Patent Description:
In the field of support elements for the human body, such as saddles for vehicles, for example bicycles, it is known to make a padding, whether or not equipped with an external covering that wraps it at its external or visible surface, which padding - after being made - is constrained, for example by gluing, to an upper surface of a plastic support base, for example called "shell" or "felt" in bicycles. According to this specific example, a "fork" can be constrained to the plastic base at its lower surface in order to bind the saddle to a seatpost of a bicycle frame.

However, it often happens that the padding, once made, is extracted from the mould and only later bound, for example by gluing, to the plastic base. In this case, it can be difficult to connect these two elements, as the padding can lose its dimensional stability and can therefore be difficult to couple with the plastic base, which, conversely, has a well-defined shape and size.

At the same time, when the external covering is present, it may be difficult to carry out the necessary trimming phase, because the padding is made of a soft material, and trimming an element such as the external covering having no support points, but finding it necessary to work on a soft support (precisely the padding), may not be easy: the trimming tool may not find a sufficiently rigid and/or conformed guide to carry out quality work.

<CIT> and <CIT> disclose related methods and moulding units for making seats.

There is also a method that makes it possible to obtain a bicycle saddle in which there is no need for gluing between the padding and the support base. Patent <CIT>, in the name of the same Applicant, describes a method for making a saddle whereby an external covering is placed over a cavity in a female part of a mould, to which it conforms by the use of vacuum means. A material is injected into the cavity where the external covering is placed, forming the padding of the saddle itself, and the mould is then closed with a male part. Due to the properties of the respective materials, the padding adheres to the external covering and also to a felt or support base, as the male part of the mould is shaped to house said felt.

In this case, therefore, the upper surface of the felt determines the lower surface of the padding, in the sense that these two surfaces are in contact with each other. At the next opening of the mould, a finished saddle is extracted, followed by the trimming of the excess part of the external covering.

It is therefore necessary to provide a method and support element that can compensate for the aforementioned shortcomings and thus enable a high quality product to be obtained, even when padding and support base are not coupled together immediately or in the same mould.

In addition, there is also a need for a mould that makes it possible to obtain the aforementioned advantages for the method just indicated.

The object of the present invention is to overcome the drawbacks of the prior art.

A further purpose of the present invention is to provide a method for making a support element for the human body that is practical and possibly automatable.

Another object of the present invention is to provide a method for speeding up and making more precise the steps for obtaining a support element for the human body.

A further purpose of the present invention is to provide a method that is relatively inexpensive.

In accordance with one aspect of the invention, there is provided a method for making a support element according to claim <NUM>.

Another object of the present invention is to provide a support element for the human body which is easily assembled.

A further object of the present invention is to provide a support element for the human body that is precise.

In accordance with an aspect of the invention there a support element for the human body according to claim <NUM> is provided.

Yet another object of the present invention is to provide a moulding unit that allows a support element, as mentioned above, to be made easily and quickly.

Another object of the present invention is to provide a moulding unit that ensures that a support element is obtained with higher quality and efficiency than traditional moulds. According to one aspect of the invention a moulding unit according to claim <NUM> is provided.

The dependent claims refer to preferred and advantageous examples of embodiments of the invention.

Other characteristics and advantages of the invention will be more evident from the disclosure of an example of an embodiment of the present invention, illustrated by way of example in the accompanying drawings:.

In the accompanying drawings, identical parts or components are distinguished by the same reference numerals.

The present invention relates to a method for making a support element for the human body, a support element, such as a vehicle saddle, for example a bicycle or motorcycle saddle, or a backrest or a seat or an armrest for anatomical chairs, or similar support elements, or a part thereof, etc., thus obtained and a relative moulding unit.

<FIG> shows a moulding unit <NUM> according to the present invention, for the production of a support element for the human body.

More specifically, unit <NUM> comprises a first component <NUM> and a second component <NUM>. The first component <NUM> is a punch element of the moulding unit <NUM> while the second component <NUM> is a die component of the moulding unit <NUM>.

The first component <NUM> can be coupled to the second component <NUM>. In particular, when the first component <NUM> is in abutment against the second component <NUM>, the moulding unit <NUM> is in a closed operating configuration while when the first component <NUM> and the second component <NUM> are moved away from each other, the moulding unit is in an open operating configuration.

Means of approaching-removing the first component <NUM> with respect to the second component <NUM> (not shown in the Figures) are therefore provided, which are capable of moving the moulding unit <NUM> from the open to the closed operating configuration and vice versa, including all intermediate operating positions between open and closed.

