U.S. patent application number 10/012922 was filed with the patent office on 2003-05-01 for chamois for cycling pants and method of making.
Invention is credited to Forsyth, Robbin Douglas, Knoll, Jonathan Robert.
Application Number | 20030079276 10/012922 |
Document ID | / |
Family ID | 21757376 |
Filed Date | 2003-05-01 |
United States Patent
Application |
20030079276 |
Kind Code |
A1 |
Forsyth, Robbin Douglas ; et
al. |
May 1, 2003 |
Chamois for cycling pants and method of making
Abstract
A chamois for use within the seat area of a cycling garment
includes a non-woven polyester interfacing or batting layer with a
bottom surface that engages the cycling garment. The polyester
layer provides a pad area for association with the buttocks of a
cycling individual, two side pad areas for association with the
upper inside thighs of the individual, and a pad area for
association with the lower abdominal area of the individual. A thin
and low hardness synthetic foam layer has a shape that complements
the polyester layer, and a bottom surface thereof engages a top
surface of the polyester layer. A thick, high hardness, synthetic
foam layer is associated with the thin foam layer and occupies the
pad area association with the buttocks. A synthetic leather layer
has a shape that complements the shape of the polyester layer and a
bottom surface thereof engages the top surface of the thin foam
layer and the top surface of the thick foam layer.
Inventors: |
Forsyth, Robbin Douglas;
(Boulder, CO) ; Knoll, Jonathan Robert; (Boulder,
CO) |
Correspondence
Address: |
Francis A. Sirr
HOLLAND & HART LLP
P.O. Box 8749
Denver
CO
80201
US
|
Family ID: |
21757376 |
Appl. No.: |
10/012922 |
Filed: |
October 22, 2001 |
Current U.S.
Class: |
2/267 |
Current CPC
Class: |
A41D 1/084 20130101 |
Class at
Publication: |
2/267 |
International
Class: |
A41D 027/26 |
Claims
What is claimed is:
1. A chamois for use within the seat area of a cycling garment
comprising: a first cloth-like member having a top surface and a
bottom surface, said bottom surface for engagement with the cycling
garment; said first cloth-like member being formed in a shape that
provides an enlarged area at one end for association with the
buttocks of a cycling individual, that provides two side areas for
association with the upper inside thighs of the individual, and
that provides an area at an opposite end for association with the
lower abdominal area of the individual; a relatively thin foam
member having a shape that complements said shape of said first
cloth-like member; said thin foam-like member having a top surface
and a bottom surface that engages said top surface of said first
cloth-like member; said thin foam-like member having a relatively
low hardness; said thin foam-like member having at least one
through opening formed therein that is located to generally be
associated with the buttocks of the individual; a thick foam-like
member having a shape that complement said shape of said at least
one opening in said thin foam-like member; said thick foam-like
member being located within said at least one opening in said thin
foam-like member; said thick foam-like member having a top surface
and a bottom surface that top engages said top surface of said
first cloth-like member; said thick foam-like member having a
relatively high hardness, a second cloth-like member having a shape
that complements said shape of said first cloth-like member; said
second cloth like member having a top surface and a bottom surface
that engages said top surface of said thin foam-like member and
said top surface of said thick foam-like member; and attachment
means securing said first cloth-like member, said thin form-like
member, said thick foam-like member, and said second cloth-like
member together as a unitary assembly.
2. The chamois of claim 1 wherein said unitary assembly is formed
into a three-dimensional shape that approximates the pelvic girdle
of the individual.
3. The chamois of claim 1 wherein said second cloth-like member is
synthetic leather
4. The chamois of claim 1 wherein said first cloth-like member is a
non-woven interfacing or batting that is constructed of polyester
fibers.
5. The chamois of claim 1 wherein said second cloth-like member is
synthetic leather and wherein said first cloth-like member is a
non-woven interfacing or batting that is constructed of polyester
fibers.
6. The chamois of claim 5 wherein said chamois is heat-formed into
a three-dimensional shape that approximates the pelvic girdle of
the individual.
7. The chamois of claim 1 wherein said thin foam-like member and
said thick foam-like member are selected from a group consisting of
an open or closed cell foam, an air/gas expanded plastic material,
a cellular material having cells that are at least partially filled
with a gel, and a cellular material having cells that are at least
partially filled with a liquid.
8. The chamois of claim 7 wherein said second cloth-like member is
synthetic leather.
9. The chamois of claim 7 wherein said first cloth-like member is
wicking polyester.
10. The chamois of claim 7 wherein said second cloth-like member is
synthetic leather and wherein said first cloth-like member is
wicking polyester.
11. The chamois of claim 10 wherein said chamois is heat-formed
into a three-dimensional shape that approximates the pelvic girdle
of the individual.
12. The chamois of claim 1 wherein said second cloth-like member is
a wicking polyester member having at least one opening formed
therein to overlay and to correspond to said at least one opening
formed in said thin foam-like member and including: at least one
synthetic leather member having a shape corresponding to said at
least one opening in said wicking polyester member; and said at
least one synthetic leather member being located to close said at
least one opening in said wicking polyester member.
13. The chamois of claim 12 wherein said thin foam-like member and
said thick foam-like member are selected from a group consisting of
an open cell or closed cell air/gas expanded plastic material, a
cellular material having cells that are at least partially filled
with a gel, and a cellular material having cells that are at least
partially filled with a liquid.
14. The chamois of claim 13 wherein said chamois is heat-formed
into a three-dimensional shape that approximates the pelvic girdle
of the individual.
15. A cycling garment including a chamois as defined in claim 1
16. A chamois for use within the seat area of a cycling garment to
be worn by a male cyclist comprising: a first generally cloth-like
sheet having a top surface and a bottom surface, said bottom
surface for engagement with the cycling garment; said first
cloth-like sheet being formed in a shape that provides two
laterally spaced and similarly shaped buttocks pad areas for
association with the buttocks of a male cyclist, that provides a
crotch pad area intermediate said two buttocks pad areas for
association with the crotch area of the male cyclist, that provides
two similarly-shaped inner thigh pad areas for association with the
inner thighs of the male cyclist, and that provides a lower
abdominal pad area for association with the lower abdominal area of
the male cyclist; a thin foam sheet having a shape that complements
said shape of said first cloth-like sheet; said thin foam-like
sheet having a top surface and a bottom surface that engages said
top surface of said first cloth-like sheet; said thin foam-like
sheet having a hardness of about 20 d; said thin foam-like sheet
having two similarly-shaped through openings therein associated
with said two buttocks pad areas of said first cloth-like sheet;
two thick foam-like sheets; said two thick foam-like sheets each
having a shape that complements said shape of said two openings in
said thin foam-like sheet; said two thick foam-like sheets being
individually located within one of said two openings in said thin
foam-like sheet; said two thick foam-like sheets each having a top
surface and a bottom surface that engages said top surface of said
first cloth-like sheet; said two thick foam-like sheets having a
common hardness in the range of from about 40 d to about 90 d; a
second cloth-like sheet having a shape that complements said shape
of said first cloth-like sheet; said second cloth like sheet having
a top surface and a bottom surface that engages said top surface of
said thin foam-like sheet and said top surfaces of said two thick
foam-like sheets; and attachment means securing said first
cloth-like sheet, said thin foam-like sheet, said two thick
foam-like sheets, and said second cloth-like sheet together as a
unitary assembly.
