U.S. patent application number 10/264841 was filed with the patent office on 2004-01-08 for ventilated bicycle saddle.
Invention is credited to Garland, Tylor, Pitfield, Geoffrey Craig, Rauda, Aldis.
Application Number | 20040004374 10/264841 |
Document ID | / |
Family ID | 30115709 |
Filed Date | 2004-01-08 |
United States Patent
Application |
20040004374 |
Kind Code |
A1 |
Garland, Tylor ; et
al. |
January 8, 2004 |
Ventilated bicycle saddle
Abstract
The invention includes a bicycle saddle whose seating surface is
made of a stretched membrane, where the membrane is stretched into
a vaulted shape from the nose extending at least partially through
the rider's crotch toward the cantle at the rear of the seat. The
invention includes a ventilation path through the seating surface
to the rider. The invention further includes at least one carrier
member acting upon the membrane to create, at least partly, the
vaulted shape, and an attachment of at least part of a perimeter of
the membrane to at least one of the carrier members. The attachment
further provides the vaulted shape to the membrane and/or a tension
to the membrane. The invention also further includes a saddle
undercarriage attached to at least one of the carrier members
providing at least part of the tension to the membrane, whenever
the saddle undercarriage flexes. The saddle undercarriage is
further comprised of a means for mounting to a seat post.
Inventors: |
Garland, Tylor; (Los
Angeles, CA) ; Rauda, Aldis; (San Francisco, CA)
; Pitfield, Geoffrey Craig; (San Francisco, CA) |
Correspondence
Address: |
Gregory Smith & Associates
3900 Newpark Mall Road, Suite 317
Newark
CA
94560
US
|
Family ID: |
30115709 |
Appl. No.: |
10/264841 |
Filed: |
October 4, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60394341 |
Jul 3, 2002 |
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Current U.S.
Class: |
297/195.1 |
Current CPC
Class: |
B62J 1/00 20130101 |
Class at
Publication: |
297/195.1 |
International
Class: |
B62J 001/00 |
Claims
1. A bicycle saddle, comprising: a seating surface including at
least one membrane stretched into a vaulted shape from a nose
extending toward a cantle; and a ventilation path through said
membrane to a rider using the saddle.
2. The apparatus of claim 1, wherein said membrane is primarily
composed of at least one member of the collection comprising an
elastomeric material, a textile, a woven fabric, and a membrane
including a plurality of apertures formed therein.
3. The apparatus of claim 1, further comprising at least one
carrier member acting upon said membrane to at least partially
create said vaulted shape.
4. The apparatus of claim 3, further comprising an attachment of at
least part of a perimeter of said membrane to at least one of said
carrier members to at least partially provide at least one member
of the collection comprising said vaulted shape to said membrane
and a tension to said membrane.
5. The apparatus of claim 4, wherein said attachment of at least
part of said membrane perimeter to said carrier member is selected
from one or more of the group consisting of: at least one
encapsulation molding attaching said at least part of said membrane
perimeter to said carrier member; at least one adhesive bonding
attaching said at least part of said membrane perimeter to said
carrier member; at least one rivet attaching said at least part of
said membrane perimeter to said carrier member; at least one
stitching attaching said at least part of said membrane perimeter
to said carrier member; and a capturing means attaching said at
least part of said membrane perimeter between at least two of said
carrier members.
6. The apparatus of claim 4, wherein said membrane is further
comprised of a sock-like shape, and wherein said attachment
includes means for engaging said sock-like shape.
7. The apparatus of claim 4, wherein said seating surface includes
a first membrane and a second membrane, both of said membranes
being stretched into said vaulted shape from said cantle to said
nose.
8. The apparatus of claim 3, further including an undercarriage
assembled to said at least one carrier member.
9. The apparatus of claim 3, wherein said saddle undercarriage
further comprises a seat post mount.
10. The apparatus of claim 4, further comprising a saddle
undercarriage attached to at least one of said carrier members
providing at least part of said tension to said membrane, when said
saddle undercarriage is flexed.
11. The apparatus of claim 10, wherein said saddle undercarriage
includes a formed assembly attached to a mating member collection;
wherein said formed assembly includes a member of the collection
comprising a formed metal piece, and a formed pair of metal pieces;
wherein each of said metal pieces is a member of the collection
comprising a metal rod, a metal tube and a metal bar; wherein said
mating member collection includes at least one member; wherein at
least one of said members of said mating member collection is
primarily composed of at least one member of a collection
comprising a metal and a plastic.
12. The apparatus of claim 11, wherein said mating member
collection is comprised of at least two members.
13. The apparatus of claim 11, wherein said saddle undercarriage
further includes said metal piece formed into a shape that is
narrow near said nose where at least two ends of said metal piece
meet, at least two rails for attaching said seat post extending
toward said cantle, and a rear section with at least two loops
supporting said cantle; a front of said mating collection members
attached to said metal piece providing a means for fastening to
said nose; and a rear of said mating collection members attached to
said metal piece providing a means for fastening to said
cantle.
14. The apparatus of claim 13, wherein each of said mating
collection members attaches to said metal piece by a member of the
collection comprising of said mating collection member being molded
over said metal piece, and said mating collection member being
assembled to said metal piece.
15. The apparatus of claim 10, wherein said saddle undercarriage
providing at least part of said tension to said membrane further
comprises a measn for adjusting said tension.