Such approaching-removing means, generally known in the industry, may comprise an electric, pneumatic or other actuator designed to reciprocally approach and/or move the first component <NUM> and the second component <NUM> along a rectilinear or angular or rotational direction. This means that the first component <NUM> can be moved relative to the second component <NUM> along a predetermined rectilinear direction, or it can be moved angularly or rotating in approach-close or move away-open mode relative to the second component <NUM>, and vice versa.

In <FIG>, the second component <NUM> is in a lower position than the first component <NUM>. Different positions, however, can be contemplated.

In the present disclosure, the term "upper" refers to an element that, in use, is positioned above or higher, or is facing upwards; with the term "lower", on the other hand, refers to an element that, in use, is positioned below or lower, or is facing downwards or towards the ground.

The term "longitudinal" refers to a direction that extends along the longest part of an element while the term "transverse" refers to a direction that extends perpendicular to the longest part of an element, or from side to side thereof.

"Vertical" means a direction or a plane that in use goes from the bottom to the top while "horizontal" means a direction or a plane that, in use, is parallel to the ground.

The second component <NUM> comprises and/or delimits a cavity <NUM>, suitable for use to house and/or to be filled with a material adapted to form a padding <NUM> of a support element <NUM>. This material can be inserted, poured or injected into the cavity <NUM> and is capable of foaming and/or hardening and/or polymerising and/or solidifying within the cavity <NUM>. The material is therefore a hardenable and/or polymerisable and/or solidifiable material. The cavity <NUM> is recessed relative to the second component <NUM> and is shaped substantially negatively with respect to the padding <NUM>.

The cavity <NUM> is open at the top, in at least one first configuration or version of the invention. Thus, the cavity <NUM> has an opening 16a.

The cavity <NUM> is formed by a shaped surface 16b, in recess, and by a perimeter edge 16c, which defines the opening 16a.

The first component <NUM> includes a punch element <NUM>. The punch element <NUM> is shaped in such a way as to abut against the cavity <NUM> and/or against its perimeter edge 16c, so as to determine the closure of the moulding unit <NUM> and/or of the cavity <NUM>.

The punch element <NUM> rises from the first component <NUM>. It comprises a shaped area 18a and an external profile 18b.

The external profile 18b corresponds to the perimeter edge 16c of the second component <NUM> and/or is adapted to come into contact with and/or abut against the perimeter edge 16c. At the external profile 18b of the punch element <NUM> there are abutment elements 18c, for example shaped like a peg or cylinder, which can be housed in appropriate and corresponding seats 16d arranged, for example, at the perimeter edge 16c of the cavity <NUM>. The position of the abutment elements 18c and of the appropriate seats 16d are matched, so that when the first component <NUM> comes into abutment against the second component <NUM>, the abutment elements 18c can be housed in the seats 16d. However, the position of the abutment elements 18c and that of the relative seats 16d can be reversed, without departing from the scope of the present invention, as defined by the claims.

The shaped surface 16b of the cavity <NUM> is defined by a first delimiting edge 16e. Similarly, the shaped area 18a of the punch element <NUM> is defined by a second delimiting edge 18d.

In the closed operating configuration, the first delimiting edge 16e and the second delimiting edge 18d abut each other.

The shaped surface 16b and the shaped area 18a determine the upper surface <NUM> and the lower surface <NUM> of the padding <NUM>, respectively.

When the moulding unit <NUM> is in a closed operating phase, a padding <NUM> of the support element <NUM> is moulded.

The method according to the present invention is defined by Claim <NUM>, thus comprises the following steps:.

In one version of the invention, the method may comprise the following steps:.

The trimming step follows the step of hardening and/or polymerising and/or solidifying or the step of removing and/or the step of extracting.

When the external covering <NUM> is present, the padding material <NUM> is positioned in the cavity <NUM> after the step of positioning the external covering and is brought into contact with the external covering <NUM> itself.

The step of locking the external covering <NUM> in place can be accomplished by locking an excess portion 120a of the external covering <NUM> by means, for example, of a retention plate <NUM>, as better disclosed below.

According to a further version, the external covering <NUM> can be locked in position directly by the punch element <NUM>, in abutment against the first component <NUM>. In particular, the external profile 18b in abutment against the perimeter edge 16c of the second component <NUM> locks in place the excess portion 120a of the external covering <NUM>. The trimming phase is swift, whether carried out manually, for example by means of a special trimming machine, or in an automated manner. Thanks to the support component <NUM>, in fact, there is no surplus material to be trimmed, since the outermost edge 122c of the support component <NUM> is placed at a certain distance, for example about <NUM>, or a distance between <NUM> and <NUM>, from the trim edge 114a of the padding <NUM>.