17. The chamois of claim 16 wherein said unitary assembly is formed
into a three-dimensional shape that approximates the pelvic girdle
of the male cyclist.
18. The chamois of claim 16 wherein said second cloth-like sheet is
synthetic leather.
19. The chamois of claim 16 wherein said first cloth-like sheet is
wickable polyester.
20. The chamois of claim 16 wherein said second cloth-like sheet is
synthetic leather, and wherein said first cloth-like sheet is
non-woven polyester.
21. The chamois of claim 20 wherein said unitary assembly is
heat-formed into a three-dimensional shape that approximates the
pelvic girdle of the individual.
22. The chamois of claim 16 wherein said thin foam-like sheet and
said two thick foam-like sheets are selected from a group
consisting of an air and/or gas-expanded plastic material and a
cellular material having cells that are at least partially filled
with a gel and/or a liquid.
23. The chamois of claim 22 wherein said second cloth-like sheet is
synthetic leather.
24. The chamois of claim 22 wherein said first cloth-like sheet is
polyester batting.
25. The chamois of claim 24 wherein said second cloth-like sheet is
synthetic leather, and wherein said first cloth-like sheet is
polyester batting.
26. The chamois of claim 25 wherein said unitary assembly is
heat-formed into a three-dimensional shape that approximates the
pelvic girdle of the individual.
27. The chamois of claim 16 wherein: said second cloth-like sheet
is wickable polyester having two through openings therein that are
similar in shape to said two through openings in said thin
foam-like sheets, and each of said two through openings in said
wickable polyester sheet overlay an individual one of said two
through openings in said thin foam-like sheet, and including; two
synthetic leather sheets having a common thickness; each of said
two synthetic leather sheets having a shape that corresponds to
said common shape of said two through openings in said wickable
polyester; each of said two synthetic leather sheets closing a
respective one of said two through openings in said wickable
polyester.
28. The chamois of claim 27 wherein said thin foam-like sheet and
said two thick foam-like sheets are selected from a group
consisting of an air and/or gas-expanded plastic material, and a
cellular material having cells that are at least partially filled
with a gel and/or a liquid.
29. The chamois of claim 28 wherein said unitary assembly is formed
into a three-dimensional shape that approximates the pelvic girdle
of the male cyclist.
30. A cycling garment having an internally-located seat portion
that includes a chamois as defined in claim 16.
31. A chamois for use within the seat area of a cycling garment to
be worn by a female cyclist comprising: a first cloth-like sheet
having a top surface and a bottom surface, said bottom surface for
engagement with the cycling garment; said first cloth-like sheet
being formed in a shape that provides one relatively large pad area
for association with the buttocks and the crotch of a female
cyclist that provides two similarly-shaped inner thigh pad areas
for association with the inner thighs of the female cyclist, and
that provides a lower abdominal pad area for association with the
lower abdominal area of the female cyclist; a thin foam-like sheet
having a shape that complements said shape of said first cloth-like
sheet; said thin foam-like sheet having a top surface and a bottom
surface that engages said top surface of said first cloth-like
sheet; said thin foam-like sheet having a hardness of about 20 d;
said thin foam-like sheet having a through opening therein
associated with said large pad area of said first cloth-like sheet;
a thick foam-like sheet; said thick foam-like sheet having a shape
that complements said shape of said opening in said thin foam-like
sheet; said thick foam-like sheet being located within said opening
in said thin foam-like sheet; said thick foam-like sheet having a
top surface and a bottom surface that engages said top surface of
said first cloth-like sheet; said thick foam-like sheet having a
hardness in the range of from about 40 d to about 90 d; a second
cloth-like sheet having a shape that complements said shape of said
first cloth-like sheet; said second cloth like sheet having a top
surface and a bottom surface that engages said top surface of said
thin foam-like sheet and said top surface of said thick foam-like
sheet; and attachment means securing said first cloth-like sheet,
said thin foam-like sheet, said thick foam-like sheet, and said
second cloth-like sheet together as a unitary assembly.
32. The chamois of claim 31 wherein said unitary assembly is formed
into a three-dimensional shape that approximates the pelvic girdle
of the female cyclist.
33. The chamois of claim 31 wherein said second cloth-like sheet is
synthetic leather.
34. The chamois of claim 31 wherein said first cloth-like sheet is
wickable polyester.
35. The chamois of claim 31 wherein said second cloth-like sheet is
synthetic leather and wherein said first cloth-like sheet is
wickable polyester.
36. The chamois of claim 31 wherein said unitary assembly is heat
formed into a three-dimensional shape that approximates the pelvic
girdle of the female cyclist.
37. The chamois of claim 31 wherein said thin foam-like sheet and
thick foam-like sheet are selected from a group consisting of an
air and/or gas-expanded plastic material, and a cellular material
having cells that are at least partially filled with a gel and/or a
liquid.
38. The chamois of claim 37 wherein said second cloth-like sheet is
synthetic leather.
39. The chamois of claim 37 wherein said first cloth-like sheet is
warp knit polyester tricot having a wicking finish.
40. The chamois of claim 37 wherein said second cloth-like sheet is
synthetic leather and wherein said first cloth-like sheet is warp
knit polyester tricot having a wicking finish.
41. The chamois of claim 40 wherein said unitary assembly is heat
formed into a three-dimensional shape that approximates the pelvic
girdle of the female cyclist.
42. The chamois of claim 31 wherein: said second cloth-like sheet
is wickable polyester having a through opening therein that is
similar in shape to said through opening in said thin foam-like
sheets; said through opening in said wickable polyester sheet
overlying said through opening in said thin foam-like sheet, and
including; a synthetic leather sheet; said synthetic leather sheet
having a shape that corresponds to said shape of said through
opening in said wickable polyester; and said synthetic leather
sheet closing said through opening in said wickable polyester.
43. The chamois of claim 42 wherein said thin foam-like sheet and
said thick foam-like sheet are selected from a group consisting of
an air and/or gas-expanded plastic material, and a cellular
material having cells that are at least partially filled with a gel
and/or a liquid.
44. The chamois of claim 43 wherein said unitary assembly is heat
formed into a three-dimensional shape that approximates the pelvic
girdle of the female cyclist.
45. A cycling garment having an internally-located seat portion
containing a chamois as defined in claim 31.