16. The apparatus of claim 10, wherein said means for mounting to
said seat post further comprises at least two rails for mounting to
said seat post.
17. The apparatus of claim 10, wherein said saddle undercarriage
attached to said carrier member further comprises at least one
member of the collection comprising: a means for attaching said
carrier member and said membrane to said saddle undercarriage, and
provision for removing and replacing said carrier member and said
attached membrane.
18. The apparatus of claim 17, wherein said means for attaching
includes at least one member of the collection comprising a
threaded fastener, a snap fit, a non-fastening mechanical
engagement, and wherein said threaded fastener uses a threaded head
fastener.
19. The apparatus of claim 18, wherein said seating surface further
includes an undercarriage assembled to said carrier, and wherein
said seating surface further comprises at least one muffin
positioned between said at least one membrane and said
undercarriage.
20. The apparatus of claim 3, wherein said seating surface further
includes at least one muffin between said at least one membrane and
said carrier member.
21. The apparatus of claim 1, wherein said seating surface further
includes a membrane collection comprising a first membrane and a
second membrane, both of said membrane collection members stretched
into said vaulted shape from said cantle to said nose.
22. The apparatus of claim 21, wherein said first membrane is
separated from said second membrane by a gap.
23. The apparatus of claim 8, further including a depression formed
in said seating surface by pulling a portion of said membrane
toward said undercarriage.
24. The apparatus of claim 22, wherein said gap narrows towards
said nose.
25. The apparatus of claim 1, wherein said membrane is further
comprised of an indented perimeter near said cantle.
26. A bicycle saddle comprising: at least one carrier, at least one
membrane coupled to said at least one carrier, and a tension
applied to said membrane by said at least one carrier pulling said
membrane into a vaulted shape from a nose of said saddle at least
partially to a cantle of said saddle, and a ventilation path
through said membrane.
27. The saddle of claim 26, wherien said membrane allows air to
pass through at least 25% of a surface area of said membrane.
28. The saddle of claim 26, wherien said membrane allows air to
pass through at least 50% of a surface area of said membrane.
29. The saddle of claim 26 wherein said membrane comprises a woven
material, and wherein said ventilation path is through spaces
between threads in said woven material.
30. The saddle of claim 29 wherein said spaces between said threads
in said woven material of said membrane comprise at least 25% of a
surface area of said membrane.
31. The saddle of claim 29 wherein said spaces between said threads
in said woven material of said membrane comprise at least 50% of a
surface area of said membrane.
32. The saddle of claim 29 wherein said spaces between said threads
in at least one portion of said woven material of said membrane
comprises at least 25% of a surface area of said membrane.
33. The saddle of claim 29 wherein said spaces between said threads
in at least one portion of said woven material of said membrane
comprises at least 50% of a surface area of said membrane.
34. The saddle of claim 26, further comprising an undercarriage
assembled to said at least one carrier.
35. The saddle of claim 34, wherein said undercarriage asserts a
force on said at least one carrier thereby at least partially
providing said tension applied by said at least one carrier to said
membrane.
36. The saddle of claim 26, wherein said tension applied to said
membrane varies over a surface of said membrane.
37. The saddle of claim 26, wherein said tension applied to a
region of said surface of said membrane is selected to reduce
pressure on the sitz bones of the user.
38. The saddle of claim 26, further comprising apparatus for
adjusting said tension applied to said membrane.
39. A method for adjusting said tension applied to said the
membrane of the saddle of claim 26 comprising the step: deforming
at least one of said at least one carrier member.
40. A method for adjusting said tension applied to said the
membrane of the saddle of claim 34 comprising the step: deforming
said undercarriage acting on said at least one carrier.
41. The saddle of claim 34, wherein said tension applied to said
membrane varies when at least one of said at least one carrier and
said undercarriage are flexed.
42. The saddle of claim 34, further including a depression formed
in said seating surface by pulling a portion of said membrane
toward said undercarriage.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. provisional patent
application serial No. 60/394,341, filed Jul. 3, 2002, the
specification and drawings of which are hereby incorporated by
reference in their entirety.
TECHNICAL FIELD
[0002] This invention relates generally to bicycle saddles and
exercise bicycle saddles, and more particularly to a saddle whose
seating surface is comprised primarily of a stretched, vaulted
membrane.
BACKGROUND ART
[0003] Bicycles are pervasive, inexpensive, reliable and are used
everyday throughout most of the world. This invention relates to
innovations in the bicycle saddle. While bicycle saddles have seen
improvements over the last century, there remain some fundamental
problems that have resisted prior art attempts to solve them.
[0004] The inventors see the prior art teaching two primary types
of bicycle saddles, which will be referred to herein as a
traditional saddle and a modern saddle. U.S. Pat. No. 823,916
(Brooks, Holt) teaches making the traditional saddle by suspending
leather between a cantle and nose. U.S. Pat. No. 6,244,655 (Minkow
et al.) teaches making the modern saddle with a plastic shell,
padding, and a seat cover of leather or plastic. Both saddle types
typically incorporate suspension rails for mounting the saddle to
the bicycle via a seat post, as taught in U.S. Pat. No. 5,466,042
(Herman).
[0005] Traditional leather suspension saddles, as exemplified by
U.S. Pat. No. 823,916 (Brooks, Holt), tend to be particularly heavy
due to the necessity of constructing them from thick leather and
heavy metal assemblies. These tendencies have reduced their use as
bicycles became increasingly lightweight.