The trim edge 114a of the padding <NUM> is the edge that ideally separates the excess portion 120a of the external covering <NUM> from the portion thereof that is adhered to the upper surface <NUM> of the padding <NUM> itself.

The trim edge 114a is the edge along which trimming of the external covering <NUM> takes place.

Thus, the trim edge 114a of the padding <NUM>, as will be better understood from the disclosure below, is determined in use by the contact between the first delimiting edge 16e and the second delimiting edge 18d of the cavity <NUM> and the punch element <NUM>, respectively.

When a support base <NUM> is constrained to the padding <NUM>, the trim edge 114a is placed inside with respect to the support base <NUM> and/or its outer perimeter profile 150a.

The step of hardening and/or polymerising and/or solidifying comprising a step of obtaining, at the lower surface <NUM> of the padding <NUM>, an internal area <NUM> at which the support component <NUM> is adhered to the hardened and/or polymerised and/or solidified material, and an annular area <NUM>, surrounding the internal area <NUM>, comprising such hardened and/or polymerised and/or solidified material.

The internal area <NUM>, in at least one version of the invention, is in recess with respect to the annular area <NUM>.

The annular area <NUM> is obtained adjacent to the trim edge 114a, between the latter and the outermost edge 122c of the support component <NUM>.

Subsequently, the method comprises a step of constraining a support base <NUM> at the support component <NUM> (and/or its external face 122b) and/or a lower surface <NUM> of the padding <NUM> (and/or at the annular area <NUM>) to which the support component <NUM> is attached, wherein the step of constraining comprises a step of applying a glue or a gluing agent on a lower surface <NUM> of the padding <NUM> and on the support component <NUM> (and/or its external face 122b) and a step of gluing the support base <NUM> on said lower surface <NUM> and on the support component <NUM> or vice versa.

The glue or gluing agent may comprise a polyurethane-based compound, e.g. a two component polyurethane glue, etc. Other components may be provided according to the specific type of materials of the elements to be glued together.

The glue or gluing agent may also be applied several times, for example twice to the lower surface <NUM> of the padding <NUM>, waiting a certain period of time between one application and the next. This can be especially useful when the glue is applied, for example, by a brush or similar tool, while it may not be necessary if the glued is sprayed on.

The method according to the present invention may comprise the steps of preparing and/or washing and/or degreasing at least an upper surface of the support base <NUM>, so that it can accommodate the glue or gluing agent and thus bind to the lower surface <NUM> of the padding <NUM> and/or to the support component <NUM>.

The method according to the present invention may also comprise steps of preparing and/or washing at least the lower surface <NUM> of the padding <NUM>. For example, such steps are performed prior to that of applying the glue or gluing agent.

The washing steps can be carried out with special washing substances, including chemical-based ones, in order to prepare the treated and/or washed surfaces. In this way, the washing substance can lead to the breakage of double bonds present in the hardened and/or polymerised and/or solidified material of the padding <NUM>.

A primer and/or a compatibilising agent may be applied to the upper surface of the support base <NUM> in order to facilitate constraining and/or gluing to the padding <NUM> and/or the support component <NUM>.

This facilitates the constraint of the support base <NUM> with the padding <NUM> itself.

The adhesion of the support component <NUM> to the material that achieves the padding <NUM> is, in at least one version of the invention, determined by the chemical affinity between the two materials and/or results from the reaction of hardening and/or polymerisation and/or solidification of the material that achieves the padding, a reaction that takes place near the support component <NUM> itself.

In an alternative version, it would be possible for the step of adhesion of the support component <NUM> to the padding <NUM> to be aided by the application, on an internal face 122a of the support component <NUM>, of a suitable compatibilising and/or adjuvant agent and/or glue.

The step of constraining the support base <NUM> at the support component <NUM> and/or the lower surface <NUM> of the padding <NUM> to which the support component <NUM> is attached may also comprise applying a glue or gluing agent to an upper surface of the support base <NUM>.

The step of constraining the support base <NUM> to the padding <NUM> may be carried out, for example, by means of a compression press machine, for example separate from the moulding unit <NUM> of the present invention.