46. The method of making a chamois for use within the seat area of
a cycling garment comprising: providing a first planar and flexible
cloth-like member having a bottom surface for engagement with the
cycling garment; forming said first cloth-like member into a shape
that provides an enlarged area at one end for association with the
buttocks of a cycling individual, that provides two side areas for
association with the upper inside thighs of the individual, and
that provides an area at an opposite end for association with the
lower abdominal area of the individual; providing a planar,
flexible and thin foam member having a relatively low hardness
property; forming said thin foam-like member into a shape that
complements said shape of said first cloth-like member; placing a
bottom surface of said thin foam-like member into engagement with a
top surface of said first cloth-like member; forming at least one
pad area on said thin foam-like member to be associated with the
buttocks of the individual; providing at least one planar, flexible
and thick foam-like member having a relatively high hardness
property; forming said at least one thick foam-like member into a
shape that complement said shape of said at least one pad area on
said thin foam-like member; placing said at least one thick
foam-like member on said at least one pad area on said thin
foam-like member; providing a second planar and flexible cloth-like
member; forming said second cloth-like member into a shape that
complements said shape of said first cloth-like member; placing a
bottom surface of said second cloth like member into engagement
with a top surface of said at least one thick foam-like member and
a top surface of said thin foam-like member; and bonding said first
cloth-like member, said thin foam-like member, said at least one
thick foam-like member, and said second cloth-like member together
as a unitary chamois assembly.
47. The method of claim 46 including the step of: forming said
unitary chamois assembly into a three-dimensional shape that
approximates the pelvic girdle of the individual.
48. The method of claim 46 wherein said second cloth-like member is
wickable polyester, and including the steps of: forming at least
one opening in said wickable polyester; placing said at least one
opening in said wickable polyester to overlay said at least one pad
area on said thin foam-like member; providing at least one
synthetic leather member; forming said at least one synthetic
leather member into a shape that corresponds to said at least one
opening in said wickable polyester; and placing said at least one
synthetic leather member within said at least one opening in said
wickable polyester.
49. The method of claim 48 including the step of: forming said
unitary chamois assembly into a three-dimensional shape that
approximates the pelvic girdle of the individual.
50. A chamois for use within the seat area of a cycling garment
comprising: a first polyester sheet having a top surface and a
bottom surface for engagement with the cycling garment; said first
polyester sheet being formed in a shape that provides at least one
enlarged pad area at one end for association with the buttocks of a
cycling individual, that provides two side pad areas for
association with the upper inside thighs of the individual, and
that provides a pad area at an opposite end for association with
the lower abdominal area of the individual; a thin synthetic foam
sheet having a shape that complements said shape of said first
polyester sheet; said thin foam sheet having a top surface and a
bottom surface that engages said top surface of said first
polyester sheet; said thin foam sheet having a relatively low
hardness; said thin foam sheet having at least one enlarged pad
area located thereon to overlay said at least one enlarged pad area
on said first polyester sheet; at least one thick synthetic foam
sheet having a shape that complements said shape of said at least
one enlarged pad area on said thin foam sheet; said at least one
thick foam sheet overlying said at least one enlarged pad area on
said thin foam sheet; said at least one thick foam sheet having a
top surface and a bottom surface that engages said top surface of
said thin foam sheet; said at least one thick foam sheet having a
relatively high hardness; a second polyester sheet having a wicking
finish and having a shape that complements said shape of said first
polyester sheet; said second polyester sheet having a top surface
and a bottom surface that engages said top surface of said thin
foam sheet and said top surface of said thick foam sheet; and
fuse-bonding means securing said first polyester sheet, said thin
foam sheet, said thick foam sheet, and said second polyester tricot
sheet member together as a unitary assembly.
51. The chamois of claim 50 wherein said unitary assembly is formed
into a three-dimensional shape that approximates the pelvic girdle
of the individual.
52. The chamois of claim 50 wherein said thin foam sheet and said
at least one thick foam sheet are selected from a group consisting
of an air/gas-expanded plastic material, a cellular material having
cells that are at least partially filled with a gel, and a cellular
material having cells that are at least partially filled with a
liquid.
53. The chamois of claim 50 wherein said second polyester sheet
includes at least one enlarged pad area thereon overlying said at
least one enlarged pad area on said thin foam sheet, and including:
at least one synthetic leather sheet having a shape corresponding
to said at least one enlarged pad area on said second polyester
sheet; and said at least one synthetic leather sheet being located
on said at least one enlarged pad area on second polyester
sheet.
54. A cycling garment including a chamois as defined in claim
53.
55. A method of making a chamois for use within the seat area of a
cycling garment to be worn by a male cyclist, comprising: providing
a first planar and generally cloth-like member having a bottom
surface for engagement with the cycling garment; forming said first
cloth-like member into a shape having two laterally-spaced buttocks
pad areas for association with the buttocks of a male cyclist,
having a crotch pad area intermediate said two buttocks pad areas
for association with the crotch are of a male cyclist, having two
inner thigh pad areas for association with the inner thighs of the
male cyclist, and having a lower abdominal pad area for association
with the lower abdominal area of the male cyclist; providing a thin
foam member having a relatively low hardness; forming said thin
foam member into a shape that complements said shape of said first
cloth-like member; providing two similarly-shaped through openings
in said thin foam member for association with said two buttocks pad
areas of said first cloth-like member; placing a bottom surface of
said thin foam member into engagement with a top surface of said
first cloth-like member; providing two thick foam members having a
common and relatively high hardness; forming each of said two thick
foam members into a shape that complements said similar shape of
said two openings in said thin foam member; placing one of said two
thick foam members within each of said two openings in said thin
foam member; providing a second cloth-like member; forming said
second cloth-like member into a shape that complements said shape
of said first cloth-like member; placing a bottom surface of said
second cloth-like member into engagement with a top surface of said
two thick foam members and a top surface of said thin foam member;
and securing said first cloth-like member, said thin foam member,
said two thick foam members, and said second cloth-like sheet
together into a unitary chamois assembly.
56. The method of claim 55 including the step of: forming said
unitary chamois assembly into a three-dimensional shape that
approximates the pelvic girdle of the male cyclist.
57. The method of claim 55 wherein said second cloth-like member is
a wickable polyester including the steps of: forming two
similarly-shaped openings in said wickable polyester; placing said
two openings in said wickable polyester to overlay said two
openings in said thin foam member; providing two synthetic leather
members; forming each of said two synthetic leather members into a
shape that corresponds to said two openings in said wickable
polyester; and placing one of said two synthetic leathers member
into each of said two openings in said wickable polyester.
58. The method of claim 55 including the step of: forming said
unitary chamois assembly into a three-dimensional shape that
approximates the pelvic girdle of the male cyclist.
59. A method of making a chamois for use within the seat area of a
cycling garment to be worn by a female cyclist comprising:
providing a first cloth-like member having a bottom surface for
engagement with the cycling garment; forming said first cloth-like
member into a shape that provides one pad area for association with
the buttocks and the crotch of a female cyclist, that provides two
thigh pad areas for association with the inner thighs of the female
cyclist, and that provides a lower abdominal pad area for
association with the lower abdominal area of the female cyclist;
providing a thin foam member having a relatively low hardness;
forming said thin foam member into a shape that complements said
shape of said first cloth-like sheet; placing a bottom surface of
said thin foam member into engagement with a top surface of said
first cloth-like member; providing a through opening in said thin
foam member for association with said large pad area of said first
cloth-like member; placing a bottom surface of said thin foam
member into engagement with a top surface of said first cloth-like
member; providing a thick foam member having a relatively high
hardness; forming said thick foam member into a shape that
complements said shape of said opening in said thin foam member;
placing said thick foam member into said opening in said thin foam
member; providing a second cloth-like member; forming said second
cloth-like member into a shape that complements said shape of said
first cloth-like sheet; placing a bottom surface of said second
cloth like sheet into engagement with a top surface of said thin
foam member and a top surface of said thick foam member; and
securing said first cloth-like member, said thin foam member, said
thick foam member, and said second cloth-like sheet together as a
unitary chamois assembly.