[0006] Further, traditional leather saddles tend to wear out by
stretching over time, resulting in the inclusion of bulky, heavy,
tensioning screws in such saddle designs. The designs assume that
the material used is ductile and has a memory, in other words that
it is capable of maintaining a shape without support once formed
into that shape, and that if flexed or bent within limits, the
material will tend to return to that shape. Leather is a relatively
inelastic material, which limits the extent to which the seating
surface can yield under a rider's load and then return to its
unloaded shape.
[0007] The leather acts as an additional layer of clothing,
increasing the rider's perspiration and temperature which is
undesirable in a physically demanding activity such as bicycling.
Further, leather designs generally fail to provide adequate
aeration to the rider, which is important as perspiration in the
seat area results in chafing and discomfort to the rider.
[0008] Traditional leather saddles are primarily stretched
longitudinally (along the front to rear axis), which limits the
shapes that can be achieved, and to maintain saddle shape, a heavy
grade of leather must be typically used. Innovation with modern
materials has largely ceased due to the decline in popularity of
leather saddles, with the result that the support carriages are
frequently bulky, heavy, and inelegant. In addition, leather
saddles frequently wear badly around their edges even with normal
usage.
[0009] Modern saddles, as exemplified by U.S. Pat. No. 6,149,230
(Bontrager), are typically made of a plastic shell, deformable
padding layers, and a seat cover of leather or plastic.
[0010] Modern saddles often suffer at least from the fact that the
deformable layers fail to optimally distribute the rider's weight
over the largest possible area. Such deformable padding layers,
which rely on varying the amounts and properties of the padding in
specific areas of the saddle to maximize comfort, fail to
accommodate the wide variety of different riding positions, as the
padding placements are necessarily optimized for only one position.
The result is that riders frequently feel extreme discomfort while
riding, to the point that many quit the sport.
[0011] Reducing padding to reduce weight comes primarily at the
expense of comfort. Modern saddles also act as an additional
clothing layer, and fail to provide adequate ventilation for the
rider. Modern saddles, particularly gel designs, may wear around
their edges with normal use. Crashing tends to accelerate this
wear.
[0012] U.S. Pat. No. 5,597,202 (Andersen) teaches a modern saddle
as a slung fabric bicycle seat, where the seat is slung in the
style of a hammock or director's chair, limiting the direction and
amount of tension, if any, that can be applied to the fabric. U.S.
Pat. No. 5,927,802 (Kesinger) teaches a modern saddle having a
flat, inelastic suspended platform upon which padding is placed to
provide cushioning. Neither these nor the previously cited patents
teach stretching a membrane into a shape conducive to use as the
primary seating surface of a bicycle saddle.
[0013] While partially addressed by modern saddles such as the
design disclosed in U.S. Pat. No. 6,244,655 (Minkow et al.), the
issue of designing anatomically proportioned ("ergonomic") saddles
remains difficult. By virtue of their load support mechanisms, both
leather and modern saddles are generally limited in their ability
to optimally distribute the rider's weight. For example, leather,
due to its inelasticity, tends to create "hot spots" under the
rider's perineum and ischial tuberosities or ischium ("sitz
bones"), resulting in, respectively, numbness in the crotch and
soreness around the sitz bones. Various medical studies have
indicated that this situation can lead to impotence in men. Other
problems attributed to the compression of the perineum in men
include nerve damage, cavernosal artery insufficiency, and site
specific vaso-occlusion.
[0014] Modern ergonomic saddles reduce the perineal pressure by
increasing the load on the sitz bones. However, due to the
previously mentioned limitations, modern saddles do not tend to
distribute loads well, and further discomfort in the sitz bone area
typically results.
[0015] Both traditional and modern saddles also have in common a
heavy appearance due to the opacity of the seating surface. As the
bicycle industry is very concerned with aesthetics, this is a
significant issue.
[0016] Due to the aforementioned shortcomings, saddles are among
the most frequently replaced bicycle components.
[0017] There are a number of needs and desires, which have been
mentioned above, and include the following: it is desirable for a
bicycle saddle to be light-weight, a bicycle saddle should be
aesthetically appealing and look light-weight, a bicycle saddle
needs to be comfortable to ride, a bicycle saddle should be
ergonomic, accommodating to the rider's specific anatomy and
distributing body weight comfortably, a bicycle saddle should
provide good aeration to the rider, a bicycle saddle should be
inexpensive to manufacture, mechanically robust, and wear well.
SUMMARY OF THE INVENTION
[0018] The invention addresses at least the needs and desires
discussed in the background to the invention.
[0019] The invention includes a bicycle saddle whose seating
surface is made of a stretched membrane, where the membrane is
stretched into a vaulted shape from the nose generally extending at
least partially toward the cantle at the rear of the seat.
[0020] The invention further includes one or more carrier members
acting upon the membrane to create, at least partly, the vaulted
shape, and an attachment of at least part of a perimeter of the
membrane to one or more of the carrier members. The attachment may
provide the vaulted shape to the membrane and/or a tension to the
membrane.
[0021] The invention also further includes a saddle undercarriage
attached to one or more of the carrier members, and may provide at
least part of the tension to the membrane, when the saddle
undercarriage is flexed. The saddle undercarriage may further
include a means for mounting to a seat post.
[0022] In some embodiments, the invention includes a ventilation
path through the seating surface to the rider.