According to an alternative version, the support base <NUM> can be constrained to a male component (not shown in the attached Figures) by appropriate engagement means. In the moulding unit <NUM>, the male component is an alternative to the first component <NUM>. In fact, once the padding <NUM> has been made, and after trimming the excess portion 120a of the external covering <NUM> (if necessary), the male component could be removably coupled to the second component <NUM>, bringing the support base <NUM> in abutment against the lower surface <NUM> of the padding <NUM> and against the support component <NUM>.

In this way, the constraint and/or bonding of the support base <NUM> with the padding <NUM> could take place through the use of this male component and thus substantially through a single moulding unit <NUM>.

As a result of the present method, the support component <NUM> is flush with the lower surface <NUM> of the padding <NUM> and/or with the annular area <NUM>. Therefore, and despite being made with a reduced thickness, in at least one version of the invention, the support component <NUM> does not protrude with respect to the padding material, the latter for example positioned at the annular area <NUM>.

Thus, the support component <NUM> is placed in a sort of corresponding imprint or recessed area (the dimensions of which correspond to those of the support component <NUM> and its thickness), which is in fact formed by the internal area <NUM>, which is determined in the padding <NUM>.

In this way, in at least one version of the invention, the lower surface <NUM> of the padding <NUM>, formed by the support component <NUM> and the annular area <NUM>, is substantially without discontinuities or steps, once realised.

Thus, the support component <NUM> is to some extent embedded and/or inserted into the material forming the padding <NUM>. This means that at least the internal face 122a of the support component <NUM>, the one intended to come into contact with the padding <NUM>, and the thickness of the support component <NUM>, will be surrounded and in contact with the material of the padding <NUM>. Conversely, an external face 122b of the support component <NUM>, which is visible after the step of making the padding and which is adapted in use to be constrained and/or glued to the support base <NUM>, is not in recess or projecting with respect to the material that constitutes the padding <NUM> and/or the annular area <NUM>, but substantially planar and/or flush with it.

Thus, the external face 122b is at least partially not covered by the hardened and/or polymerised and/or solidified material that constitutes the padding <NUM>.

This is also clear considering that the external face 122b of the support component <NUM> is the one in use which is in contact with the shaped area 18a of the punch element <NUM>. In this way, therefore, the means that hold the support component <NUM> in position do not allow the passage, between the external face 122b and the shaped area 18a, of the material that constitutes the padding <NUM>.

The method may also include a step of abrading the material of this annular area <NUM>, so that the annular surface becomes rough and/or wrinkled and/or has a rough and/or wrinkled pattern.

In fact, as mentioned, it is possible that the material that makes up the padding <NUM> is at least superficially compact following hardening and/or polymerisation and/or solidification. This abrading step is capable of making the surface of the annular area <NUM> more absorbent of the glue or gluing agent required for the subsequent constraint of the support base <NUM>. The abrading step, at least in one version of the invention, may open the chemical bonds of the material constituting the padding <NUM> and/or may mechanically roughen and/or wrinkle that area, so as to facilitate the gluing step.

The abrading step may be performed by milling and/or abrasion and/or scraping and/or removal and/or mechanical etching of the surface layer of said annular area <NUM>.

The method according to one version of the present invention can provide that at least one of its steps and/or at least the step of abrading and/or applying a glue or a gluing agent and/or trimming is automated and/or performed by a robot, for example anthropomorphic. This is another advantage conferred by the presence of the support component <NUM>: its dimensional stability and consistency enable the padding <NUM>, once made and with the support component <NUM> attached to its lower surface <NUM>, to be positioned on a template or special tool. In this way, the steps of the method and/or the step of trimming the external covering <NUM> and/or the steps of preparing the padding <NUM>, and/or the step of abrading (as visible in <FIG>) and/or the step of applying a glue or a gluing agent (as visible in <FIG>) are carried out automatically, for example by a robot, for example anthropomorphic, instead of manually.

The template or the appropriate tool has, for example, a shape corresponding in negative to that of the padding <NUM> and/or its upper surface <NUM>, and/or comprises a vice and/or an undercut.

Finally, the step of constraining or gluing the padding <NUM> to the support base <NUM> can be performed by placing said elements or only one of them in an oven, for example convective, which brings the entire mass of said elements or only one of them to a temperature corresponding, for example, of about <NUM>. Subsequently, a coupling, for example manual, and pressing of the two elements onto each other, takes place. In this way, in at least one version of the invention, the support element <NUM> will be ready for marketing, without the need for further finishing and/or cleaning steps.

