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JP-2026514309-A - Support elements for the human body, including recycled materials, and methods for manufacturing the same.

JP2026514309AJP 2026514309 AJP2026514309 AJP 2026514309AJP-2026514309-A

Abstract

The present invention relates to a support element for the human body comprising recycled material in the form of granules, wherein these granules are composed of at least two materials that differ in type and/or hardness and/or density and/or stiffness, and the present invention relates to a method for making a support element or for making a filling element for such a support element.

Inventors

  • ビゴリン，バーバラ
  • メイソン，マッテオ

Assignees

  • セラ ロイヤル グループ エッセ．ピ．ア．

Dates

Publication Date
20260508
Application Date
20240430
Priority Date
20230505

Claims (20)

  1. A support element (1) for human use, wherein the support element is a saddle, seat, handlebar, or grip for a bicycle or vehicle, and the support element (1) comprises a filling element (2), the filling element (2) comprising at least one component in a foamed material and restrainable to at least one surface of a support base (3), the component in the foamed material comprising granular material (4), the granular material (4) comprising and/or made from recycled material, the recycled material of the granular material (4) being made from at least two materials differing in type and/or hardness and/or density and/or stiffness, and the support element (1) is characterized by originating from waste of the manufacturing process of the support element, a discarded support element or its discarded portion, e.g., an outer cover or at least one portion of a cover, a filling element made of at least one foamed material, at least one gel or elastomer insert, and at least one of the waste materials of a support base for human use made of, for example, a rigid or semi-rigid plastic material.
  2. The support element according to claim 1, wherein the granular body (4) containing and/or made from the recycled material comprises at least one or at least two of the following: foaming material, e.g., foam, e.g., polyurethane foam, ethylene vinyl acetate (EVA), foamed thermoplastic material, foaming material having a density of 50 kg / m³ to 600 kg/ m³ , and/or elastomer material, gel material, e.g., polyurethane gel, or elastomer having a density equal to, for example, 1000 kg/ m³ , and/or PVC, TPU, and/or rigid or semi-rigid plastic or polymer material, polypropylene, polyamide, e.g., plastic or polymer material having a density of 500 to 1000 kg/m³, or mixtures thereof.
  3. Each granular body (4) comprises or is made from a mixed material comprising at least two of the following materials: - foam material, e.g., recycled from foam or filling elements, and/or - gel or elastomer material, e.g., recycled from inserts of filling elements, and/or - PVC and/or TPU, e.g., recycled from covers, and/or - rigid or semi-rigid plastic material, e.g., recycled from support bases of support elements for the human body, as described in claim 1 or 2.
  4. The support element according to any one of claims 1 to 3, wherein the recycled material resulting from the waste of the support element manufacturing process is waste from the foaming process for manufacturing the support element, and/or the recycled material does not contain any metal or metal alloy material.
  5. The support element according to one or more of claims 1 to 4, wherein the granular material (4) is uniformly distributed among the filling element (2) and/or components in the foamed material from the viewpoint of at least one of the following: position, density, properties, type of material constituting the granular material (4), and/or rigidity; and/or the granular material (4) has an irregular shape; and/or the granular material (4) has a diameter of less than 10 mm, or 0.1 mm to 10 mm, or 1 mm to 10 mm, or preferably 3 mm to 6 mm, or more preferably 4 mm or less than 6 mm, or an average size of less than 4 mm.
  6. The support element according to one or more of claims 1 to 5, wherein the component in the foaming material of the packing element is made of a foamed polyurethane polymer, foamed thermoplastic, EVA, a foaming material having a density of 50 kg/ m³ to 600 kg/m³, or a combination thereof , formed by the reaction of material A, such as a foam, such as a polyurethane foam, a self-skinning polyurethane foam, such as an isocyanate, and material B, such as a polyol compound containing, for example, at least one polyol and at least one additive such as a catalyst, a cellular modifier, or a colorant.
  7. The support element according to one or more of claims 1 to 6, wherein the packing element (2) comprises at least one gel or elastomer insert in addition to the components of the foaming material, and the granular material (4) is present within the components of the foaming material and, optionally, also within the at least one gel or elastomer insert.
  8. The support element according to one or more of claims 1 to 7, wherein the recycled material is present in a weight percentage of 1% to 50%, or 1% to 35%, or 5% to 35%, or 1% to 10%, or 5% to 15%, or less than 25%, or less than 35%, relative to the total material of the packing element (2).
  9. The support element according to one or more of claims 1 to 8, wherein the support element (1) includes an external cover element (5) optionally equipped with one or more transparent windows (6) to allow the granular material (4) to be visible from the outside.
  10. The support element according to one or more of claims 1 to 9, wherein the packing element (2) comprises a self-skinning polyurethane foam that essentially forms an outer cover element during its foaming or polymerization, and the granular material (4) is optionally also present in the outer cover element.
  11. The support element according to claim 9 or 10, wherein the external cover element has a rough or granular appearance, and this appearance is determined by the presence of at least the granular material (4) internally.