[0023] The membrane is preferably primarily composed of one or more
of the following: elastomeric materials and textiles, including
woven fabrics composed primarily of elastomeric materials. The
membrane material preferably exhibits minimal creep, thereby
maintaining its shape and tension for extended periods of time. In
other embodiments, the membrane may be primarily composed of a
molded elastomer having hole patterns to provide ventilation and/or
to provide variable tensioning.
[0024] The carrier member(s) may be made of a thermoplastic
material, which may further be glass-filled. The carrier member(s)
may be attached to the membrane using one or more of the following,
but not limited to, encapsulation molding, adhesive bonding,
stitching, riveting, threaded fasteners, or capturing between two
capturing members. In some embodiments, the carrier member(s) may
be attached to the entire perimeter of the membrane.
[0025] The invention also includes the carrier member(s) at least
partly providing tension to the membrane. The invention may further
include the membrane being variably tensioned by the carrier
member(s) and/or saddle undercarriage. This variable tensioning may
be used to reduce the pressure created by the saddle surface on the
rider's perineum to achieve increased comfort and optimal
anatomical fit without compromising the saddle's weight. In some
embodiments invention includes the variable tensioning achieved by
variations in the weave of a woven fabric membrane. The variable
tensioning feature of the invention shows great promise in reducing
health risks to men.
[0026] The invention includes bicycle saddles having greatly
reduced parts count relative to other suspended saddle designs,
inherently reducing the cost of manufacture.
[0027] The invention includes bicycle saddles having abrasion
and/or tear resistant edges, reducing susceptibility to wear in the
course of normal usage or crashing.
[0028] The invention includes alternate saddle configurations
including multiple stretched membranes providing halves of a saddle
and forming a gap between those halves to accommodate the rider's
anatomy, or a perimeter indentation in the stretched membrane
designed to accommodate the rider's anatomy.
[0029] Another embodiment of the present invention includes a rider
replaceable carrier/membrane assembly.
[0030] Another embodiment of the present invention provides an
additional padding layer, or muffin, such as foam rubber or gel.
The muffin may be attached to the top of the membrane using
over-molding, lamination, chemical, mechanical bonding, or other
methods commonly known to those skilled in the art. Alternatively,
the muffin may be positioned between the membrane and the carrier
member, situated near the cantle or the nose of the saddle.
[0031] A preferred embodiment of the invention includes a
one-piece, continuous carrier member formed by encapsulation
molding of thermoplastic about the perimeter of an elastomeric
woven fabric membrane that is pre-tensioned. This carrier/membrane
assembly is then attached via conventional methods such as threaded
fasteners to a saddle undercarriage providing mechanical support
and tensioning to the carrier/membrane assembly and rails for
mounting to a standard bicycle seat post.
[0032] The invention also includes a method of providing a bicycle
seating surface by providing a vaulted shape by stretching the
membrane(s) with at least one carrier member from essentially the
nose at least partially toward the cantle. The method may also
include one ore both of the following: (1) providing a membrane
tension adjustment by adjusting an attachment of the membrane with
at least one of the carrier members, and (2) providing a first
membrane tension near a rider perineum contact area distinct from
the membrane tension away from the rider perineum contact area.
[0033] The invention's method further includes one or more of the
following: (1) replacing the membrane to provide the vaulted shape
by stretching at least one replacement membrane with at least one
replacement carrier member, (2) providing the tension adjustment
for the replacement membrane by adjusting a second attachment of
the at least one replacement membrane with at least one of the
carrier members, (3) providing at least part of the adjustment of
the membrane tension by adjusting an attachment of a saddle
carriage to the carrier member, (4) providing at least part of the
tension to the membrane, when the saddle undercarriage is
flexed.
[0034] Other preferred embodiments of the invention include the
dimensions, materials, and other features or characteristics of the
invention modified to accommodate the specific and distinct needs
of comfort for distinct riders, exercise bicycles, road bicycles,
mountain bicycles, hybrid bicycles, and other variations known to
those skilled in the art.