The step of positioning the support component <NUM> onto the punch element <NUM> comprises a step of positioning and/or securing the support component <NUM> through retention means present on the punch element <NUM>. Such retaining means comprise a containment rim <NUM> and/or retention means <NUM> and appropriate seats and/or holes <NUM> on the support component <NUM> itself, as further specified below.

According to a version of the invention, the support element <NUM> can have a hole, preferably a through hole, in a central and/or longitudinal area thereof. The hole may be circular or elongated. This is particularly useful when the support element <NUM> is a saddle for a vehicle, as such a hole may allow better ventilation or may provide pressure relief for the user at certain points, such as prostate or soft tissue points.

When such a hole is present, it can affect both the padding <NUM> and the support component <NUM>. In particular, in the latter an opening is made, for example circular or elongated, during the preparation or moulding phase of the support component itself. With regard to the padding <NUM> and/or the external covering <NUM>, this hole can be made, possibly at the opening provided on the support component, even after the step of making the padding itself. In this case, the method can comprise a step of making such a hole at the substantially central and/or longitudinal part of the external covering <NUM> and/or the padding <NUM>, after the step of hardening and/or polymerisation and/or solidifying, or after the step of distancing, or after the step of extracting, possibly at the corresponding opening present in the support component <NUM>. This can be performed, for example, by a pressure cutting element or by shearing or other similar methods.

According to a version of the invention, the padding <NUM> can comprise at least one insert. Such an insert can be made, for example, of a polyurethane material, and/or of a material having a different density with respect to the remaining material that constitutes the padding and/or in a material with different chemical and/or physical and/or mechanical properties with respect to the remaining material that constitutes the padding and/or in a material distinguishable by at least one property from the material that constitutes the rest of the padding <NUM>. According to one version, such at least one insert may be made of a polyurethane gel or ethylene-vinyl acetate (EVA).

Such at least one insert may be positioned at the at least one area of the padding where it is desired to obtain a different density and/or mechanical properties than the rest of the padding, e.g. improved comfort, and/or improved cushioning and/or increased stiffness and/or firmness.

The method according to the present invention may therefore comprise a step of providing at least one insert and positioning such at least one insert internally proximate the external covering <NUM> and/or the support component <NUM>.

The step of supplying the at least one insert may comprise either a step of supplying an already pre-shaped insert or a step of pouring a suitable material at the at least one area where such an insert is to be placed.

The support element <NUM> obtained with the method according to the present invention therefore comprises a padding <NUM>, possibly comprising at least one insert, and a support component <NUM>.

When the at least one insert is provided pre-shaped, it can be constrained, for example, to the internal face 122a of the support component <NUM>, so that after the realisation of the padding <NUM> it is incorporated therein. The presence of such at least one insert, e.g. made of EVA, makes it possible to stiffen the material at the same time, both due to the intrinsic characteristics of such an insert and to the fact that, where it is present, the volume that can be occupied by the padding <NUM> is reduced and thus the same material will in fact be denser and/or less expansive and/or stiffer (compared to the same material that can be positioned in a larger volume). The at least one insert may, for example, be glued to the support component <NUM>.

When the insert is poured, it may be poured into specific areas of the cavity <NUM>, prior to the insertion of the material that will constitute the padding <NUM>. In this case, a certain period of time can be allowed to elapse, for example to enable at least partially the polymerisation and/or hardening and/or solidification of the material of the at least one insert, so that the material that constitutes the padding does not invade the areas designated to the at least one insert and/or mix with the latter.

The support component <NUM> has a conformation substantially corresponding to that of the padding <NUM>, but slightly smaller than the latter.

When the support element <NUM> is a saddle for a vehicle, such as a bicycle saddle, both the padding <NUM> and the support component <NUM> have a first portion, front or anterior in use, of substantially elongated conformation, and a second portion, rear in use, of substantially enlarged conformation. The first portion is connected to the second portion, as the overall conformation of the padding <NUM> and/or the support component <NUM> is substantially triangular, with rounded edges.

The flanks or side portions connecting the first portion to the second portion, according to at least one version of the invention, are at least slightly contoured, so as to present a kind of concavity (with a cavity facing outwards and to the side). Such shaping may, for example, facilitate pedalling by the user.

The support component <NUM> may be made of a composite material, e.g. a latex-impregnated cellulose agglomerate, such as the commercially available material Texon, and/or a synthetic material and/or a plastic and/or thermoplastic material, such as a material comprising or consisting of polyester and viscose, and/or a thermoformable material, and/or a rigid polyurethane or a soft polyurethane, etc..

