusion has at least one extension configured for fixing the inner pad element on the saddle shell.

9. The bicycle saddle of claim 8, wherein the at least one extension engages behind the saddle shell.

10. The bicycle saddle of claim 1, wherein the inner pad element is arranged in a seat region of the bicycle saddle.

11. The bicycle saddle of claim 1, wherein the inner pad element is arranged in a center region of the bicycle saddle.

12. The bicycle saddle of claim 10, wherein a common inner pad element is arranged in the seat region and in the center region.

13. The bicycle saddle of claim 11, wherein the inner pad element arranged in the center region is thinner than the inner pad element arranged in the seat region.

14. The bicycle saddle of claim 1, wherein the inner pad element is completely enclosed by the outer pad element and the saddle shell.

15. The bicycle saddle of claim 1, wherein a rear region of the inner pad element is not enclosed by an outer pad element.

16. The bicycle saddle of claim 15, wherein the rear region of the inner pad element is arranged on a rear side of the saddle shell.

17. A bicycle saddle comprising a saddle shell, a saddle frame connected with a lower side of the saddle shell, and a saddle pad arranged on an upper side of the saddle shell, the saddle pad comprising at least two pad elements, wherein a main pad element is connected with the upper side of the saddle shell, and an auxiliary pad element is arranged in a recess of the main pad element.

18. The bicycle saddle of claim 17, wherein the main pad element has a plurality of recesses in which an auxiliary pad element is arranged, respectively.

19. The bicycle saddle of claim 17, wherein the auxiliary pad element is arranged in at least one of a seat region or a center region of the bicycle saddle.

20. The bicycle saddle of claim 19, wherein the auxiliary pad element arranged in the center region is thinner than the auxiliary pad element arranged in the seat region.

21. The bicycle saddle of claim 17, wherein the auxiliary pad element is spanned with textile material at least on the outside.

22. The bicycle saddle of claim 17, wherein the auxiliary pad element is glued into the recess.

23. The bicycle saddle of claim 1, wherein at least one of the inner pad element or the main pad element comprises at least one of TPU, EVA, EPP, TPE, EPE, or a combination thereof.

24. The bicycle saddle of claim 1, wherein at least one of the outer pad element or the auxiliary pad element comprises PU-foam.

25. A saddle pad for a bicycle saddle of claim 1, wherein the saddle pad comprises at least one pad element made of at least one of TPU, EVA, EPP, TPE, or EPE, and at least one pad element made of a foamable material.

26. The saddle pad of claim 24, wherein an inner pad element comprising at least one of TPU, EVA, EPP, TPE, or EPE is enclosed by an outer pad element which is made of foamed material.

27. A bicycle saddle comprising a saddle shell, a saddle frame connected with a lower side of the saddle shell, and a saddle pad arranged on an upper side of the saddle shell, the saddle pad comprising at least two pad elements, wherein at least one of the pad elements comprises at least one of TPU, EVA, EPP, TPE, or EPE, and at least one of the pad elements comprises a foamable material.

28. A method for producing a bicycle saddle of claim 1, comprising the steps of: fastening an inner pad element on an upper side of the saddle shell, placing the saddle shell into a casting mold, and introducing material into the casting mold to form an outer pad element.

29. The method of claim 28, wherein the material for forming the outer pad element is foamed.

30. The method of claim 28, wherein the inner pad element is prefabricated.

31. The method of claim 28, wherein the inner pad element comprises a retaining protrusion pressed into a recess of the saddle shell to fasten the inner pad element.

32. The method of claim 28, wherein the saddle shell is placed into the casting mold with the upper side directed downward.

33. The method of claim 28, wherein prior to placing the saddle shell into the casting mold, a saddle cover is placed into the casting mold and is retained in the casting mold.

34. A method for producing a saddle pad of claim 25, comprising the steps of: fastening a first pad element made of at least one of TPU, EVA, EPP, TPE, or EPE in a mold, and introducing a foamed material into the mold to form a second pad element.