[0035] The invention preferably provides a lightweight,
comfortable, ventilated, aesthetically pleasing bicycle saddle that
is robust and readily manufactured. Other features and advantages
of the present invention will be apparent from the accompanying
drawings and from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 illustrates an exploded view of the components of
certain preferred embodiments of the invention;
[0037] FIG. 2 illustrates an assembled top perspective view of the
invention as illustrated in FIG. 1;
[0038] FIG. 3A illustrates two carrier members 200 and 220 to be
attached to a membrane 100 of FIGS. 1 and 2 by a capturing
means;
[0039] FIG. 3B illustrates two carrier members 200 and 220 to be
attached to a membrane 100 by a capturing means based upon
mechanical fastening;
[0040] FIG. 3C illustrates a carrier member 200 attaching to
membrane 100 using a mechanical fastener 130;
[0041] FIG. 3D illustrates a carrier member 200 attaching to
membrane 100 using a second mechanical fastener 130;
[0042] FIG. 3E illustrates a carrier member 200 attaching to
membrane 100 using adhesive 240;
[0043] FIG. 3F illustrates a carrier member 200 attaching to
membrane 100 using a mechanical fastener 130, where carrier member
200 is fabricated of two parts attached around fastener 130;
[0044] FIG. 3G illustrates a carrier member 200 attaching to
membrane 100 using a screw-type mechanical fastener 242;
[0045] FIGS. 3H and 3I illustrate carrier member 200 attaching to
membrane 100 using a mechanical fastener 130;
[0046] FIG. 3J illustrates a carrier member 200 attaching to
membrane 100 by adhesive 242 placed between the carrier member 200
and the membrane 100, and also and adhesive 244 placed on the side
of the membrane 100 opposite the carrier member 200;
[0047] FIG. 3K illustrates a carrier member 200 attaching to
membrane 100 by encapsulating the membrane 100 in the carrier
member 200;
[0048] FIG. 3L illustrates sock like membrane 100 slipped over a
carrier member 200;
[0049] FIGS. 4A and 4B illustrate an embodiment of the invention
including multiple carrier members, rear carrier member 372 and
front carrier member 374, optionally connected by elastomeric
carrier member 370 to provide an edge treatment to membrane 100
edges, that would otherwise be exposed and subject to increased
wear;
[0050] FIG. 5 illustrates another embodiment of the invention
providing a rider variable tensioning mechanism 340 as part of the
saddle carriage/carrier assembly;
[0051] FIG. 6 illustrates an alternative embodiment of the
invention including an indented perimeter 110 formed in carrier
member 204 and membrane 100;
[0052] FIG. 7 illustrates an embodiment of the invention with the
seating surface including two membranes 100 and 102 with a gap
between them 104, providing pressure relief for the rider's
perineum;
[0053] FIG. 8 illustrates an embodiment of the invention wherein
the seating surface is formed with a carrier member 200 shaped to
provide relief from pressure in the rider's perineum;
[0054] FIG. 9 illustrates an embodiment of the invention including
bicycle saddles with a greatly reduced parts count relative to
other suspended saddle designs, inherently reducing the cost of
manufacture;
[0055] FIG. 10 illustrates an embodiment of the invention with a
saddle carriage 300 consisting essentially of a metal piece,
preferably forged into its shape, preferably providing rails 330 as
a means for mounting to a bicycle seat post;
[0056] FIG. 11A illustrates an embodiment of the invention
including a muffin 340 with attachment inserts situated between
membrane 100 and carrier member 200, where attachment inserts on
muffin 340 face carrier member 200;
[0057] FIG. 11B illustrates a cross section of muffin 340 between
attachment inserts;
[0058] FIG. 11C illustrates a cross section of muffin 340 through
an attachment insert;
[0059] FIG. 12 illustrates contact regions 120 of a rider's sitz
bones, which have a different tension to relieve rider's soreness;
and also region 140 which may have a different tension or which may
be pulled down away for the rider to form a depression, in certain
embodiments of the invention;
[0060] FIG. 13 illustrates a seating surface of the invention made
of membrane 100 attached to carrier member 200 which can be readily
removed and replaced with regards to saddle carriage 300,
preferably using carriage notch 350; and
[0061] FIG. 14 illustrates an embodiment of the invention forming a
saddle carriage including one preferably metallic tube with ends
310, rails 320 and nose attachment area 322, to be at least press
fit into attachment member 300 with attached slots 302.
DETAILED DESCRIPTION OF THE INVENTION
[0062] The invention includes a bicycle saddle whose seating
surface is made of a stretched membrane, where the membrane is
stretched into a vaulted shape whose cantle or rear supports the
rider's buttocks and whose nose extends through the rider's
crotch.
[0063] The membrane, which may also be referred to as a web or
webbing, may be fabricated of materials including elastomeric
materials and textiles, including woven fabrics composed primarily
of elastomeric materials. The membrane material preferably exhibits
minimal creep, thereby maintaining its shape and tension for
extended periods of time. In alternate embodiments, the membrane
may also be primarily composed of a molded elastomer having hole
patterns to provide ventilation and/or provide variable
tensioning.
[0064] The following terms are used herein and include the
following definitions:
[0065] Membrane: A web or sheet of material that returns to its
original shape when any applied force is removed. Materials used to
fabricate the membrane may include, but are not limited to, the
following: textiles and woven fabrics, including woven fabrics
including elastomeric materials, elastomeric sheets, including
sheets manufactured to provide ventilation between the two sides of
the sheet.
[0066] Carrier: A structure, preferably plastic, used to capture a
membrane. The capturing means may be any typically known to those
skilled in the art, including, but not limited to, encapsulation
molding, adhesive bonding, or any of a number of known mechanical
fasteners.
[0067] Elastomers: Materials that exhibit a high degree of
rubber-like elasticity.
[0068] Thermoplastic elastomers: Polymeric compositions which
soften or melt at elevated temperatures, permitting them to be
fabricated into a shape, which when cooled, retains the original
physical and chemical properties the compositions had before
heating.
[0069] Encapsulation, Encapsulated: The attachment of a plastic
carrier member about a membrane such that the plastic material
flows and becomes intimately secured with the membrane. Preferably,
the carrier member and membrane materials are chosen to form a
chemical bond between the membrane and carrier member after
encapsulation attachment.
[0070] Saddle undercarriage: The mechanical part or assembly to
which the carrier member(s) are attached and which attaches to the
seat post of a bicycle. In some embodiments, the saddle
undercarriage and the carrier member(s) are a single unitary
item.
[0071] Vaulted: In the shape of an arch, having cross-section that
is concave when viewed from below for at least the region distant
from a rider's perineum and under the rider's crotch.
[0072] Cantle: The rear or tail area of a bicycle saddle.
[0073] Nose: The front or nose area of a bicycle saddle.
