IT201900014499A1 - PROCESS FOR MAKING A PROFILE COVERING AND PROFILE COVERING MADE ACCORDING TO THIS PROCEDURE - Google Patents

Description

DESCRIPTION

attached to a patent application for an INDUSTRIAL INVENTION PATENT entitled:

“PROCEDURE FOR MAKING A PROFILE COVERING

AND PROFILE COVERING MADE ACCORDING TO

THIS PROCEDURE "

FIELD OF THE INVENTION

The present invention relates to a process for making a profiled covering.

The invention also relates to a profiled lining, preferably made according to the aforementioned procedure.

In addition, the present invention relates to a technical and / or sports article comprising at least one profiled covering.

The invention also relates to an equipment for making a profiled coating.

By way of example, the invention can find advantageous application in the field of coatings for technical and / or sporting articles and of technical and / or sporting articles, such as for example a helmet or goggles or a mask or a pad or a backpack or a brace or a suit or a piece of technical and / or sports clothing in general (for example for skiing, cycling, motorcycling, motoring, hiking, boxing, martial arts, athletics, team sports).

STATE OF THE ART

Coatings are known in the technical sector of reference, for example for helmets and similar technical articles. In the continuation of the discussion of the state of the art, reference will be made, in fact, to coatings for helmets.

A method for making helmet covers is known, which involves shearing pieces of fabric, placing a padding between them and sewing together the previously sheared pieces of fabric so that the padding is interposed between the pieces of fabric. The pieces of fabric sewn together represent the shell of the upholstery, inside which the padding is arranged. The sewing phase is done manually; the known helmet coatings are therefore assembled, to date, in an artisanal way.

The currently known method for producing helmet coatings, and consequently the helmet coatings obtained by means of this method, have many drawbacks.

A first drawback is related to the sewing step; providing the known method of manually making the seams, it does not allow to obtain high precision and reliable repeatability. The known method therefore does not allow for an optimal engagement between the constituent fabrics, once sewn, the casing of the helmet cover. Consequently, the coatings for helmets made by the known method are not free from defects.

In addition, the quality of known helmet coverings highly depends on the experience and skills of the operator prepared to sew the pieces of fabric. Consequently, in accordance with known methods, the quality of the helmet coverings made may vary when the operator changes. Variation in the quality of helmet coatings is highly undesirable as it determines, in addition to an oscillating quality of helmet coatings, also the variability of the quality of the helmets themselves within which such coatings are used.

In addition to the above, due to the very nature of the sewing operation, the seams generally cause residual tension. In the specific case of helmet coatings, the seams to which the fabrics are subjected cause residual tension in the shell of the coating; these residual stresses are responsible for defects in the finished product. In addition, the residual tensions do not allow an optimal comfort of the helmet coverings; in fact, residual tensions affect the performance of helmet coatings and, also decreasing the comfort for the user, worsen the experience of using the helmet coating. Consequently, residual tensions also worsen the experience of using the helmet using these coatings (or other similar technical items using these coatings).

The drawbacks linked to residual tensions are accentuated by the fact that the known method provides for the sewing of the seams by hand; in this way an element of performance variability and additional uncertainty is generated, which is potentially the cause of further errors and / or non-conformities.

Furthermore, the known manufacturing method of helmet coatings is long and, therefore, is not efficient.

In addition to the above, the known method has a high production cost of helmet coverings due to both the high labor costs and the manual management of the sewing phase, which increases, for the reasons previously explained, the costs associated with defects in coatings, non-conformities and therefore products to be discarded.

PURPOSE OF THE INVENTION

The aim of the present invention is therefore to solve at least one of the drawbacks and / or limitations of the previous solutions.

A first object of the present invention is to provide a process for producing a profiled coating which allows the quality of the profiled coatings obtained by this method to be repeatable and homogeneous.

It is a further object of the present invention to provide a process for producing a profiled coating capable of reducing or even canceling the defects or non-conformities of the profiled coatings.

It is also an object of the present invention to provide a process for producing a profiled covering which allows to produce profiled coverings with a solid and robust structure.

A further object of the invention is to provide a process for making a profiled covering that allows to realize profiled coverings without residual stresses.

It is also an object of the present invention to provide a process for producing a profiled lining capable of minimizing material waste in the production of profiled cladding.

It is an additional object of the present invention to provide profiled coatings with a solid and robust structure.

An additional purpose of the invention is to provide profiled coatings free of residual stresses.

It is also an object of the present invention to provide technical and / or sports articles capable of guaranteeing optimal comfort of use for a user.

It is also the object of the invention to provide an equipment capable of producing profiled coatings with a solid and robust structure.

An additional object of the present invention is to provide an apparatus capable of producing profiled coatings free of residual stresses. These objects and others, which will become more apparent from the following description, are substantially achieved by a process for making a profiled covering, a profiled covering, a technical and / or sporting article and an apparatus for making a profiled covering. in accordance with one or more of the attached claims and / or with one or more of the following aspects.

SUMMARY

Aspects of the invention are described below.