35. The method of claim 34, wherein the first pad element is clamped in the mold.

36. The method of claim 34, wherein the first pad element is prefabricated.

Description

[0049] The inventions will be explained in more detail hereinafter with reference to preferred embodiments and to the accompanying drawings.

[0050] In the FIGS.:

[0051] FIG. 1 is a schematic top plan view of a first preferred embodiment of a bi cycle saddle,

[0052] FIG. 2 is a schematic sectional view along the line II-II in FIG. 1,

[0053] FIG. 2a is a schematic sectional view through an alternative embodiment to FIG. 2,

[0054] FIG. 3 is a schematic sectional view along line II-II through an alternative embodiment,

[0055] FIG. 4 is a schematic top plan view on another embodiment of a bicycle saddle,

[0056] FIG. 5 is a schematic sectional view along line V-V in FIG. 4,

[0057] FIG. 6 is a schematic top plan view on another embodiment of a bicycle saddle, and

[0058] FIG. 7 is a schematic sectional view along line VII-VII in FIG. 6.

[0059] In the different preferred embodiments of the inventions described hereinafter, similar and identical parts are respectively identified by the same reference numerals.

[0060] The bicycle saddles illustrated each have a saddle shell 10. A saddle frame 14 is connected with a lower side 12 of the saddle shell 10. Here the saddle frame 14 is formed in particular by two metal bars of which the rear bar is visible in sectional views (FIGS. 2, 3, 5 and 7). In the region of a saddle tip 16, the two bars are fixed in a protrusion 18 of the saddle shell 10. In the region of the rear side 20 of the saddle, the two bars of the frame 14 are each fixed separately in a protrusion 22 of the saddle shell 10.

[0061] On an upper side 24 of the saddle shell 10, a saddle pad 26 is arranged which is built-up differently in the different embodiments.

[0062] In the first preferred embodiment (FIGS. 1 and 2), the saddle pad 26 has an inner pad element 28 as well as an outer pad element 30 surrounding the inner pad element 28 substantially completely. The inner pad element 28 is preferably made of TPU and the outer pad element 30 is made of a PU foam. The inner pad element 28 contacts the upper side 24 of the saddle shell 10 by a flat lower side 32. Possibly, the inner pad element 28 is connected with the upper side 24 of the saddle shell 10 by gluing. The PU foam serves to produce the outer pad element 30 which surrounds all sides of the inner pad element 28 except for the lower side 32. Possibly, the inner pad element 28 may also be arranged such that the outer pad element 30 does not surround the same e.g. in the region of a rear side 34 so that the inner pad element 28 is visible in this region.

[0063] In the embodiment illustrated in FIGS. 1 and 2, the inner pad element 28 is arranged in a seat region 36 of the saddle. Contiguous to the seat region 36 are a center region 38 as well as a saddle tip 40. In this embodiment, only a saddle pad of PU foam is arranged both in the center region 38 and in the region of the saddle tip 40, so that only the outer pad 30 is provided in this region.

[0064] In an alternative embodiment in FIG. 2a, similar and identical parts are identified by the same reference numerals. The only difference between the embodiments illustrated in FIG. 1 and FIG. 2a is in the design of the inner pad element 28. In the design shown in FIG. 2a, the inner pad element 28 has an upward extending protrusion 20. The protrusion 29 is preferably formed integrally with the inner pad element 28. In this embodiment, an upper side 31 of the protrusion 29 is not covered by the outer pad element 30 so that the upper side 31 of the protrusion 29 is well visible to the user.

[0065] In an alternative embodiment (FIG. 3), the inner pad element 28 is designed such that it has protrusions or feet 42 directed towards the upper side 24 of the saddle shell 10. An inner pad element 28 of such design is connected, e.g. glued, with the upper side 24 of the saddle shell 10 in particular via the feet 24. By providing the feet it is possible to form regions 44 beneath the inner pad element 28. These may be designed as cavities or may also be filled with the foam in the material of the outer pad element 30.

[0066] With the embodiment illustrated in FIG. 3, the damping and rebound characteristics of the saddle can be varied in the seat region 36.