[0074] Muffin: A material generally positioned between the membrane
and other structures.
[0075] The invention includes one or more carrier members attached
to at least part of the perimeter of the membrane providing, at
least in part, the vaulted shape. The carrier members may be made
of a thermoplastic material, which may further be glass-filled. The
carrier members may be attached to the entire perimeter of the
membrane. The invention also includes the carrier member(s) at
least partly providing tension to the membrane.
[0076] A preferred embodiment of the invention includes a
one-piece, continuous carrier member formed by encapsulation
molding of a thermoplastic about the perimeter of an elastomeric
woven fabric membrane that is pre-tensioned. This carrier/membrane
assembly is then attached via conventional methods to a saddle
undercarriage providing mechanical support and tensioning to the
carrier/membrane assembly and rails for mounting to a standard
bicycle seat post.
[0077] FIG. 1 illustrates an exploded view of the components of
preferred embodiment of the invention. FIG. 2 illustrates an
assembled view of the invention as illustrated in FIG. 1. The
membrane 100 may be stretched by carrier member 200 and assembled
to saddle undercarriage comprising elements 300 and 310. This
embodiment of the invention provides ventilation directly through
the seating surface by using an air permeable membrane. In some
preferred embodiments, ventilation is possible through at least 25%
of the surface area of the membrane, in more preferred embodiments,
ventilation is possible through at least 50% of the surface area of
the membrane. In some embodiments, more permeability provides
better cooling and comfort. Therefore, it may be beneficial in some
embodiments for ventilation to be possible through even greater
percentages of the surface area of the membrane. The amount of
ventilation allowed may be varied over the surface of the membrane
100 by varying the air permeability of the membrane 100. For
example, the weave of a woven membrane 100 may be varied to allow
more ventilation in some regions and less ventilation in
others.
[0078] Encapsulation molding is a preferred method of attaching
membrane 100 to carrier member 200. Referring to FIGS. 1 and 2,
membrane 100 may be stretched before being placed in an injection
mold. In the injection molding process, the carrier member 200 is
encapsulation molded about the membrane 100 using thermoplastic,
forming a strong bond between carrier member 200 and membrane 100.
The thermoplastic is preferably glass filled. Membrane 100 is
trimmed as needed after molding. Other materials may be used, for
example, in other embodiments carrier member 200 may be primarily
composed of metal or other materials with similar properties of
strength and flexibility.
[0079] In other embodiments, the carriers may be attached to the
membrane using one or more of the following, but not limited to,
encapsulation molding, adhesive bonding, stitching, riveting,
threaded fasteners, or capturing between two capturing members. The
carrier members may be of one-piece construction, and there may be
as few as one carrier member.
[0080] FIGS. 3A to 3L illustrate alternative attachment mechanisms
of membrane 200 to carrier member(s) 100 as found in FIG. 1.
[0081] FIG. 3A illustrates two carrier members 200 and 220 to be
attached to a membrane 100 of FIGS. 1 and 2 by a capturing means,
which may include a snap fit coupling system.
[0082] FIG. 3B illustrates two carrier members 200 and 220 to be
attached to a membrane 100 by a capturing means based upon
mechanical fastening.
[0083] FIG. 3C illustrates a carrier member 200 attaching to
membrane 100 using a mechanical fastener 130.
[0084] FIG. 3D illustrates a carrier member 200 attaching to
membrane 100 using a second mechanical fastener 130.
[0085] FIG. 3E illustrates a carrier member 200 attaching to
membrane 100 using adhesive 240.
[0086] FIG. 3F illustrates a carrier member 200 attaching to
membrane 100 using a mechanical fastener 130, where carrier member
200 is fabricated of two parts attached around fastener 130.
[0087] FIG. 3G illustrates a carrier member 200 attaching to
membrane 100 using a screw-type mechanical fastener 242.
[0088] FIGS. 3H and 3I illustrate carrier member 200 attaching to
membrane 100 using another mechanical fastener 130.
[0089] In other embodiments, attachment of membrane 100 to carrier
members 200 can be achieved with similar results by using different
materials, assembly techniques, and bonding techniques than those
specifically disclosed.
[0090] Membrane 100 can be formed from a pliable material.
Preferably, membrane 100 is primarily composed of a fabric made by
the Quantum Fabric company, however, many alternate materials may
be easily selected by one skilled in the art. As previously
discussed, attachment of membrane 100 to carrier member 200 can be
done using one or more of the following: adhesive bonding,
stitching, riveting, threaded fasteners, or other mechanical
fasteners. Some of the possible ways to attach are shown in FIGS.
3A-3D. The pre-stretching of membrane 100 does not require a
fixture; it can also be achieved manually. However, it is often
preferable to use a fixture to stretch membrane 100.
[0091] The attachment of membrane 100 to carrier members 200
results in an assembly that holds its shape, which is that of a
seating surface for a bicycle saddle. By virtue of its form and
mechanical characteristics, carrier member 200 imparts to membrane
100 a vaulted shape, as well as other features that are conducive
to the assembly's use as the seating surface of a bicycle
saddle.
[0092] For instance, the nose narrows down as it must fit between
the rider's legs, and cantle widens out to provide support to the
rider's buttocks. The carrier member 200 enables the membrane 100
to hold a tension that was applied to the membrane 100 in the
attachment process.
