Abstract:
A seat incorporating insert(s) intermediate its upper and lower surfaces. A seat insert for the support of the users buttocks conforms to the user&#39;s body, has “rebound” properties, and areas adapted to underlie the perineum and/or ischiums of a user softer than the rest of the seat insert. Alternatively, a perineal insert and/or ischium inserts may be used without the seat insert described. Finally, a heatable insert can be used in conjunction with or in the absence of said seat inserts to provide heat for the comfort of a seat user. In all cases, the aforesaid inserts are preferably completely encapsulated and enclosed by the foam materials making up the seat, which can be accomplished by molding the seat around the insert(s), creating a seat with various internal density zones, adjustable heat, and enhanced abilities to conform to the user&#39;s body, while limiting pressure on perineum and/or ischiums.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of parent application Ser. No. 13/775,111 titled “Molded Seat” filed Feb. 22, 2013, which was a continuation-in-part of parent application Ser. No. 13/624,905 titled “Molded Seat” filed Sep. 22, 2012 the same being incorporated herein by reference and claiming priority thereto. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    Field of the Invention 
         [0003]    This invention pertains generally to seat bottoms and seat bottom construction, but may have more general applicability to overall seat construction design and techniques. More specifically, the invention pertains to a molded seat bottom which incorporates and has been molded around an insert or inserts shaped in particular ways, having particular characteristics, comprised of particular materials chosen to impart desirable characteristics to the seat, including heating elements, and/or methods and systems for producing seats of this type. 
         [0004]    Description of the Related Art 
         [0005]    Polyurethane, produced by combining monomers including isocyanate functional groups and hydroxyl groups, is a known material for forming resilient seating of all types, including motorcycle seats. The combination process typically requires a catalyst and, for applications similar to those of interest in the instant invention, a mold of some type. In this process, liquid isocyanate and resin are blended at a specific ratio, and the reacting liquid is dispensed into the mold and allowed to cure, then the finished part is demolded. Typically, in high volume manufacturing applications, a dispensing unit is used to combine and dispense the reacting liquid into the mold used in forming the finished piece in a process commonly known as reaction injection molding (“RIM”). 
         [0006]    Examples of prior art patents that may be found to have teachings relevant to the invention are:
       (1) U.S. Pat. No. 3,787,278 for a “Molded Multiple Density Polyurethane Foam” issued Jan. 22, 1974, to Ready et al., describing molded, multiple density polyurethane foams and a process for their preparation.   (2) U.S. Pat. No. 4,572,856 for a “Composite Molded Article and Process Using Self-Positioning Laminated Stiffener” issued Feb. 25, 1986, to Gembinski, describing a stiffener insert incorporated into a molded composite article such as an automobile dashboard by inserting the stiffener insert between a pre-formed plastisol skin forming opposing mold walls.       
 
         [0009]    However, there is a continuing need for devices providing new and improved features in the field of the invention. Further, there are no prior art devices possessing the unique features and advantages inherent in my invention. 
       SUMMARY OF THE INVENTION 
       [0010]    The instant invention teaches a seat having insert(s) or “mat(s)” incorporated therein intermediate its upper and lower surfaces so as, in most cases, to be generally parallel to the upper surface of the seat (i.e., the surface on which the posterior of the user will rest). The primary embodiments of an insert/mat described herein are comprised of material that conforms to the contours of the user&#39;s body over a period of time, has certain “rebound” properties (or spring-like performance), and features areas adapted to underlie the perineum and/or ischiums of a user seated on the seat, which areas are softer than the rest of the insert either by virtue of included gap(s) in the insert or by virtue of a softer material filling said gap(s). In another embodiment of the invention, the insert(s) is/are adapted and shaped to underly, e.g., the perineum or ischiums of a user and is/are comprised of a softer material than the surrounding foam. Other insert embodiments may include heating elements. Materials for use in forming such inserts may include a variety of materials including gel-like materials, gel packets, air packets (which may be made adjustable in terms of pressure), and foams. 