  12. A method for realizing a support element (1) for the human body, wherein the support element is a bicycle or vehicle saddle, seat, bicycle handlebar or vehicle grip as described in one or more of claims 1 to 11, the support element (1) comprises a packing element (2) that can be restrained on at least one surface of a support base (3), the packing element (2) comprises a granular material (4), and the method comprises the following steps, namely, - A step of providing recycled materials resulting from waste such as a manufacturing process for support elements, discarded support elements or their discarded parts, e.g., an outer cover or at least one of covers, a filling element made of at least one foamed material, at least one gel or elastomer insert, or at least one of a support base for a support element for the human body made of a rigid or semi-rigid plastic material, wherein the waste comprises at least two materials that differ in type and/or hardness and/or density and/or stiffness, - A step of crushing (10) the recycled material to obtain the granular material (4), wherein the recycled material of the granular material (4) is made from at least two materials that differ in type and/or hardness and/or density and/or stiffness, - A step of providing at least one material for the packing element (2) in a fluid state, - The step of mixing (30) the granular body (4) with the at least one material in a fluid state to obtain a mixture, - A step of providing a mold having at least one female part having a cavity having a shape at least partially corresponding to the shape of at least a part of the support element (1) and/or the filling element (2), - The step of pouring or injecting (40) the mixture into the cavity of the mold, - The step of foaming or polymerizing the mixture to obtain at least one component in the foaming material of the filling element (2), - The step of providing a support base (3), - The step of closing the cavity of the mold with the support base (3) positioned and/or constrained male mold component, thereby obtaining a closed cavity, allowing the step to foam or polymerize within the closed cavity, and consequently adhering and/or constraining the filler element (2) to at least one surface of the support base (3), A method characterized by obtaining at least one component in the foaming material of the filling element (2), which includes the granular body (4) containing and/or made from the recycled material.
  13. The method according to claim 12, wherein the step of providing at least one material for the packing element (2) in a fluid state comprises providing material A, such as an isocyanate, and material B, such as a polyol compound comprising at least one polyol and at least one additive, such as a catalyst, a cellular modifier, a colorant, etc., wherein material A and material B can react to form a foamed polyurethane polymer, a foam, such as a polyurethane foam, a self-skinning polyurethane foam, a foamed thermoplastic, EVA, a foamed material having a density of 50 kg/ m³ to 600 kg/ m³ , or a combination thereof.
  14. The method according to claim 12 or 13, comprising the step of sieving (20) the granular material (4) to select granular material having a diameter of less than 10 mm, or 0.1 mm to 10 mm, or 1 mm to 10 mm, or preferably 3 mm to 6 mm, or more preferably 4 mm or less than 6 mm, or an average size of less than 4 mm.
  15. The method according to any one of claims 12 to 14, comprising the steps of: providing a cover element (5) having one or more optional transparent windows (6); creating a vacuum within the cavity of the mold; and positioning and/or molding the cover element (5) within the cavity.
  16. The method according to claim 15, wherein during the foaming or polymerization step, the filling element (2) is bonded and/or restrained to the outer cover element (5).
  17. The method according to any one of claims 12 to 16, comprising the steps of: providing a gel or elastomer material; optionally mixing the granular material (4) with the gel or elastomer material; pouring or inserting the gel or elastomer material into the cavity or region; and optionally polymerizing or reacting the gel or elastomer material to obtain at least one gel or elastomer insert within the filling element (2), preferably in or near the outer cover element (5), prior to the step of pouring or injecting the mixture constituting the at least one component in the foaming material of the filling element (2).
  18. The method according to any one of claims 12 to 17, wherein the step of compressing the granular material (4), the step of compressing the mixture, and the step of compressing the components in the foaming material of the filling element (2) are not included, so as not to alter the cushioning and/or support properties of the support element (1).
  19. A method for realizing a padding element (2) of a support element (1) for human body, wherein the support element is a bicycle or vehicle saddle, seat, bicycle handlebar or vehicle grip as described in one or more of claims 1 to 11, and the padding element (2) can be restrained to at least one surface of a support base (3) when in use, the method comprising the following steps, namely: - A step of providing recycled materials resulting from waste such as a manufacturing process for support elements, discarded support elements or their discarded parts, e.g., an outer cover or at least one of covers, a filling element made of at least one foamed material, at least one gel or elastomer insert, or at least one of a support base for a support element for the human body made of a rigid or semi-rigid plastic material, wherein the waste comprises at least two materials that differ in type and/or hardness and/or density and/or stiffness, - A step of crushing (10) the recycled material to obtain granular material (4), wherein the recycled material of the granular material (4) is made from at least two materials that differ in type and/or hardness and/or density and/or stiffness, - A step of providing at least one material for the packing element (2) in a fluid state, preferably a liquid, - The step of mixing (30) the granular body (4) with the at least one material in a fluid state to obtain a mixture, - A step of providing a mold having at least one female part that includes a cavity having a shape that at least partially corresponds to the shape of at least a part of the filling element (2), - The step of pouring or injecting (40) the mixture into the cavity of the mold, - The step of foaming or polymerizing the mixture to obtain at least one component in the foaming material of the filling element (2), A method characterized by obtaining at least one component in the foaming material of the filling element (2), which includes the granular body (4) containing and/or made from the recycled material.
  20. The method according to claim 19, wherein the step of providing at least one material for the packing element (2) in a fluid state comprises providing material A, such as an isocyanate, and material B, such as a polyol compound comprising at least one polyol and at least one additive, such as a catalyst, a cellular modifier, a colorant, etc., wherein material A and material B can react to form a foamed polyurethane polymer, a foam, such as a polyurethane foam, a self-skinning polyurethane foam, a foamed thermoplastic, EVA, a foamed material having a density of 50 kg/ m³ to 600 kg/ m³ , or a combination thereof.

