Method for making an anatomical multilayer bicycle-type seat

Claim 1

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; and (f) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, whereby said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection.

Claim 2

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; and (f) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, whereby said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection.

Claim 4

A method for constructing an anatomical multilayer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated soft, resilient gel layer between said shell and said flexible outer cover sheet, said method comprising the steps of: (a) providing a first mold half; (b) placing a resilient layer on the first mold half; (c) placing said gel layer on said resilient layer; (d) placing said rigid shell, acting as a second mold half above the first mold half to form a cavity; (e) injecting a foam or rubber-like material into said cavity; (f) curing the foam material; (g) removing the first mold half; and (h) attaching a flexible cover sheet firmly to the periphery of said shell; whereby the gel layer is constrained on at least two edges by said foam material against substantial lateral movement and is permitted only limited up-and-down vertical deflection by at least said shell and said cover sheet.

Claim 5

A method for constructing an anatomical multilayer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated soft, resilient gel layer between said shell and said flexible outer cover sheet, said method comprising the steps of: (a) providing a first mold half; (b) placing a resilient layer on the first mold half; (c) placing said gel layer on said resilient layer; (d) placing said rigid shell, acting as a second mold half above the first mold half to form a cavity; (e) injecting a foam or rubber-like material into said cavity; (f) curing the foam material; (g) removing the first mold half; and (h) attaching a flexible cover sheet firmly to the periphery of said shell; whereby the gel layer is constrained on at least two edges by said foam material against substantial lateral movement and is permitted only limited up-and-down vertical deflection by at least said shell and said cover sheet.

Claim 8

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; and (f) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, wherein said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection wherein steps (c), (d), (e) and (f), comprise: first placing said gel layer on the upper surface of said shell acting as said first mold surface; placing said second mold surface above said first mold surface to form a cavity therebetween; injecting said foam or rubber-like material into said cavity between said mold surfaces; curing said foam or rubber-like material; and removing subsequently said second mold surface.

Claim 9

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; and (f) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, wherein said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection wherein steps (c), (d), (e) and (f), comprise: first placing said gel layer on the upper surface of said shell acting as said first mold surface; placing said second mold surface above said first mold surface to form a cavity therebetween; injecting said foam or rubber-like material into said cavity between said mold surfaces; curing said foam or rubber-like material; and removing subsequently said second mold surface.

Claim 10

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; (f) placing a layer of resilient material above the foam-encapsulated gel layer; (g) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, wherein said gel layer is constrained against substantial lateral movement and is permitted only limited vertical defection; and wherein steps (c), (d), (e) and (g), comprise first placing said gel layer on the upper surface of said shell acting as said first mold surface; placing said second mold surface above said first mold surface to form a cavity therebetween; injecting said foam or rubber-like material into said cavity between said mold surfaces; curing said foam or rubber-like material; and removing subsequently said second mold surface.

Claim 11

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; (f) placing a layer of resilient material above the foam-encapsulated gel layer; (g) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, wherein said gel layer is constrained against substantial lateral movement and is permitted only limited vertical defection; and wherein steps (c), (d), (e) and (g), comprise first placing said gel layer on the upper surface of said shell acting as said first mold surface; placing said second mold surface above said first mold surface to form a cavity therebetween; injecting said foam or rubber-like material into said cavity between said mold surfaces; curing said foam or rubber-like material; and removing subsequently said second mold surface.

Claim 12

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to escape at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; and (f) placing a layer of resilient material above the foam-encapsulated gel layer; (g) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, wherein said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection, wherein steps (c), (d), (e) and (g) comprise: placing said resilient layer on said second mold surface; placing said gel layer on top of said resilient layer; placing said mold surface above said second mold surface to form a cavity therebetween; injecting a foam material into said cavity and curing the foam material; and removing said second mold surface.

Claim 13

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to escape at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; and (f) placing a layer of resilient material above the foam-encapsulated gel layer; (g) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, wherein said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection, wherein steps (c), (d), (e) and (g) comprise: placing said resilient layer on said second mold surface; placing said gel layer on top of said resilient layer; placing said mold surface above said second mold surface to form a cavity therebetween; injecting a foam material into said cavity and curing the foam material; and removing said second mold surface.

Claim 14

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; (f) placing a layer of resilient material above the foam-encapsulated gel layer; (g) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, whereby said gel layer is constrained against substantial lateral movement, wherein steps (c), (d), (e) and (g) comprise placing said first mold surface above said second mold surface to form a cavity therebetween; injecting said foam or rubber-like material into said cavity; curing said foam material; removing said second mold surface; and placing a gel packet into said depression.

Claim 15

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; (f) placing a layer of resilient material above the foam-encapsulated gel layer; (g) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, whereby said gel layer is constrained against substantial lateral movement, wherein steps (c), (d), (e) and (g) comprise placing said first mold surface above said second mold surface to form a cavity therebetween; injecting said foam or rubber-like material into said cavity; curing said foam material; removing said second mold surface; and placing a gel packet into said depression.

Claim 16

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; (f) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, whereby said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection, and wherein said layer of resilient material is placed prior to attaching of the flexible cover sheet, wherein said steps (c), (d), (e) and (f) comprise: providing said second mold surface with a downward projection shaped to form a depression corresponding to the desired shape of said gel layer; placing said first mold surface above said second mold surface to form a cavity therebetween; injecting said foam or rubber-like material into said cavity; curing said foam or rubber-like material; removing said second mold surface; and placing a gel packet into said depression.

Claim 17

A method for constructing an anatomical multi-layer bicycle-type seat having a lower rigid shell, a flexible outer cover sheet, and an encapsulated gel layer located between said shell and said outer cover sheet, the method comprising the steps of: (a) providing an upper surface of a formed relatively rigid lower shell as a first mold surface; (b) providing a rigid shaped object having a desired upper surface shape of said seat as a second mold surface; (c) forming a mold cavity with said first and second mold surfaces; (d) forming a cured foam or rubber-like material layer in said mold having a central cavity; (e) including a soft resilient gel layer in said central cavity so as to engage at least two lateral edges of said gel layer to constrain the gel layer against substantial lateral movement; (f) placing a flexible cover sheet over said foam and gel layers after separating said mold surfaces and attaching said cover sheet firmly onto the periphery of said shell, whereby said gel layer is constrained against substantial lateral movement and is permitted only limited vertical deflection, and wherein said layer of resilient material is placed prior to attaching of the flexible cover sheet, wherein said steps (c), (d), (e) and (f) comprise: providing said second mold surface with a downward projection shaped to form a depression corresponding to the desired shape of said gel layer; placing said first mold surface above said second mold surface to form a cavity therebetween; injecting said foam or rubber-like material into said cavity; curing said foam or rubber-like material; removing said second mold surface; and placing a gel packet into said depression.