         [0011]    In the preferred embodiments taught herein the aforesaid inserts are completely encapsulated and enclosed by the foam materials making up the seat with this being advantageously accomplished by molding the seat around the inserts. This is made possible, in accordance with the teachings of the invention, by providing means for suspending inserts within the mold used in forming the seat so as to be in proper spaced relationship to the upper surface of the seat (on which the user will be seated) and the lower surface of the seat (facing away from the seated user) when formed in the mold. Thus, my invention is enabled to provide a more comfortable seat for the user with—even in the most basic embodiments discussed—enhanced abilities to conform to the user&#39;s body and enhanced springiness, while limiting pressure on the perineum. In addition, the “integrated or molded in” aspect of the invention maintains the integrity of the exterior foam seat surfaces, in particular the upper surface of the seat/foam. In this manner, the essential “mechanics” or “workings” of my invention (as provided by said insert(s)) are “hidden” inside the foam making up the seat; protected thereby from wear, weather and the elements; and creating little or no interruption of the top surface in terms of aesthetics or the look/feel of upholstery fit, etc. Further, carefully selecting and designing the properties of the various foams, gels and/or other materials involved, i.e., insert materials, perineal gap materials, ischial gap materials, heating insert materials, and surrounding foam, provides the ability to control the overall suspension effect with zone density control, to better adapt the final composite to the human anatomy and pressures for various applications, and to provide a heated seat with elements hidden from view and protected from wear and weather. 
         [0012]    Thus, as opposed to simply adding the same (or a similar) pad on top of the molded foam (which might be an obvious approach), “embedding” or “in-molding” creates a subtle transition between the generally firm areas of the foam and the softer pressure relief areas. It creates soft spots and/or springy areas deep within the foam. Also, simply adding a foam pad on top (consisting of soft, springy and/or firm sections), would result in too abrupt a transition between areas of varying characteristics and density, as opposed to the more “blended” transitions achieved by the instant invention. Another potential problem that adding a pad on top would create (consisting of presumably bonded foam composite of varying densities), is the potential for delamination of the pad composite due to wear and sheer forces. By molding foam around the pad, all of the above issues are solved, and we have created a foam cushion composite with incredibly strong construction and gentle transitions between areas of firm support and soft areas. 
         [0013]    These goals and others are all accomplished in an efficient and economical manner using the method I have developed for molding the seat around an insert or inserts including and providing the characteristics described. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  provides a schematic perspective view of a mold and dispenser for forming an exemplary polyurethane seat in accordance with the teachings of prior art. 
           [0015]      FIG. 2  provides a schematic perspective view of a preferred embodiment of a seat insert in accordance with the teachings of my invention. 
           [0016]      FIG. 3  provides a schematic perspective view of the preferred embodiment of a seat insert illustrated in  FIG. 2 , wherein the perineal gap therein is filled with an insert which may be comprise, e.g., gel-like materials, gel packets, air packets (which may be made adjustable in terms of pressure), and soft foams or other similar filler(s), 
           [0017]      FIG. 4  provides a schematic perspective view of the mold and dispenser of  FIG. 1  as adapted for placement and support of a seat insert therein by inclusion of appropriately spaced and configured support pegs in accordance with the teachings of my invention. 
           [0018]      FIG. 5  provides a schematic perspective view of the mold and dispenser including appropriately spaced and configured support pegs as illustrated in  FIG. 4  with the seat insert appropriately mounted thereon in accordance with the teachings of my invention. 
           [0019]      FIG. 6  provides another schematic perspective view of the mold and dispenser including appropriately spaced and configured support pegs as illustrated in  FIG. 4  with the seat insert appropriately mounted thereon in accordance with the teachings of my invention. 
           [0020]      FIG. 7  provides a schematic perspective view of the mold and dispenser including appropriately spaced and configured support pegs as illustrated in  FIG. 4  with another preferred seat insert embodiment appropriately mounted thereon in accordance with the teachings of my invention. 
           [0021]      FIG. 8  provides a schematic cross-sectional perspective view of an exemplary motorcycle seat with integral seat insert of the types previously illustrated included therein. all formed in accordance with the teachings of my invention. 