60. The method of claim 59 including the step of: forming said
unitary chamois assembly into a three-dimensional shape that
approximates the pelvic girdle of the female cyclist.
61. The method of claim 59 wherein said second cloth-like member is
a wickable polyester including the steps of: forming an opening in
said wickable polyester; placing said opening in said wickable
polyester to overlay said opening in said thin foam member;
providing a synthetic leather member; forming said synthetic
leather member into a shape that corresponds to said opening in
said wickable polyester; and placing said synthetic leather member
into said opening in said wickable polyester.
62. The method of claim 60 including the step of: forming said
unitary chamois assembly into a three-dimensional shape that
approximates the pelvic girdle of the female cyclist.
63. The method of making a chamois for use within the seat area of
a cycling garment comprising the steps of: providing a first
cloth-like sheet; providing a thin foam sheet having a low
hardness; providing a second cloth-like sheet; placing said thin
foam sheet intermediate said first cloth-like sheet and said second
cloth-like sheet to thereby form a three-sheet assembly; binding
said three-sheet assembly together to form a unitary three sheet
assembly; cutting said unitary three-sheet assembly into a
plurality of three sheet pieces each having a shape of said
chamois; identifying an area within each of said three sheet pieces
that is adapted to be associated with the buttocks area of a
cyclist; providing a thick foam sheet having a high hardness;
providing a third cloth-like sheet; placing said thick foam sheet
onto said third cloth-like sheet to thereby form a two-sheet
assembly; binding said two-sheet assembly together to form a
unitary two sheet assembly; cutting said unitary two-sheet assembly
into a plurality of two sheet pieces each having a shape
corresponding to said identified area within each of said three
sheet pieces; placing at least one of said two sheet pieces on one
of said three sheet pieces with said thick foam sheet of said at
least one two sheet pieces in physical engagement with said
identified area within said three sheet piece; and binding said at
least one two sheet piece to said one three sheet piece to form
said chamois.
64. The method of claim 63 wherein said third cloth-like sheet is a
sheet of synthetic leather.
65. The method of claim 63 wherein said thin foam sheet has a
hardness of about 20 d, and wherein said thick foam sheet has a
hardness in the range of from about 40 d to about 90 d.
66. The method of claim 63 including the step of: forming said
chamois into a three-dimensional shape approximating the shape of
the pelvic girdle of a cyclist.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the field of garments to be worn
by humans, and, more specifically, to a chamois for use within
cycling pants or shorts to be worn by a male or a female while
operating a bicycle.
[0003] 2. Description of Related Art
[0004] Cycling pants/shorts of various configurations have become
popular because they provide durability, they provide cushioning
between the bicycle seat and the cyclist, and they minimize chafing
of the body of the cyclist. Cycling pants conventionally include an
inner pad that is located within the crotch and buttocks regions of
the cyclist. Such pads have become known as chamois. While some
chamois are composed of a number of pieces of flexible material
that are stitched together, other chamois are formed of one piece
of material.
[0005] For example, U.S. Pat. No. 4,961,233 (incorporated herein by
reference) provides a two-layer, one-piece, heat-formed, and
seamless chamois that includes an inner liner that faces the body
of the cyclist and is made of a synthetic leather-like material,
such as the brand Ultrasuede, and an outer synthetic fleece
(polyester) member that is compressible. The inner liner and the
synthetic fleece are adhesive bonded. The chamois is heat-formed to
impart a generally form-fitting shape to the chamois wherein the
edges of the chamois are over edge stitched. U.S. Design Pat. DES.
No. 360,971 also appears to be directed to the above anatomical
seat pad.
[0006] U.S. Pat. No. 5,271,101 (incorporated herein by reference)
provides cycling shorts that include a padded, three-layer, seat
liner having a plurality of integrally formed and embossed break
lines that create seamless indentations in the liner. These break
lines are positioned such that the liner conforms to the anatomical
profile of a cyclist who is positioned in a riding position on a
bicycle. The liner is stitched or laminated to a body portion of
the cycling pants. The liner includes a nylon tricot backing layer,
a high-density polyurethane foam layer having open or closed cells
that overlies the backing layer, and a synthetic suede covering
layer that overlies the foam layer. The synthetic suede has a
soft-napped side that faces the cyclist body. The embossed break
lines are located in positions that represent pressure crease point
of the seat liner when a cyclist is in a cycling position, and as
the cyclist moves to other positions so as to prevent the bunching
of excess material. The embossed break lines are formed without
using stitching or sewn seams by heat molding the seat liner in a
flat position.
[0007] U.S. Pat. No. 4,805,243 (incorporated herein by reference)
describes bicycle shorts having openable pockets that removably
receive seat and crotch synthetic foam pads having different
thickness, thus adapting the padding to suit individual
preferences.
[0008] U.S. Pat. No. 4,945,571 (incorporated herein by reference)
provides bicycling shorts having a liquid-filled cushion for
cushioning the rider thighs and buttocks, the cushion having a
plurality of layers of material to facilitate perspiration wickage.
The liquid cushions include overlying layers of a polyurethane
material and water, non-freezable silicon or glycerin or mixtures
thereof, oils or other slippery material.
[0009] While the art provides various type of cycling garments, as
exemplified above, the need remains in the art for chamois and
cycling garments that provide additional and improved benefits to
the wearer as a bicycle is operated.
SUMMARY OF THE INVENTION
[0010] In embodiments of the present invention, a cycling chamois
is provided that is formed of a number of flexible sheets or pieces
of fabric or fabric and/or synthetic leather, and that includes
strategically located pieces of relatively low-hardness foam and
relatively high-hardness foam.
[0011] Chamois in accordance with the present invention provide
support for the pelvic girdle of a male or a female cyclist. As is
well known, the pelvic girdle (also known as the bony pelvis) is a
basin-shaped complex of bones that connect the truck and legs, that
supports and balances the trunk, and that contains and supports the
intestines, the urinary bladder, and the internal sex organs. The
pelvic girdle includes paired hipbones that are connected in the
front by the pubic symphysis and at the back by the sacrum, and
includes the ischium on which weight falls in sitting wherein the
ischial tuberosity is called the sitting bone.
[0012] When chamois constructed and arranged in accordance with the
present invention is attached to the inside of a cycling garment,
and when the garment is then worn by a cyclist, a garment-side of
the chamois that faces the garment, and a body-side of the garment
faces the cyclist body. In the following discussion, the side of
the chamois that faces the garment will be called the bottom side
or the garment-facing side of the chamois, and the side of the
chamois that faces the cyclist body will be called the top side or
the body-facing side of the chamois.
[0013] This invention provides embodiments of chamois wherein two
pieces of relatively high-hardness foam are strategically located
to accommodate the pelvic girdle of a male cyclist, and the
invention provides other embodiments of the invention wherein one
piece of relatively high-harness foam is strategically located to
accommodate the pelvic girdle of a female cyclist.