The support component <NUM> is at least partially inserted and/or embedded in the hardened and/or polymerised and/or solidified material of the padding <NUM>. This is except for its external face 122b.

In one version of the invention, the support component <NUM> is not made of a material such as a fabric or a mesh. Fabric or mesh, in general, do not provide the necessary stiffness desired with the support component <NUM> of the present invention. Moreover, the fabric or mesh - at least the traditional one - does not help to maintain the dimensions of the padding, does not provide a "guide" for trimming the external covering, and does not prevent dimensional shrinkage of the padding material itself.

The support component <NUM> is of a very slender thickness, in the order of a few millimetres or approximately <NUM> or less.

The support component <NUM> provides a certain "stiffness" to the padding <NUM>. For example, the support component has a Young modulus stiffness of <NUM> to <NUM> Mpa. The support component <NUM> is in fact stiffer than the material constituting the padding <NUM> and/or the material constituting the external covering <NUM>.

The support component <NUM>, in at least one version of the invention, has the same stiffness as the support base <NUM> but of a very reduced thickness compared to the latter.

The support component <NUM> may be produced, in a version of the invention, by a thermoforming process.

The support component <NUM> has two major faces, having substantially the same conformation as that of the support component itself. These major faces, in fact, are spaced from each other by the thickness of the support component which, as mentioned, is very thin.

The larger faces of the support component are an internal face 122a, adapted in use to be facing towards and/or constrained with the material of the padding <NUM>, and an external face 122b, adapted in use to be facing towards and/or constrained with the support base <NUM>.

The support base <NUM> (for example visible in <FIG> and <FIG>) may, for example, be made of a plastic and/or synthetic material such as, for example, polyamide, or a metallic or composite material.

At least one of the internal face 122a and external face 122b, preferably the one in external use 122b, is at least partially rough and/or includes unevenness, ripples, grooves and valleys that are more or less irregular or have been adjusted, etc. In this way, the support component <NUM>, through its external face 122b having this particular pattern or texture, more easily retains the glue or the gluing agent that is used for the bonding with the support base <NUM> and/or is impregnated more easily by such glue or gluing agent. In this way, it is possible, for example, to avoid using a primer between the support component and the material that will constitute the support base <NUM>.

The support element <NUM>, in a version of the invention, can comprise at least one external covering <NUM>. Such external covering <NUM> may be made of a plastic or natural material, such as a fabric, leather, imitation leather, a layer of compact and/or closed cell or foamed polyurethane material, a high density material, a synthetic and/or polymeric material such as PVC or polyvinyl chloride, etc..

When the external covering <NUM> is present, a layer of primer or compatibilising agent, for example based on polyurethane and/or components thereof, may be present and/or applied to facilitate adhesion of the external covering <NUM> to the padding <NUM>. In such a case, this layer is applied on a face 120c, in internal use, of the external covering <NUM>, adapted to be facing and/or constrained with the upper surface <NUM> of the padding <NUM>. It is apparent that, when the external covering <NUM> is present, the upper surface <NUM> of the padding <NUM> is not external or accessible from the outside or by a user, as it is covered by the external covering <NUM> and/or constrained thereto.

The external covering <NUM> also has an external face 120b which, when present, is adapted to come into contact with the user and/or be visible from the outside.

The material constituting the padding <NUM> may include a foam, a self-skimming foam, a polyurethane foam, a printed insert, e.g. by means of a three-dimensional printer, a cushioning and/or comfort insert, etc. Such material is able to expand, in at least one version of the invention. Furthermore, in one version of the invention, such material can be inserted, poured or injected into the cavity <NUM> of the moulding unit <NUM> and is adapted to foam, harden and/or polymerise and/or solidify inside the cavity <NUM> itself.

As can be seen, the present invention therefore also relates to a support element for the human body obtainable by a method according to the present invention, wherein the support element <NUM> comprises the padding <NUM>, the support component <NUM> and, optionally, the support base <NUM>, wherein the padding <NUM> comprises a hardened and/or polymerised and/or solidified material to which the support component <NUM> is adhered. The support component <NUM> may be placed, in use, between the padding <NUM> and the support base <NUM>, when the latter is present.

This support component <NUM> is adhered to the padding <NUM> and/or glued to the support base <NUM>.

There may be an external covering <NUM>, which covers at least partially or completely the padding <NUM>.

In at least one version of the invention, the padding <NUM>, with the support component <NUM> attached, constitutes a semi-finished assembly. In this case, therefore, it constitutes a part of a support element <NUM>. In order to obtain the usable and/or complete support element <NUM>, in fact, it is useful for the support base <NUM> also to be present. However, due to the presence of the support component <NUM>, as mentioned above, the dimensional stability of the moulded padding <NUM> is maintained, which could then be sold as such or stored for later application of the support base <NUM>.