           [0022]      FIG. 9  provides a schematic perspective view of the mold and dispenser including appropriately spaced and configured support pegs for and with a perineal insert appropriately mounted thereon in accordance with the teachings of my invention. 
           [0023]      FIG. 10  provides a schematic cross-sectional perspective view of an exemplary motorcycle seat with integral perineal insert formed in accordance with the teachings of my invention. 
           [0024]      FIG. 11  provides a schematic perspective view of an exemplary heating element pad/insert in accordance with the teachings of my invention. 
           [0025]      FIG. 12  provides a schematic perspective view of the mold and dispenser including appropriately spaced and configured support pegs with seat insert and heating element pad/insert appropriately mounted thereon in accordance with the teachings of my invention. 
           [0026]      FIG. 13  provides a schematic perspective view of the mold and dispenser including appropriately spaced and configured support pegs with seat insert and heating element pad/insert appropriately mounted thereon in accordance with the teachings of my invention, wherein said inserts have appropriately spaced and configured perineum and ischium openings. 
           [0027]      FIG. 14  provides a schematic perspective view of another version of the initial preferred embodiment of a seat insert in accordance with the teachings of my invention, but having both perineal and ischium openings which are filled with gel-like materials, gel packets, air packets (which may be made adjustable in terms of pressure). and soft foams or other similar filler(s). 
           [0028]      FIG. 15  provides a schematic cross-sectional perspective view of an exemplary motorcycle seat with inserts as illustrated in  FIG. 14 , all formed in accordance with the teachings of my invention. 
           [0029]      FIG. 16  provides a schematic perspective view of a mold and dispenser including appropriately spaced and configured support pegs for and with a perineal insert and ischium inserts, all appropriately mounted thereon in accordance with the teachings of my invention. 
           [0030]      FIG. 17  provides a schematic cross-sectional perspective view of an exemplary motorcycle seat with inserts as illustrated in  FIG. 16 , all formed in accordance with the teachings of my invention. 
       
    
    
     DESCRIPTION 
       [0031]    The process, construction and apparatus used in the instant invention can best be understood by careful and ordered review of the above-referenced drawing figures, beginning with  FIG. 1 , which illustrates a mold  1  having an upper mold part  1 A and a lower mold part  1 B, defining a hollow mold space  1 C (in the desired shape of a motorcycle seat in this case) when closed together. (The motorcycle seat shown in the drawing figures provides an example of how the teachings of the invention can be applied in this context, but should not be seen as limiting the scope of the inventive concept to this particular type of seating). As illustrated, and in accordance with the prior discussion of the reaction injection molding process, a dispensing unit  2  is used to combine and dispense the reacting liquid  30  into the mold  1  used in forming the finished piece, a polyurethane motorcycle seat (not illustrated), in accordance with the teachings of prior art. Once an appropriate amount of liquid  30  is dispensed into mold space  1 C, the mold is closed, and the reacting liquid  30  expands to fully till the mold space  1 C, taking the desired form/shape of a motorcycle seat as defined by the shape of mold space  1 C. 
         [0032]    With the background previously provided, especially in regard to  FIG. 1 , the teachings and novelty of  FIGS. 2 and 3  can be better appreciated. These drawing figures illustrate an initial preferred embodiment of a seat insert  10  in accordance with the teachings of my invention. As will be noted, both versions illustrated feature foam dispersion and distribution openings/vents  11  scattered across their surfaces, mounting peg openings  12 , and a perineal opening  13 , with the version of the first embodiment illustrated in  FIG. 3  varying from that in  FIG. 2  by virtue of the inclusion of a sub-insert/perineal insert  14  in perineal opening  13  which may be comprised of gel-like materials, gel packets air packets, and soft foams or other similar filler(s), such as super-light density foam. (Where an air packet forms an insert or pad such as perineal insert  14 , its pressure may be adjusted by means known in the art by the inclusion of a tube (not shown) leading from the packet to an activatable pump (not shown) or release valve (not shown) which can be used to adjust the pressure/firmness of the insert). Another embodiment is illustrated in  FIG. 7 , where perineal opening  13  forms a gap completely separating the two halves of seat insert  10 . However, possible embodiments are not restricted to those including seat inserts  10 . An embodiments using only a perineal insert  14  is illustrated in  FIGS. 9 and 10 , while a still further variation, using only perineal inserts  14  and ischium inserts  15  is illustrated in  FIGS. 16 and 17 . 