[0014] More specifically, male-use chamois in accordance with the
invention provide two physically-spaced pieces of relatively
high-hardness foam that support the two buttocks of a male cyclist,
while leaving a crotch space therebetween that is occupied by
relatively low-hardness foam, whereas female-use chamois in
accordance with the invention provides one piece of relatively
high-hardness foam that supports both the buttocks and the crotch
of a female cyclist.
[0015] Both a male-use chamois and a female-use chamois in
accordance with the invention include a garment-facing cloth or
cloth-like member whose outline forms the generally flat external
shape or profile of the chamois. This garment-facing cloth member
is adapted to physically engage the inner surface of a garment to
be worn by a male/female cyclist
[0016] This garment-facing cloth can be a woven cloth or a
non-woven cloth, and it can be formed of a natural material or of a
synthetic material, with polyester scrim being preferred, or with a
non-woven interfacing or batting that is constructed of polyester
fibers being preferred.
[0017] In use, this garment-facing cloth member is usually sewn to
the inside of the seat area of a cycling garment.
[0018] Both a male-use chamois and a female-use chamois in
accordance with the invention include a layer of relatively
low-hardness foam whose outline forms the external shape or profile
of the chamois.
[0019] In an embodiment of a male-use chamois in accordance with
the invention, this layer of relatively low-hardness foam contains
two buttocks-region holes that are filled by two pieces of
relatively high-hardness foam. In another embodiment of a male-use
chamois in accordance with the invention, this layer of relatively
low-hardness foam is a continuous layer, and two physically-spaced
pieces of relatively high-hardness foam overly two
physically-spaced spaced buttocks regions on the layer of
relatively low-hardness foam.
[0020] In an embodiment of a female-use chamois in accordance with
the invention, this layer of relatively low-hardness foam contains
one buttocks/crotch-region hole that is filled by one piece of
relatively high-hardness foam. In another embodiment of a
female-use chamois in accordance with the invention, this layer of
relatively low-hardness foam is a continuous layer, and one piece
of relatively high-hardness foam overlies the
buttocks/crotch-region on the layer of relatively low-hardness
foam.
[0021] As used herein, the term foam means a flexible, porous,
natural or synthetic material whose volume contains a relatively
high percentage of open or closed cells, and a relatively low
percentage of the natural or synthetic material from which the foam
is formed. While the spirit and scope of the invention is not to be
limited thereto, in an embodiment of the invention, the
low-hardness foam had a hardness of about 20 durometer (20 d) as
measured by a durometer, and the relatively high-hardness foam had
a hardness from about 40 d to about 90 d.
[0022] The term foam, as used herein, is also intended to mean a
foamed or expanded plastic material that has been treated so as to
cause air or gas bubbles or cells to be formed therein, these cells
being either closed cells or open cells. However, within the spirit
and scope of the invention, the term foam includes both presently
known and after-developed equivalent means, such as gel-filled
members and/or liquid-filled members. A non-limiting example is an
open-cell polyurethane foam.
[0023] Both a male-use chamois and a female-use chamois in
accordance with the invention include a garment-facing cloth or
cloth-like member outline forms the external shape or profile of
the chamois.
[0024] In an embodiment of a male-use chamois in accordance with
the invention, this garment-facing cloth member is a continuous
member. In another embodiment of a male-use chamois in accordance
with the invention, this garment-facing cloth member contains two
buttocks-region holes that are filled by two pieces of synthetic
leather. In another embodiment of a male-use chamois in accordance
with the invention, this garment-facing member is a continuous
member, and two physically-spaced pieces of synthetic leather
overly two physically-spaced buttocks regions on the body-facing
cloth member.
[0025] In an embodiment of a female-use chamois in accordance with
the invention, this garment-facing cloth member is a continuous
member. In another embodiment of a female-use chamois in accordance
with the invention, this garment-facing cloth member contains one
buttocks/crotch-region hole that is filled by one piece of
synthetic leather. In another embodiment of a female-use chamois in
accordance with the invention, this garment-facing member is a
continuous member, and one piece of synthetic leather overlies the
buttocks/crotch-region on the body-facing cloth member.
[0026] This body-facing member can be a woven cloth or a non-woven
cloth, and it can be formed of a natural material or of a synthetic
material, with warp knit polyester tricot having a wicking finish
being preferred.
[0027] In embodiments of the invention, a unitary chamois is formed
of the various members by providing a heat-melting plastic ribbon
the extends along the edges or boarders of the various member, such
that the use of a heat press operates to melt the plastic ribbon
and form a unitary chamois from the various chamois members.
[0028] As a feature of the invention, the chamois in accordance
with this invention is formed into a single unit by the use of a
bonding agent, and/or by the application of heat and pressure that
operates to fuse the various pieces of the chamois together into a
single unit.
[0029] As a feature of the invention, the application of heat and
pressure to the chamois in accordance with this invention operates
to form the chamois into a three-dimensional shape that generally
matches the pelvic girdle of a male or a female.
[0030] While the invention will be described while making reference
to the use of foam sheets, which may include open cell and/or
closed-cell foams, the spirit and scope of the invention includes
the use of both existing equivalent members and after-developed
equivalent foam members. Examples of existing and equivalent foam
members include, but are not limited to, gel-filled foam members,
liquid-filled foam members, air-filled foam members, and
combinations thereof, preferably to replace the above-descried
thick foam sheets, but also to replace the above-described thin
foam sheet.
BRIEF DESCRIPTION OF THE DRAWING
[0031] FIG. 1 is a top or body-side view of an embodiment of a
chamois in accordance with the invention that is constructed and
arranged for use by a male cyclist (i.e., the side of the chamois
that faces the body of a cyclist).
[0032] FIG. 2 is a bottom or garment-side view of the FIG. 1
male-cyclist chamois (i.e., the side of the chamois that faces a
cycling garment), this figure also showing optional edge stitching
that is provided along the forward and side edges of the
chamois
[0033] FIG. 3 is a body-side view of another embodiment of the
invention for use by a male cyclist, this embodiment being
generally similar to FIG. 1, but including an additional thin-foam
pad that is stitched to the forward or lower-abdominal edge of the
FIG. 1 chamois.
[0034] FIG. 4 is a garment-side view of the FIG. 3 male-cyclist
chamois.
[0035] FIG. 5 is a view similar to FIG. 4 that is useful to
identify exemplary and non-limiting dimensions of portions of the
chamois, these dimensions being typical of embodiments of the
invention intended for use by a male cyclist.
[0036] FIG. 6 is a section view of the chamois of FIGS. 1 and 3
taken on the line 6-6.
[0037] FIG. 7 is a section view of the chamois of FIGS. 1 and 3
taken on the line 7-7.
[0038] FIG. 8 is a section view of the chamois of FIGS. 1 and 3
taken on the line 8-8.
[0039] FIG. 9 is a body-side view of another embodiment of a
chamois in accordance with the invention that is constructed and
arranged for use by a female cyclist.
[0040] FIG. 10 is a garment-side view of the FIG. 9 chamois.
[0041] FIG. 11 is a section view of the chamois of FIG. 9 taken on
the line 11-11.
[0042] FIG. 12 is a section view of the chamois of FIG. 9 taken on
the line 12-12.