Description

Designated inventors: Matteo Mason and Barbara Bigolin This invention relates to support elements for the human body, such as saddles, seats, and handlebar grips for bicycles or vehicles in general, including recycled materials. Furthermore, this invention also refers to methods for manufacturing such support elements. The challenge of whether we can obtain environmentally sustainable products now extends to every field. Similarly, there is a growing need to reduce waste and production waste. In particular, it should be noted that frequently used items, such as bicycle saddles made from different types of materials, cannot be recycled, and only the smallest possible portion of the materials that make them up can be recovered. On the sidelines, we must not forget the enormous costs that companies must bear regarding the disposal of waste and production waste, which ultimately makes the system unsustainable from both an economic and ecological standpoint. The applicant has long been committed to creating increasingly environmentally friendly products. See, for example, Patent Documents 1 and 2. However, none of these products meet the current level of environmental friendliness required to meet current needs. Patent Document 3 describes a mold in which small pieces or flakes of polyurethane foam are guided into a closed mold together with a binder. A compression step is performed within this mold, followed by the introduction of steam to polymerize the resulting product, such as a chair or stool cushion, and then cooling. Patent document 4 describes a vehicle seat comprising a cushion having at least one foam element, a cover that at least partially covers the outer surface of the cushion, and a heating device for the seat itself. The foam element includes metal granules designed to act as a heat conductor. Patent Document 5 describes a method for manufacturing a cushion for an automobile seat element, the method comprising the step of mixing elastically compressible foam and/or regenerated fiber particles with a precursor mixture of flexible polyurethane resin to bond the particles and/or fibers together and obtain a mixture suitable for forming a padding block for the cushion itself. Furthermore, this method includes a step of compressing the material inserted into the mold so that it takes the shape of the cavity in which the material is placed. Therefore, the possibility of developing further products and methods that are more ecologically sustainable, help reduce or completely eliminate waste and scrap, while simultaneously maintaining the functional properties of the resulting products, such as mechanical and comfort properties, is of considerable importance. EP2139751 specificationEP2736795 specificationInternational Application No. WO2007/049973 SpecificationGerman Patent Application Publication No. 102021115436EP3838543 specification The objective of this invention is to overcome the shortcomings of known technologies. Another object of the present invention is to provide a support element for the human body that includes recycled materials. A further object of the present invention is to provide an environmentally friendly support element for the human body. A further object of the present invention is to provide a support element for the human body that has optimal functionality in terms of mechanical performance and comfort characteristics. According to one aspect of the present invention, a support element for the human body as described in claim 1 is provided. The object of this invention is to provide a simple and rapid method for manufacturing support elements for the human body. A further object of the present invention is to provide a more ecologically sustainable method for manufacturing support elements for the human body. Another object of the present invention is to provide a method for manufacturing support elements for the human body that is substantially compatible with conventional manufacturing plants. According to one aspect of the present invention, a method for manufacturing a support element for the human body as described in claim 12 and a method for manufacturing a filling element as described in claim 19 are provided. The dependent claims refer to preferred and advantageous embodiments of the present invention. Other features and advantages of the present invention will become more apparent from the description of embodiments of the invention, which are illustrated as examples in the accompanying drawings. In the attached drawings, identical parts or components are identified by the same reference number. One top view shows two versions of a support element for the human body according to the present invention, in the form of a bicycle saddle.This is a top view of one of two versions of a support element for the human body according to the present invention, in the form of a bicycle saddle.This is a top view of a further embodiment of a support element for the human body acco