         [0033]    In the embodiments having larger inserts  10 , it is sometimes advantageous to include openings  11  so that reacting liquid  30  can freely move through and around the seat inserts  10  so that there are no unfilled gaps left in the molded seat  20 . These holes/openings  11  may be of varying size, frequency of distribution or not included at all, depending on the flow characteristics and/or requirements of each particular mold/insert/seat. Thus, they are not shown in all illustrations, particularly those where open perineal openings  13  and/or ischium openings  19  provide alternate means of distribution which have been found sufficient by themselves for the aforesaid purpose without the inclusion of openings  11 . However, the primary purpose of perineal openings  13  and/or ischium openings  19  is to create, include and incorporate a softer area or cushion below the perineum and/or ischiums of the person seated on seat  20 . 
         [0034]    Perineum/perineal openings  13  are provided as the perineum is more sensitive than surrounding areas for many people. By leaving the perineal opening  13  unfilled (as illustrated in  FIG. 2 ), this area will be filled with the somewhat softer polyurethane foam making up the remainder of seat  20 . Alternately, as illustrated in  FIGS. 3, 9 and 10 , a sub-insert/perineal insert  14 —which may be comprised of gel-like materials gel packets, air packets (which may be made adjustable in terms of pressure), and soft foams or other similar filler(s), such as super-light density foam—provides an even softer substrate for this same purpose. Thus, in the version of seat insert  10  illustrated in  FIG. 2  (and  FIG. 7 ) openings  11  will generally be found to be unnecessary, but in the version of insert  10  illustrated in  FIG. 3 , they will serve a valuable purpose in allowing the complete and even spreading of reacting liquid  30  so that no gaps remain. 
         [0035]    As will be appreciated from the drawing figures (and in accordance with their anatomical purpose of underlying the perineal regions of a user), perineal opening  13  and perineal inserts  14  are preferably elongate, which shape defines a long axis that will be aligned with the bilateral axis of the user when seated on seat  20 , and serve to separate seat  20  and/or mat/insert  10  into two halves, each of which would support, anatomically, respective buttocks/thighs of the user. 
         [0036]    Insert  10  is preferably formed from closed cell foam with characteristics important to the purposes of my invention, though other materials having similar characteristics or other chosen characteristics can be used for this purpose. One such characteristic is “Compression Set”, a property that describes the fact that a permanent foam setting or deformation is achieved when a load is place on the seat insert  10  over a period of time. In the instant application this is advantageous because it allows the insert to form itself to the contours of the user&#39;s body over a period of time, adapting itself to the particular shape and configuration of the user for added user comfort. Vinyl nitrile foam has been found ideal for these purposes. Another important property of any such insert  10  is “rebound” (or spring-like performance), which is a property of vinyl nitrite foam by virtue of its closed cell construction. The inclusion and incorporation of insert  10  in molded seat  20  results in a final molded foam composite (seat  20 ) that is enhanced with these added properties derived from insert  10 . However, as previously mentioned. other materials may be useful for this purpose, particularly other closed cell foam materials. 
         [0037]    Review of  FIGS. 4 through 6  provide insight into the manner in which, and apparatus used, to adapt the mold  1  of  FIG. 1  for placement and support of a seat insert  10  therein in a position intermediate upper mold half  1 A and lower mold half  1 B. In this position it will be completely enveloped and surrounded by polyurethane foam as part of the reaction injection molding process previously described and thereby completely encapsulated in, enveloped by, and embedded in, the seat  20  formed thereby. (See, e.g.,  FIG. 8 ). This is accomplished by the inclusion of appropriately spaced and configured support pegs  3  in mold space  1 C, preferably via mounting/attachment of said pegs  3  to lower mold part  1 B as illustrated in  FIG. 4 . 