Due to the presence of the support component <NUM>, coupling operations between the padding <NUM> and the support base <NUM> take a few seconds, whereas in the absence of the support component, or by application of materials other than those listed here for the support component <NUM>, coupling operations take up to a few minutes. Furthermore, in the absence of the support component <NUM>, the operator's ability is decisive for a correct constraint with the support base. Conversely, this operation is also very easy for the operator when support component <NUM> is present.

The advantage of the support component <NUM> is also measured in terms of effectiveness during the trimming operation of the excess portion 120a of the external covering <NUM>. In fact, the advantage lies in having a consistent and compact component - namely, the support component <NUM> - which facilitates the operator in carrying out this operation. The present invention also has as an object a moulding unit <NUM>. This moulding unit <NUM> is adapted to be used for the method according to the present invention and/or for the realisation of the support element described above.

When the external covering <NUM> is present, the moulding unit <NUM> may comprise vacuum means and/or a special retention plate (e.g. indicated by <NUM> in <FIG>). The retention plate <NUM> is positioned above the cavity <NUM>, so that, when the external covering is present, a layer of material adapted to make it is positioned at the cavity <NUM>. The size of the external covering layer is larger than the size of the cavity so that, once positioned at the cavity <NUM>, it can overlap with respect to the perimeter edge 16c and/or the first delimiting edge 16e of an excess portion 120a (visible for example in <FIG>).

The retention plate <NUM> locks the external covering <NUM> in place by pressing and constraining the excess portion 120a, then the vacuum means are actuated and the external covering <NUM> adheres to the moulded surface 16b, assuming the conformation of the latter. The retention plate <NUM> has a substantially annular surface and is provided with a through opening corresponding to the opening 16a of the cavity <NUM>.

In particular, the outer covering has the external face 120b, adapted to come into contact with the cavity <NUM> and intended to constitute the outermost layer of the padding <NUM> in use, and the internal face 120c, adapted to come into contact with the padding material <NUM>. The internal face 120c of the external covering <NUM> in use is not visible.

When the external covering <NUM> is not present, however, the material that constitutes the padding <NUM> is able independently to create a more compact film and/or with more closed and/or less expanded cells (compared to the material that will constitute the remaining part of the padding <NUM>) in contact with the shaped surface 16b.

According to the invention, and as mentioned, the punch element <NUM> comprises retention means for the support component <NUM>.

Such retention means, for example placed at the shaped area 18a of the punch element <NUM>, may comprise a containment rim <NUM>, adapted in use to contain and/or retain a support component <NUM> and/or retention means <NUM>.

In one version of the invention, the rim <NUM> is able to prevent the material that constitutes the padding from passing through the rim itself and overlapping the external face 122b of the support component <NUM>.

The containment rim <NUM> is internal with respect to the external profile 18b and/or the second delimiting edge 18d of the punch element <NUM>. In fact, the external profile 18b has a larger size than the second delimiting edge 18d and/or the containment rim <NUM>. According to one version of the invention, the containment rim <NUM> is located about <NUM> from the external profile 18b. Accordingly, the area enclosed by the containment rim <NUM> is smaller than the area enclosed by the second delimiting edge 18d, which corresponds to the shaped area 18a, which in turn is smaller than the area enclosed by the external profile 18b.

The containment rim <NUM>, therefore, divides the shaped area 18a into an internal area <NUM> at the rim <NUM> and an annular area <NUM>, surrounding the internal area <NUM>.

This containment rim <NUM> protrudes with respect to the shaped area 18a, as shown in <FIG>.

In an alternative version, not illustrated in the Figures, the containment rim <NUM> could be flush with the shaped area 18a and could enclose an internal area <NUM>, recessed with respect to the shaped area 18a. The depth of the indentation of this internal area may correspond to the thickness of the support component <NUM>. In such a case, the annular area <NUM> would also be flush with the rim <NUM>. The rim <NUM>, therefore, would be determined by the difference in depth between the internal area and the annular area.

The shaped area 18a, however, as visible, for example, in <FIG>, is shaped to correspond, as mentioned, to the lower surface <NUM> of the padding <NUM>.

The internal area <NUM>, therefore, determines the formation of most of the lower surface <NUM> of the padding <NUM> and/or of the internal area <NUM> while the annular area <NUM> determines the formation of the annular area <NUM> of the padding <NUM>.