[0043] FIG. 13 is a section view of the chamois of FIG. 9 taken on
the line 13-13.
[0044] FIG. 14 is a view similar to FIG. 9 that is useful to
identify exemplary and non-limiting dimensions of portions of the
chamois, these dimensions being typical of embodiments of the
invention for use by a female cyclist.
[0045] FIG. 15 is an exploded side view of a portion of male-use
chamois of the invention wherein the chamois is assembled from five
pieces that include (piece 1) a garment-side cloth member, (piece
2) a sheet of thin and low-hardness foam having two through-holes
cut therein that complement the shape of (pieces 3 and 4) two
pieces of thick and high-hardness foam, each piece of thick foam
closely fitting within a through-hole that is formed in the sheet
of thin foam, and (piece 5) a body-side cloth member.
[0046] FIG. 16 is an exploded side view of a portion of a
female-use chamois of the invention wherein the chamois is
assembled from four pieces that include (piece 1) a garment-side
cloth member, (piece 2) one sheet of thin and low-hardness foam and
having one through-hole cut therein that complements the outer
shape of (piece 3) a sheet of relatively thick and high-harness
foam, this sheet of thick foam closely fitting within the
through-hole that is formed in the sheet of thin foam, and (piece
4) a body-side cloth member.
[0047] FIG. 17 is an exploded side view of a portion of a male-use
chamois of the invention wherein the chamois is assembled from
seven pieces that include (piece 1) a body-facing cloth member
having two generally tear-drop shaped through-holes formed therein
that directly overly two generally tear-drop shaped thorough-holes
that are formed in (piece 2) a thin and low-hardness foam layer and
(pieces 3 and 4) two thick and high-hardness foam pieces, each of
the two through-holes in the body-facing cloth member being filled
by (pieces 5 and 6) a piece of similarly shaped synthetic leather
that directly overlies one of the two pieces of thick foam, and
including (piece 7) a garment-facing cloth member.
[0048] FIG. 18 is an exploded view of a portion of a female-use
chamois of the invention wherein the chamois is assembled from five
pieces that include (piece 1) a body-facing cloth member that has
one through-hole formed therein that directly overlies a
through-hole that is formed in (piece 2) a thin and low-hardness
foam layer, the through-hole in the body-facing cloth member being
filled by (piece 3) a piece of similarly-shaped synthetic leather
that directly overlies (piece 4) a piece of thick and high-harness
foam, and including a garment facing cloth member (piece 5).
[0049] FIG. 19 is an exploded view of a male-use chamois in
accordance with the invention wherein the chamois is assembled from
seven pieces that include (piece 1) a continuous garment-facing
cloth member, (piece 2) a continuous sheet of thin and low-hardness
foam that overlies the garment-facing cloth member, (piece 3) a
continuous body-facing cloth member that overlies the low-hardness
foam sheet and that has two tear-drop shaped areas thereon that
carry (pieces 4 and 5) two generally tear-drop shaped thick and
high-hardness foam pieces, each of the thick foam pieces carrying
(pieces 6 and 7) a piece of synthetic leather.
[0050] FIG. 20 is an exploded view of a female-use chamois in
accordance with the invention wherein the chamois is assembled from
five pieces that include (piece 1) a continuous garment-facing
cloth member, (piece 2) a continuous sheet of thin and low-hardness
foam that directly overlies the garment-facing cloth member, (piece
3) a continuous body-facing cloth member that directly overlies the
low-hardness foam sheet and that has an area thereon that carries
(piece 4) a piece of thick and high-hardness foam, the thick foam
piece carrying (piece 5) a piece of synthetic leather.
[0051] FIG. 21 is an exploded view that shows how weld lines
operate to bind layers of the chamois of the invention together by
placing a thin ribbon of heat-meltable plastic intermediate
adjacent chamois layers, such that when the chamois assembly is
thereafter placed within a heat press, the plastic ribbon melts and
binds the chamois assembly together as a thin weld lines are
concomitantly formed.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0052] The present invention provides both male-use and female-use
chamois for use within cycling garments in order to improve the
comfort and the protection to the body of a male/female operating a
bicycle.
[0053] FIG. 1 is a body-side view (i.e., the side of the chamois
that faces the cyclist body) of a chamois 10 in accordance with the
invention wherein chamois 10 is constructed and arranged for use by
a male cyclist.
[0054] Chamois 10 is symmetrical about a front-to-back centerline
11, the forward end of chamois 10 being indicated by numeral 12,
and the rearward end of chamois 10 being indicated by numeral
13.
[0055] Chamois 10 includes two relatively thick and high-hardness
foam pad areas 14 and 15 that are established by two relatively
high-hardness and generally tear-drop shaped pieces of foam 16 and
17 (see FIG. 6) that are contained within chamois 10. Teardrop
shaped thick pad area 14 is adapted to support the right buttocks
of a male cyclist, and teardrop shaped thick pad 15 is adapted to
support the left buttocks of a male cyclist.
[0056] By way of a non-limiting example, relatively thick pad areas
14 and 15 are about 10 mm to about 14 mm thick, preferably about 12
mm thick, and they are formed of a relatively high density,
polyester-based, expanded polyurethane foam having a hardness in
the range of from about 40 durometer (40 d) to about 90 d, as
measured by a durometer instrument.
[0057] In the art, normal density, polyester-based, expanded
polyurethane foam is known to have a density of about 20 d, whereas
relatively high density, polyester-based, expanded polyurethane
foam has a hardness in the range of from about 40 d to about 90
d.
[0058] The term cloth or cloth-like member or sheet as used herein
is intended to mean a pliant sheet material that is usually made by
weaving, felting, or knitting natural or synthetic fibers and/or
filaments.
[0059] While the term synthetic leather will be used in describing
embodiments of the invention, it is intended that the use of a more
expensive natural leather, rather than a synthetic material that is
fabricated so as to imitate natural leather, is also encompassed by
this term.
[0060] All chamois areas with the exception of thick pad areas 14
and 15 are formed by a sheet of relatively thin foam having a
relatively low hardness. By way of a non-limiting example, these
other pad areas are about 4 mm to about 8 mm thick, preferably
about 6 mm thick, and the relatively thin foam that forms these
other pad areas is expanded, polyester-based, polyurethane foam
having a harness of about 20 d.
[0061] These other relatively thin and low-hardness chamois pad
areas include a relatively narrow, forward tapered, and
centrally-located thin foam pad 20 that generally corresponds to
the crotch area of a male cyclist, a right side upper interior
thigh pad 21, a left side upper interior thigh pad 22, a forward
lower abdominal pad 23, and two rear pads 26 and 27 that generally
surround the rear of thick and high-hardness form pads 14 and
15.
[0062] The various foam pad areas 14, 15, 20, 21, 22, 23, 26, and
27 of chamois 10 are surrounded or outlined by thin heat-formed
lines 24 that are about 2 mm thick.
[0063] FIG. 2 is a garment-side view of chamois 10 (i.e., the side
of chamois 10 that faces a cycling garment), this figure also
showing the optional use of stitching 25 along the forward edge of
chamois 10 and along the edges of the chamois' thigh portions.