         [0038]    As will be noted, pegs  3  can be advantageously formed with a base portion  3 A (adapted for insertion in a registering opening provided in mold base portion  3 A), support portion  3 B (which holds the insert  10  in place within the mold  1  in spaced relationship to the upper mold portion  1 A and lower mold portion  1 B when the mold  1  is closed), a ledge portion  3 C (with a substantially conical shape providing direct support of the insert  10  from below while allowing the seat  20  to be withdrawn—due to its sloped portion—from the mold  1  when it is formed), a barrel section  3 D (dimensioned in terms of diameter and length to fit the width of mounting peg openings  12  and the thickness of insert  10 ), and a substantially conical head  3 E (adapted to push through the somewhat flexible material of insert  10  while holding the insert  10  in place from above). Thus, insert  10  can be pressed onto the pegs  2  in mold  1  (as illustrated in  FIGS. 5 and 6 ) so as to be positioned adjacent barrel section  3 D so as to be held firmly in place between ledge portion  3 C and head  3 E through the molding process, and both insert  10  and seat  20  can be freed from pegs  3  and pulled out of mold  1  easily de-molded), when the molding process is complete. 
         [0039]    However, as a practical matter, it has also been found that the addition of a flexible elastic band  31  (typically in the form of a fairly large circular “rubber” band) can assist and facilitate the molding process and that the pegs  3  of the invention are ideally shaped and structured for this purpose. The need for such facilitation arises from the fact that the reacting liquid  30  can churn and grow inside the mold in such a manner that it generates enough force to occasionally dislodge element(s) placed on pegs  3  (e.g., heatable insert  16  and/or seat insert  10 ) and cause it/them to float off of pegs  3  despite the pegs enlarged head  3 E. This can be remedied by stretching an elastic band  31  around pegs  3  intermediate inserts  10 ,  16  and peg heads  3 E as illustrated in  FIG. 5 . The elastic band  31 , being flexible, does not have any adverse effect as an artifact left over in the finished seat  20 . In addition, it is advisable to add small bumps (¼ in high) to the surface of the mold in select areas under inserts  10 ,  16  to keep them from sagging between the pegs  3 . (Two to four of these are sufficient). Particularly with this modification, the seats  20  are consistently formed with inserts  10 ,  16  suspended exactly ¼ inch beneath the foam seating surface. When removed, as illustrated in  FIG. 8 , the seat  20  of the invention will feature a completely embedded and encapsulated insert  10  having the features previously described. Similarly,  FIGS. 9 and 10  illustrate the aforesaid teachings and techniques as applied to a perineal insert  14 , when used without a seat insert  10 . 
         [0040]      FIGS. 11 through 13  provide further insights into the possibilities of my invention. In this case, illustrating the potential for including a heatable seat insert  16  as well as the previously mentioned ischium openings  19  in seat insert  10  and heatable insert  16 . The heatable insert  16  can be made from materials suitable for embedding a heating element/wire  17 , and can advantageously be electrically activated by leads  18  connected via a switch to a source of electrical power in accordance with techniques known in the electrical and mechanical arts. The heatable insert  16  is best placed under the seat insert  10  (as illustrated in  FIGS. 12 and 13 ), which assists in buffering, spreading and diffusing the heat produced by the heatable insert  16 . 