[0093] The invention includes a saddle undercarriage assembling to
the carrier member(s). The saddle undercarriage may provide
tensioning to the carrier member-membrane assembly. The saddle
undercarriage may incorporate rails for mounting to the seat post.
In FIG. 1, the undercarriage assembly preferably includes a bent
rod or tube 310 and a thermoplastic tail 300. Tail member 300
provides two holes 302 into which the ends of rod 310 can be
press-fit and/or adhesively attached.
[0094] Optional nose member 324 fits into the bend 322 at the end
of the rod or tube 310. This assembly is then attached to the
carrier member 200 via mating mechanical snap details 304 and 206.
The undercarriage assembly provides additional tension both along
both the longitudinal and transverse axes of the bicycle saddle.
The undercarriage assembly further preferably provides standard
rails 320 for attaching to seat posts of the design and dimensions
standard to the cycling industry. This saddle undercarriage further
provides added structural integrity to the bicycle saddle. The
saddle undercarriage must be capable of sustaining the significant
loads to which it is subjected during the course of normal use. The
nose piece 324 may provide additional shape to the seating
surface.
[0095] The saddle undercarriage can also be achieved with similar
results by using different materials and assembly designs. The
undercarriage assembly can be formed from a single piece, instead
of several, of plastic or metal or other material of similar or
desirable mechanical characteristics. The assembly can also be
formed from two rods that mate into a structural nosepiece, as
illustrated by FIG. 4A.
[0096] In FIG. 1, the undercarriage is preferably assembled to the
carrier member 200 via a mechanical snap assembly of two posts 206
on the carrier assembling into mating slots 304 on the frame. The
preferred assembly process is inexpensive and reversible with
simple tools, making the carrier/membrane assembly replaceable by
the rider. Those skilled in the art will appreciate that this
assembly step can also be achieved by other means, including but
not limited to threaded fasteners, adhesive bonding agents (which
may be less preferred), and other similar processes.
[0097] Certain embodiments of the invention include multiple
carrier members to achieve the desired effects of shaping,
tensioning, and load transmission. The invention also includes
bicycle saddles having abrasion and/or tear resistant edges,
reducing susceptibility to wear in the course of normal usage or
crashing.
[0098] FIGS. 4A and 4B illustrate an embodiment of the invention
including multiple carrier members, rear carrier member 372 and
front carrier member 374, optionally connected by elastomeric
carrier member 370 to provide an edge treatment to membrane 100
edges, that would otherwise be exposed and subject to wear.
[0099] The invention as illustrated in FIGS. 4A-4B, limits the
amount of longitudinal tension that can be provided to the saddle,
but provides shape to the saddle. The longitudinal tension is then
re-introduced by attaching this carrier assembly to a saddle
carriage 320 similar to that previously described.
[0100] The invention includes variably tensioning the membrane by
adjusting the carrier(s) and/or saddle undercarriage. This variable
tensioning may be used to reduce the pressure created by the saddle
surface on the rider's perineum, and to achieve increased comfort
and optimal anatomical fit without compromising the saddle's
weight. The carrier member(s) and/or saddle undercarriage may be
adjusted in a number of known ways to adjust or vary the tension of
all of, or portions of, the membrane. The means for adjusting
tension may include flexing or bending the carrier member(s) and/or
saddle undercarriage.
[0101] Another embodiment of the present invention provides the
ability of the rider to tension or adjust the desired firmness of
the seating surface.
[0102] FIG. 5 illustrates another embodiment of the invention
providing a rider variable tensioning mechanism 340 as part of the
saddle carriage/carrier assembly. The rider variable tensioning
mechanism 340 enables riders to adjust for wear and stretch in
membrane 200 over time, and to adjust the seating surface tension
to their liking. Further, the membrane 200 may be stretched
variably during the assembly process to provide added comfort to
the rider by focusing the load on areas of the rider's anatomy most
suited to load bearing.
[0103] Another embodiment of the present invention provides a
perimeter indentation, or cut out, in the stretched membrane,
designed to accommodate the rider's anatomy. For example, FIG. 6
illustrates an alternative embodiment of the invention including an
indented perimeter 110 formed in carrier member 204 and membrane
100. The indented perimeter 110 provides pressure relief for the
rider's perineal area. This can be achieved through a variety of
combinations of the saddle undercarriage and carrier members
described earlier. Membrane 100 is preferably encapsulation molded
in a one-piece carrier member 200 attached to a saddle carriage 330
built of bent and welded rod.
[0104] Another embodiment of the present invention provides
multiple stretched membranes, providing halves of a saddle and
forming a gap between those halves to accommodate the rider's
anatomy. For example, FIG. 7 illustrates an embodiment of the
invention with the seating surface including two membranes 100 and
102 with a gap between them 104, providing pressure relief for the
rider's perineum.
[0105] The embodiment of the invention illustrated in FIG. 7 can be
achieved through a variety of combinations of the embodiments of
the saddle carriage and carrier members described earlier. In a
preferred embodiment, membranes 100 and 102 are encapsulation
molded with carrier members 200 and 210. Carrier members 200 and
210 are preferably the mirror image of each other. Carrier members
200 and 210 are then assembled to a saddle undercarriage 320 built
of bent rod attached to nose and tail members.
[0106] In some embodiments of the configuration shown in FIG. 7,
membrane 100 may comprise a sock-like shape, which is slipped over
carrier member 204.