[0064] FIGS. 6, 7 and 8 are section views of male-use chamois 10
that are taken along the lines 6-6, 7-7 and 8-8 of FIG. 1. These
three figures perhaps best show the relative thickness of the
chamois' various foam pads and heat-formed line areas 24.
[0065] FIG. 3 is a body-side view of a chamois 30 in accordance
with the invention that is constructed and arranged for use by a
male cyclist. Chamois 30 is similar to above-described chamois 10,
with the exception that an additional lower-abdominal pad 31 has
been stitched or heat attached to the forward edge 32 chamois 30.
Pad 31 contains a sheet of relatively thin and low-hardness foam,
as was described above relative to pads 21, 22, 23, 26 and 27.
[0066] FIG. 4 is a garment-side view of FIG. 3 chamois 30, this
figure showing that pad 31 has been stitched at 33 to the forward
end 32 of chamois 30.
[0067] FIGS. 6, 7 and 8 are section views of chamois 30 that are
taken along the lines of 6-6, 7-7 and 8-8 of FIG. 3. These three
figures perhaps best show the relative thickness of the chamois'
various foam pads and heat-formed line areas 24.
[0068] FIG. 5 is a view similar to FIGS. 3 and 4 that is useful in
identifying exemplary and non-limiting physical dimensions of
portions of chamois 30, these dimensions being typical of a chamois
10 or 30 in accordance with the invention that are for use by a
male cyclist.
[0069] FIG. 15 is an exploded side view of a portion of a male-use
chamois 10 and 30 in accordance with the invention, this figure
showing how the chamois is assembled from five pieces that include
a garment-facing cloth member 35, a sheet 36 of relatively thin and
low-hardness foam that has the same outer shape as garment-side
cloth member 35, and that has two through-holes 37 and 38 cut
therein in order to form two holes 37, 38 that complement the outer
shape of two pieces 39 and 40 of thick and high-hardness foam, each
piece 39, 40 of thick foam closely fitting within a through-hole
37, 38 that is formed in thin foam sheet 36, and a body-facing
cloth member 41.
[0070] As a feature of the invention, body-facing cloth member 41
is formed of a synthetic leather (for example, of the brand
ALCANTARA), garment-facing cloth member 35 is formed of a
polyester, preferably a wicking polyester, thin foam layer 36 is
about 6 mm thick and has a hardness of about 20 d, and each of the
two thick foam pieces 39, 40 is about 12 mm thick and has a
hardness in the range of from about 40 d to about 90 d.
[0071] FIG. 17 shows another embodiment of the invention wherein a
male-use chamois 45 comprises seven pieces that include a
body-facing cloth member 41 that is formed of a wicking polyester,
and includes two generally tear-drop shaped through-holes 47 and 48
that are formed therein so as to directly overly two generally
tear-drop shaped through-holes 37 and 38 that are formed in a thin
and low-hardness foam layer 36. Each of the two through-holes 47,
48 within body-facing cloth member 46 are then filled by a piece of
similarly shaped and similar thickness synthetic leather 79, 80
that individually directly overlie one of the two pieces 39, 40 of
thick foam.
[0072] FIG. 19 shows another embodiment of the invention wherein a
male-use chamois 81 comprises seven pieces that include a
continuous garment-facing cloth member 35, a continuous
low-hardness foam layer 36, a continuous body-facing cloth member
41 that is preferably formed of a synthetic wicking polyester
(i.e., a warp knit polyester tricot with a wicking finish) that
includes two generally tear-drop shaped areas 84 and 85 thereon
that each receive a piece 39, 40 of similarly shaped, thick, and
high-harness foam 39 and 40, with the top surfaces of thick foam
pieces each individually receiving a piece of synthetic leather 79,
80.
[0073] The top and bottom views of chamois 81 are generally
identical to FIGS. 1 and 2 with the exception that stitching 25 of
FIG. 2 is not provided on chamois 81. Chamois 81 does, however,
include weld lines 24.
[0074] FIG. 21 is an exploded view that shows how the weld lines 24
that bind the edges of body-facing cloth member 35, this foam layer
36, and garment-facing cloth member 41 are formed by placing thin
ribbons 100 of heat-meltable plastic intermediate layers 35 and 36
and intermediate layers 36 and 41. When the FIG. 21 assembly 35,
36, and 41 is placed within a heat-press, ribbons 100 melt and bind
the edges of the assembly together as a thin weld line 24 is
formed.
[0075] This or another heat/pressure process can also be used to
form chamois 81 into a three-dimensional shape that approximates
the pelvic girdle of a male cyclist. As a result, chamois 81 is
devoid of stitching and the like.
[0076] An important feature of the FIG. 19 embodiment of the
invention is that a first large-size sheet can be formed that
comprises the three layers 35, 36, 41, and a second large-size
sheet can be formed that comprises the two layers 39, 40 and 79,
80. Preferably, the layers of the first and second multi-layer
sheets are bonded together to thereby form two unitary sheets that
are relatively easy to handle during manufacture of a chamois in
accordance with the invention.
[0077] The first three-layer sheet can be then stamped or cut to
form a plurality of individual three-layer pieces 41, 36, 35 (FIG.
19) that are each of the overall chamois shape that is shown in
FIG. 1. In addition, the second two-layer sheet can then be
stamped, or cut to form a first plurality of tear-drop shaped
individual pieces 79, 39 (FIG. 19) that are of the thick-pad shape
14 that is shown in FIG. 1, and the second two-layer sheet can also
be stamped or cut to form a second plurality of tear-drop shaped
individual pieces 80, 40 (FIG. 19) that are of the thick pad shape
15 that is shown in FIG. 1.
[0078] A single chamois 81 can then be formed by using one of the
three-layer chamois-shaped pieces, by using one of the two layer
thick pad shapes 14, and by using one of the two-layer
thick-pad-shapes 15.
[0079] Turning now to a description of chamois in accordance with
the invention that are constructed and arranged for use by a female
cyclist, FIG. 9 is a body-side view of a chamois 55 in accordance
with the invention wherein chamois 55 is constructed and arranged
for use by a female cyclist. Chamois 55 is symmetrical about a
front-to-back centerline 56, the forward end of chamois 55 being
indicated by numeral 57, and the rearward end of chamois 55 being
indicated by numeral 58.
[0080] Chamois 55 includes one relatively thick and high-hardness
foam pad area 59 that is generally of an elongated heart-shape.
Thick pad area 59 is provided by a piece of relatively
high-hardness foam, as discussed above, that is contained
internally of chamois 55, as shown in FIGS. 11 and 12 Thick pad
area 59 is symmetrical about centerline 56 and it is adapted to
support the right buttocks, the left buttocks and the crotch area
of a female cyclist.
[0081] Again by way of a non-limiting example, thick pad area 59 is
about 12 mm thick, and the thick foam that forms pad area 59 has a
durometer of about 40 d to about 90 d.
[0082] All chamois areas, with the exception of thick pad area 59,
are formed by a sheet of relatively thin and low-hardness foam. By
way of a non-limiting example, these other pad areas are about 6 mm
thick, and the relatively thin foam that forms these other pad
areas has a durometer of about 20 d.