         [0041]    A problem to be dealt with in this context is that the heatable insert  16  may become too rigid when traditional heating pad technology is used. Such heating pads utilize cloth carrier sheets to form the body of the heating pad sandwiching the resistive wire (which in this case would be analogous to, respectively, heatable insert  16  and wires  17 ). However, the reacting/pressurized liquid  30  forms foam that saturates/plugs such cloth heating pad carrier sheets, creating a very rigid end product that sticks to the material of seat  20 , which is counterproductive to comfortable seating. Consequently, in the invention it has been found beneficial to form the heatable insert  16  from a substance that cannot be saturated in this manner. Thus, a preferred embodiment of the invention uses heatable inserts  16  formed using a material that repels reacting liquid  30  such as conformable PTFE, vinyl, or silicone carrier sheets with the right strength, conformability (flex), and temperature rating. By not bonding/sticking to the reacting foam while it is forming, the heatable insert  16  creates its own individual “cell” and is allowed to “float” independently inside this cell in the foam comprising seat  20 , thus allowing movement (flexibility) within the final foam part. Another way to avoid the problems set forth above is to replace the carrier sheets discussed above in reference to heatable insert  16  with a “conformable adhesive film” and weaving/placing wires  17  onto the adhesive surface  32  of said film, which is oriented so as to face the foam insert  10  and then sticking the heatable insert  16  formed in this manner to the foam insert  10  before molding it in (s illustrated in  FIG. 12 ). This has been found to provide superior comfort and ease of assembly, when heat is added to the overall assembly. 
         [0042]    The ischium openings  19  illustrated for both seat insert  10  and heatable insert  16  in  FIG. 13  are provided because the ischium bones are primary weight supporting skeletal features for the human body when seated, and adjustment of density and seat response under these bones can greatly increase the comfort of a seat to a user. Thus, the ischium openings  19  can be left open as illustrated in regard to seat insert  10  in  FIG. 13 , or can accommodate an appropriately sized ischium insert  15  having qualities generally in accordance with those previously discussed with regard to perineal inserts  14  in the perineal opening  13 . (See, e.g.  FIGS. 14 and 15 ). 
         [0043]    Alternatively, particularly with regard to the heatable insert  16 , the size of the seat ischium openings  19  can be left open, but minimized as illustrated in  FIG. 13 , to allow for less interruption in the density of heating element/wires  17 , and also allow for the same heatable insert  16  to be used in other applications with full heat wire coverage when no ischium opening  19  is desired. This can be done by closing off most of the ischium opening  19  with tabs  19 A that can flex and give under the weight of a user (alternatively, it could be said that the opening  19  is comprised of “X” shaped slots that create such tabs  19 A). 
       PARTS AND FEATURES ILLUSTRATED IN DRAWING FIGURES 
       [0044]      1  Mold
         1 A upper mold part     1 B lower mold part       
 
         [0047]      2  Dispenser 
         [0048]      3  Pegs
         3 A base portion     3 B support portion     3 C ledge portion     3 D barrel section     3 E conical head       
 
         [0054]      10  Seat Insert 
         [0055]      11  Insert openings 
         [0056]      12  Mounting peg openings 
         [0057]      13  Perineal opening 
         [0058]      14  Perineal insert 
         [0059]      15  Ischium insert 
         [0060]      16  Heatable insert 
         [0061]      17  Embedded heating elements/wires 
         [0062]      18  Lead wires for heating element 
         [0063]      19  Ischium opening
         19 A Ischium opening tabs       
 
         [0065]      20  Seat
         20 A upper surface of seat (molded by lower mold part  1 B)     20 B lower surface of seat (molded by upper mold part  1 A)       
 
         [0068]      21  Openings left in seat  20  by part  3 B 
         [0069]      30  Reacting liquid 
         [0070]      31  Elastic Band 
         [0071]      32  Adhesive Surface 
         [0072]    In view of the foregoing, it should be clear that numerous chances and variations can be made without exceeding the scope of the inventive concept outlined. Thus, though the preferred embodiment is illustrated in the context of a motorcycle seat, the teachings of the invention are not necessarily restricted to such seats. Indeed, potential applications range from seats for all kinds of riders (horseback/motorcycle/ATV) to more mundane chairs and seats used in other applications. Further, though the preferred materials comprising the seat are specified, other materials with similar support and/or molding characteristics may certainly be substituted. In addition, though single layer mats/inserts are shown, the inventive concept does not preclude multiple mat/insert layers or further subdivision of the mat/insert in terms of its constituent materials than those shown. Accordingly, it is to be understood that the embodiment(s) of the invention herein described is/are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiment(s) is not intended to limit the scope of the claims, which will themselves recite those features regarded as essential to the invention