The annular area <NUM>, as visible in <FIG>, therefore extends from the rim <NUM> to the second delimiting edge 18d of the punch element <NUM>. It may be inclined outwards, for example downwards and outwards, away from the rim <NUM>, according to the view in <FIG>.

This inclined surface can be straight or curved, with convexity towards the inside or towards the outside of the punch element <NUM>.

As mentioned, in at least one version of the invention, the punch element <NUM> can comprise suitable retention means <NUM> of the support component <NUM>, such as the coupling pins (visible in <FIG>).

Such retention means <NUM> can be shaped, for example, as a pin 30a, having a first end constrained or connected to the shaped area 18a and a second end or free end 30b, opposite the first end, having a section greater than that of the pin 30a.

The cross section of the peg 30a may be circular or polygonal. Similarly, the cross section of the free end 30b may be circular or polygonal.

The height of the peg 30a may be corresponding to or only slightly greater than the thickness of the support component <NUM>.

Naturally, the retention means <NUM> can have any other form suitable for the purpose, without departing from the scope of protection of the present invention, as defined by the claims.

In an alternative version, there may be no retention means <NUM>, as the support component may be held in position exclusively by the rim <NUM>.

According to a further version of the invention, the retention means <NUM> could be present, but not the rim <NUM>.

There could then be means for making the vacuum, adapted to hold the support component <NUM> in position on the punch element <NUM>, in the presence or absence of the rim <NUM> and/or the retention means <NUM>.

When the retention means <NUM> are present, the support component <NUM> will have special seats or special through holes <NUM> (for example visible in <FIG> and <FIG>), having a circular or polygonal section adapted to allow the passage of the retention means itself and, at the same time, to retain the support component <NUM> on the punch element <NUM>.

In one version of the invention, the retention means <NUM> are positioned at the shaped area 18a, or rather at the internal area <NUM>, possibly in the vicinity of the annular area <NUM>.

At the support base <NUM>, when the support element <NUM> is a saddle for a vehicle, in particular, for example, for a bicycle, a fork <NUM>, of a type known in the field, can be connected to the bicycle or vehicle frame.

In one version of the invention, the moulding unit <NUM> and/or at least the first component <NUM> is made of aluminium or other suitable metallic material.

The first component <NUM> and/or the second component <NUM> comprise a main plate from which the punch element <NUM> is raised and/or in which the cavity <NUM> is recessed respectively.

In the closing operating position of the moulding unit <NUM>, the first component <NUM> and the second component <NUM> may also be in contact with the respective main plates. Therefore, a sealed condition (by means of special gaskets, if desired) is created for the cavity <NUM> with the punch element <NUM> or rather with its shaped area 18a.

Characteristics defined for one variant or embodiment may also be present for other variants or embodiments, unless explicitly provided otherwise.

Claim 1:
Method for making a support element for the human body, such as a vehicle saddle, a bicycle or motorcycle saddle, a backrest or seat or armrest for an anatomical chair, or a similar support element, comprising the following steps:
- provide a material suitable for making a padding (<NUM>) of said support element (<NUM>),
- provide a support component (<NUM>), comprising an external face (122b) suitable in use to be constrained to a support base (<NUM>) of said support element,
- place said support component (<NUM>) at a punch element (<NUM>) of a first component (<NUM>) of a molding unit (<NUM>),
- insert and/or pour and/or inject said material into a cavity (<NUM>) of a second component (<NUM>) of said molding unit (<NUM>),
- close said cavity (<NUM>) with said punch element (<NUM>), bringing said first component (<NUM>) closer to said second component (<NUM>) or vice versa, bringing said support component (<NUM>) to face towards said cavity (<NUM>), determining for said molding unit (<NUM>) a closing operating configuration,
- harden and/or polymerize and/or solidify said material, obtaining a hardened and/or polymerized and/or solidified material which forms a padding (<NUM>), with consequent adhesion of said support component (<NUM>) to said padding (<NUM>), in which said support component (<NUM>) is at least partially inserted and/or embedded in said hardened and/or polymerized and/or solidified material of said padding (<NUM>), so that said external face (122b) of said support component (<NUM>) is at least partially not-covered by said hardened and/or polymerized and/or solidified material of said padding (<NUM>),
- move said first component (<NUM>) away from said second component (<NUM>) or vice versa, determining an open operating configuration for said molding unit (<NUM>),
- extract said padding (<NUM>) from said molding unit (<NUM>).