[0083] These other relatively thin chamois pad areas include a
right-side upper inside thigh pad 60, a left-side upper inside
thigh pad 61, a forward lower-abdominal pad 62, and two rear pad
areas 63 and 64 that generally surround the rear of thick foam pad
59.
[0084] The various pad areas 59, 60, 61, 62, 63, and 64 of chamois
55 are outlined or surrounded by thin heat-formed lines 66 that are
about 2 mm thick. FIG. 10 is a garment-side view of chamois 55.
[0085] FIGS. 11, 12 and 13 are section views of chamois 55 that are
taken along the lines 11-11, 12-12 and 13-13 of FIG. 9. These three
figures perhaps best show the relative thickness of the chamois'
various pad areas 59, 60, 61, 62, 63, and 64, and the heat-formed
lines 66 that outline or boarder these pad areas. FIG. 14 is a view
that is useful to identify exemplary and non-limiting physical
dimensions of portions of female-use chamois 55, these dimensions
being typical of a chamois 55 in accordance with the invention for
use by a female cyclist
[0086] FIG. 16 is an exploded view of a portion of a female-use
chamois 55 in accordance with the invention showing how chamois 55
is assembled from four pieces that include (piece 1) a garment-side
cloth member 70, (piece 2) a sheet 71 of relatively thin and
low-hardness foam 71 having the same outer shape as garment-side
cloth member 70 and having one through-hole 72 that is cut therein
that complements the outer shape of (piece 3) a piece 73 of thick
and high-hardness foam, wherein piece 73 of thick foam closely fits
within the through-hole 72 that is formed in the sheet 71 of thin
foam, and (piece 4) a body-side cloth member 74.
[0087] As a feature of the invention, body-side cloth member 74 is
formed of a synthetic leather and/or garment-side cloth member 70
is formed of a polyester, preferably a warp knit polyester tricot
having a wicking finish, thin foam layer 71 is about 6 mm thick and
has a hardness of about 20 d, and thick foam piece 73 is about 12
mm thick and has a hardness of from about 40 d to about 90 d.
[0088] FIG. 18 shows an embodiment of the invention wherein a
female-use chamois 75 is a five-piece chamois having a body-facing
cloth member 74 that is formed of a wicking polyester that includes
a through-hole 77 that is formed therein so as to directly overly a
thorough-hole 72 that is formed in thin and low-hardness foam layer
71. The through-hole 77 within body-facing cloth member 74 is then
filled by a piece 78 of similarly shaped and similar thickness
synthetic leather that directly overlies a piece 73 of thick and
high-hardness foam. Again chamois 75 of FIG. 18 is held together by
an adhesive and/or by heat sealing.
[0089] FIG. 20 shows an embodiment of the invention wherein a
female-use chamois 91 comprises a five-piece synthetic chamois
having a continuous garment-facing cloth member 70, a continuous
thin and low-hardness foam layer 71, a continuous body-facing cloth
member 74 that includes one elongated and heart-shaped area 94 that
receives a heart-shaped piece of thick and high-hardness foam 73,
and a heart-shaped piece of synthetic leather 78 that directly
overlies thick foam piece 73.
[0090] The top and bottom views of chamois 91 are generally
identical to FIGS. 9 and 10. Chamois 91 includes weld lines 66 that
are preferably formed as was above described relative to FIG. 21
wherein the heat/pressure process can also be used to form chamois
91 into a three-dimensional shape that approximates the pelvic
girdle of a female cyclist As a result, chamois 91 is devoid of
stitching and the like.
[0091] An important feature of the FIG. 20 embodiment of the
invention is that a first large size sheet can be formed that
comprises the three layers 70, 71, 74, and a second large size
sheet can be formed that comprises the two layers 73 and 78.
Preferably, the first three-layer sheet and the second two-layer
sheet are layer bonded so as to form unitary three-layer and
two-layer sheet assemblies.
[0092] The first three-layer sheet assembly can be then stamped or
cut to form a plurality of individual three-layer pieces that are
each of the overall chamois-shape that is shown in FIG. 9. In
addition, the second two-layer sheet assembly can then be stamped
or cut to form a plurality of heart-shaped pieces that are of the
thick pad shape 59 that is shown in FIG. 9.
[0093] A single chamois 91 can then be formed by using one of the
three-layer chamois-shaped pieces and by using one of the two-layer
heart-shaped pieces.
[0094] While physical dimensions of chamois in accordance with this
invention are not to be construed as a limitation on the spirit and
scope of the invention, FIG. 5 shows various dimensions of male-use
chamois in accordance with the invention, these dimensions being
shown in the following Table 1. In this male-use embodiment of the
invention, the chamois had a major width L10 of 205 mm and a major
length L15 of 355 mm.
1 TABLE 1 Dimension L1 55 mm Dimension L2 115 mm Dimension L3 105
mm Dimension L4 50 mm Dimension L5 60 mm Dimension L6 140 mm
Dimension L7 180 mm Dimension L8 20 mm Dimension L9 75 mm Dimension
L10 205 mm Dimension L11 245 mm Dimension L12 265 mm Dimension L13
35 mm Dimension L14 55 mm Dimension L15 355 mm
[0095] FIG. 14 shows various dimensions of a female-use chamois in
accordance with the invention, these dimensions being shown in the
following Table 2. In this female-use embodiment of the invention,
the chamois had a major width L7 of 210 mm and a major length L10
of 290 mm.
2 TABLE 2 Dimension L1 45 mm Dimension L2 90 mm Dimension L3 65 mm
Dimension L4 45 mm Dimension L5 50 mm Dimension L6 145 mm Dimension
L7 210 mm Dimension L8 200 mm Dimension L9 220 mm Dimension L10 290
mm
[0096] One manner in which the various cloth/foam/leather
layers/pieces of chamois in accordance with the present invention
can be formed into a single unitary chamois assembly is to provide
these various members as synthetic members (i.e., as members that
are formed by chemical synthesis), and to then fuse these synthetic
members together by the application of heat and pressure, perhaps
in the presence of a bonding agent such as an adhesive. When such a
heat/pressure process is used to fuse the various chamois
layers/pieces together, the resulting chamois is devoid of
stitching and the like.
[0097] In addition, such a heat/pressure bonding process (perhaps
with the additional use of a heat-setting adhesive) can be
accomplished by a hot press that additionally operates to emboss
the above-described thin lines that outline the various areas of
the chamois. In addition, a heat-meltable plastic ribbon can be
used intermediate the layers, and at the location of the thin lines
that outline the various areas of the chamois as above described
relative to FIG. 21.
[0098] For example, a RF welding process may be used to fuse the
various layers and pieces of the chamois together into a unitary
chamois assembly, and a RF welding processes may also be used to
form the chamois' thin seam-like lines.
[0099] As a feature of the invention, a heat-forming process can
then be used to form the unitary chamois assembly into a
three-dimensional shape that generally conforms to the pelvic
girdle of a male or a female cyclist.
[0100] The present invention has been described in detail while
making reference to various embodiments thereof. However, since it
is known that others skilled in the related art will, upon learning
of this invention, readily visualize yet other embodiments that are
within the spirit and scope of this invention, the above detailed
description is not to be taken as a limitation on the spirit and
scope of this invention.
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