[0067] In an alternative embodiment, the inner pad element 28 illustrated in FIG. 3 can also have a protrusion 29 similar to the embodiment illustrated in FIG. 2a.

[0068] The inner pad element may also, as illustrated in FIG. 5, be designed as an inner pad element 46 or may have another shape. In the seat region 36, the inner pad element 46 is designed similar to the inner pad element 28 illustrated in FIG. 2. In addition, the inner pad element 46 with the part 48 arranged in the seat region is provided with a part 50 of the inner pad element 46 in the center region 38. Both parts 48, 50 of the inner pad element 46 are formed integrally. The part 50 of the inner pad element 46 is thinner or has a lower height than the part 498 arranged in the seat region 48.

[0069] A retaining protrusion 54 is arranged on a lower side 52 of the inner pad element 46. The retaining protrusion 54 is connected with an extension 56 which in the embodiment illustrated is designed as a bead. In the embodiment illustrated, the retaining protrusion 54 is cylindrical and the extension 56 is designed as an annular bead. In the saddle shell 10, a recess or opening 58 is arranged which in the embodiment illustrated is continuous. For fixing the inner pad element 46, it is thus possible to press the retaining protrusion 54, together with the bead 56, through the opening 58 in FIG. 5 from above. Owing to the bead 56, which has a larger dimension than the opening 58, a secure retention of the inner pad element 46 is achieved.

[0070] For producing the bicycle saddles illustrated in the FIGS. 1 to 5 or described above, the corresponding inner pad element 28 or 46 is produced in a corresponding mold in a first step. The inner pad element 28, 46 is preferably made of TPU and in particular the material sold by BASF under the trademark Infinergy. In the next step, the inner pad element 28, 46 is connected with or fixed to the upper side 24 of the saddle shell 10. In the embodiments illustrated on FIGS. 1 to 3, this is effected e.g. by gluing. In the embodiment illustrated in FIGS. 4 and 5, the connection is made by pressing the retaining protrusion 54 into the opening 58. In the next step, the saddle shell is placed into a casting mold together with the inner pad element 28, 46 fastened thereto and together with the frame 14 provided on the outer side. The placing into the casting mold is effected such that the saddle frame is directed upward. Thereafter, the material for producing the outer pad element 30 is filled into the casting mold and is foamed. Due to the saddle being placed into the casting mold with the saddle frame directed upward, filling in the material for the outer pad element 30 is possible in a simple manner. By fixing the inner pad element 28, 46 to the saddle shell 10, it is ensured that the element remains in contact with the upper side 24 of the saddle shell 10.

[0071] Possibly, prior to placing the saddle shell into the casting mold, the same can be lined with a saddle cover. The saddle cover is fixed in the casting mold preferably by means of vacuum so that a smooth surface is realized.

[0072] In the embodiment illustrated in FIGS. 6 and 7, a main pad element 60 is connected with the upper side 24 of the saddle shell 10. In this case, the main pad element 60 is preferably made of TPU. The main pad element 60 can be produced in a separate mold and be glued on the upper side 24 thereafter. Likewise, it is possible to arrange the material for producing the main pad element 60 in a mold together with the saddle shell 10. When TPU is used to produce the main pad element 60, the raw material is exposed to vapor. Therefore, it is advantageous that the saddle shell 10 has small passage openings for introducing vapor. The shape main pad element 60 is designed such that at least one recess 62 is provided in the seat region 36. In the center region 38, one further recess 64 (FIG. 6) is provided on either side. Auxiliary pad elements 66, 68 are arranged n all recesses 62, 64. The auxiliary pad elements 66, 68 are made in particular of PU foam and are covered with a saddle cover material preferably on the outer sides. Thus, by arranging the auxiliary pad elements 68, friction is reduced in particular at the sides in the center portion 38. By the combination of the two pad elements 60, 66, a good damping and a good rebound behavior are achieved in the seat region 36.

[0073] As an alternative, it is possible in all above described embodiments to produce the saddle pads 26 independently of the saddle shell. The corresponding saddle pads which comprise at least two different pad elements, can then be e.g. glued on the upper side 24 of the saddle shell 10.