[0107] In FIG. 8, carrier member 200 includes a "bent" geometry 204
to provide relief from pressure in the rider's perineum. This
carrier 200 is then attached to a saddle carriage 320.
[0108] One feature of some embodiments is the provision of bicycle
saddles with a greatly reduced parts count relative to other
suspended saddle designs, inherently reducing the cost of
manufacture. The saddle shown in FIG. 9 is an example of a reduced
part count embodiment wherein membrane 100 is attached to a single
carrier member 200. The seating surface formed by membrane 100 and
carrier member 200 is then attached to saddle carriage 300
including rails 320 for attaching to a standard bicycle seat post.
The ends 310 of saddle carriage 300 attach, by at least a pressure
fit, to mounts 302. The attachment of saddle carriage 300 to
carrier member 200 assembled with membrane 100 provides additional
tension to the seating surface.
[0109] Many embodiments of the invention may provide ventilation
directly through the seating surface. For example, the membrane may
be characterized by a selected air permeability to increase air
flow to the region of the rider in contact with the saddle. In some
embodiments, the saddle may include structures intended to direct
air flow through the membrane 100. Each of the embodiments seen in
FIGS. 2, 6A, 7, 8, 9, 10, and 13, and possibly others, could
include this ventilation feature.
[0110] FIG. 10 illustrates an embodiment of the invention with a
saddle carriage 300 consisting essentially of a metal piece,
preferably forged into its shape, preferably providing rails 330 as
a means for mounting to a bicycle seat post.
[0111] Another embodiment of the present invention provides an
additional padding layer, such as foam rubber or gel, attached to
the top of the membrane using over-molding, lamination, chemical,
mechanical bonding, or other methods commonly known to those
skilled in the art.
[0112] Another embodiment of the invention provides an additional
padding layer, or muffin, between the membrane and the carrier
member, and/or between the membrane and the undercarriage,
typically situated near the cantle. In some embodiments, the
attachment of the muffin may be as a layer between the membrane and
carrier member as part, at least locally, of the attachment of the
membrane and carrier member.
[0113] FIG. 11A illustrates an embodiment of the invention
including a muffin 340 with attachment inserts situated between
membrane 100 and carrier member 200, where attachment inserts on
muffin 340 face carrier member 200. FIG. 11B illustrates a cross
section of muffin 340 between attachment inserts. FIG. 11C
illustrates a cross section of muffin 340 through an attachment
insert.
[0114] The invention includes the variable tensioning achieved by
variations in the weave of a woven fabric membrane.
[0115] FIG. 12 illustrates contact regions 120 of a rider's sitz
bones, which have a different tension from other portions of the
membrane 100 to relieve rider's soreness, in certain embodiments of
the invention.
[0116] In addition, contact region 140 may also have a different
tension form other portions of the membrane 100. The change in
tension may be accomplished by means including, but not limited to,
varying the tension applied to the membrane, varying the weave or
kind of material used in the membrane in selected regions, and by
forming holes in the membrane in selected regions. Alternatively,
region 140 may comprise a region that has been pulled downward to
provide a depression that accommodates a rider's anatomy. A
depression may be formed in region 140 in a number of acceptable
ways. For example, an element of any desired shape may be attached
to the underside of the membrane 100, woven into the membrane 100
or positioned on the top surface of the membrane 100. Then the
element may be pulled downward to create a depression by lines
attached at one end to the element. The shape of the depression may
be controlled by the shape of the element, and the amount of force
applied by the lines. The ends of the lines opposite the element
may be attached to anchoring structures such as the
undercarriage.
[0117] Another embodiment of the present invention provides a rider
replaceable carrier/membrane assembly. For example, FIG. 13
illustrates a seating surface of the invention made of membrane 100
attached to carrier member 200 which can be readily removed and
replaced with regards to saddle carriage 300, preferably using
carriage notch 350.
[0118] FIG. 14 illustrates an embodiment of the invention forming a
saddle carriage including one preferably metallic tube with ends
310, rails 320 and nose attachment area 322, to be at least press
fit into attachment member 300 with attached slots 302.
[0119] The method of making a bicycle saddle in accord with the
invention may include the step of stretching the at least one
membrane with at least one carrier member to provide a vaulted
shape from essentially the nose at least partially toward the
cantle.
[0120] The method may further include the step of adjusting an
attachment of at least one membrane with at least one of the
carrier members to provide a desired tension for the membrane. In
some embodiments, this step may be accomplished by adjusting the
membrane tension by adjusting an attachment of a saddle carriage.
In still other embodiments, the method may include the step of
providing at least part of the tension to the membrane, when the
saddle undercarriage is flexed.
[0121] The method may also include the step adjusting the tension
of the membrane near a rider perineum contact area of the saddle
distinct from the membrane tension away from the rider perineum
contact area of the saddle.
[0122] The method may include the step of replacing the membrane by
stretching at least one replacement over the carrier member, and
this method may further include the step of adjusting a tension for
the replacement membrane.
[0123] In some embodiments, the method may include the step
providing a ventilation path through at least part of the
membrane.
[0124] Other preferred embodiments of the invention include the
dimensions, materials, and other embodiments of the invention
modified to accommodate the specific and distinct needs of comfort
that distinct riders, exercise bicycles, road bicycles, mountain
bicycles, hybrid bicycles, and other variations known to those
skilled in the art.
[0125] The preceding embodiments have been provided by way of
example and are not meant to constrain the scope of the following
claims.
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