In a 1st aspect, a process for producing a profiled covering is provided, for example for technical and / or sports items such as helmets or masks or seat pads or backpacks or braces or overalls or technical and / or sports clothing in general, comprising the following steps:

- providing at least one element in sheet material, for example substantially flat,

- positioning said at least one element in sheet material on a mold base equipped with at least one recess or a profiled relief,

- printing said at least one element in sheet material,

in which molding said at least one sheet material element comprises a counter-shaping, by means of a counter mold configured to cooperate with the mold base, of at least a portion of said at least one sheet material element to a profile of said at least one recess or relief profiled.

In a 2nd aspect according to the 1st aspect, at the end of said counter-shaping said at least one element in sheet material has three-dimensional stability of shape and / or is self-supporting.

In a 3rd aspect according to the 1st or 2nd aspect, the counter-shaped portion of said at least one element in sheet material defines at least one housing, the process further comprising the steps of:

- insert at least one padding element inside said at least one housing,

- optionally, stably and without the aid of seams tie said at least one padding element to said at least one element in sheet material.

In a 4th aspect according to the 1st or 2nd or 3rd aspect, the positioning of said at least one element in sheet material provides for facing at least one surface of said at least one element in sheet material to said at least one withdrawal or profiled relief.

In a 5th aspect according to the 4th aspect:

- said at least one profiled recess of the mold base has a concavity or said at least one profiled relief of the mold base has a convexity, and

- facing at least one surface of said at least one sheet material element to said at least one profiled recess or relief comprises facing a surface of said at least one sheet material element to the concavity of said at least one profiled recess of the mold base or to the convexity of said at least one profiled relief of the mold base.

In a 6th aspect according to any one of the 1st to 5th aspects, printing said at least one element in sheet material comprises:

- providing a counter mold configured to cooperate with the mold base and equipped with at least one profiled relief or recess having a complementary and / or corresponding and / or substantially counter-shaped profile to the profile of said at least one profiled recess or relief of the mold base, and - relatively moving the mold base and counter-mold in mutual approach, the counter-shaping being contextual to the relative movement of the mold base and counter-mold.

In a 7th aspect according to any one of the 1st to 6th aspects, the counter-shaping of said at least one portion of said at least one element in sheet material comprises a plastic deformation, by means of said counter-mold, of said at least one portion in such a way that it assumes the profile of said at least one relief or profiled recess of the counter-mold.

In an 8th aspect according to the 7th aspect, in the plastic deformation step said at least one recess or profiled relief of the mold base acts as a deformation abutment or anvil.

In a 9th aspect according to the 7th or 8th aspect, the plastic deformation phase confers three-dimensional stability of shape to said at least one element in sheet material designed to make said at least one element in self-supporting sheet material. In a 10th aspect according to any one of the 1st to 9th aspects, the counter-shaping of at least a portion of said at least one element in sheet material to a profile of said at least one recess or profiled relief provides for counter-shaping, by means of said counter-mold , at least a portion of said at least one sheet material element to a profile of said at least one profiled recess of the mold base.

In an 11th aspect according to any of the 6th to 10th aspects:

- the step of preparing a counter-mold provides for the provision of a counter-mold configured to cooperate with the mold base and equipped with at least one profiled relief having a complementary profile and / or corresponding and / or substantially counter-shaped to the profile of said at least one profiled recess of the mold base,

- the phase of relative movement of the mold base and of the counter-mold involves moving the counter-mold towards the mold base.

In a 12th aspect according to any one of the 7th to 11th aspects, the plastic deformation step of said at least one portion of said at least one sheet material element provides for plastically deforming, by means of said counter-mold, said at least one portion of said at least one element made of sheet material in such a way that it assumes the profile of said at least one profiled relief of the counter-mold, in the step of plastic deformation said at least one profiled recess of the mold base acting as a deformation abutment or anvil. In a 13th aspect according to any of the aspects from the 1st to the 12th, the counter-shaping phase lasts between 30 seconds and 150 seconds.

In a 14th aspect according to any one of the 1st to 13th aspects, the counter-shaping step is carried out at a temperature between 50 ° C and 170 ° C.

In a 15th aspect according to any one of the 1st to 14th aspects, the counter-shaping step is carried out at a pressure between 5 bar and 8 bar, in particular substantially equal to 7 bar.

In a 16th aspect according to the 15th aspect, said pressure is permanently constant during the counter-shaping phase.

In a 17th aspect according to any one of the 3rd to 16th aspects, stably binding said at least one padding element to said at least one sheet material element comprises:

- superimposing a further element in sheet material or a further portion of said at least one element in sheet material on a constraint portion of said at least one element in sheet material in such a way as to cover said previously counter-shaped portion and said at least one element padding,

- at least partially engaging said further element in sheet material or said further portion of said at least one element in sheet material to said constraint portion of said at least one element in sheet material.

In an 18th aspect according to the 17th aspect, said step of at least partial engagement of said further element in sheet material or said further portion of said at least one element in sheet material to said constraint portion of said at least one element in sheet material is made by thermoforming.

In a 19th aspect according to the 17th or 18th aspect, at least partially engaging said further sheet material element or said further portion of said at least one sheet material element to said constraint portion of said at least one sheet material element sheet material provides for engaging said further sheet material element to said constraint portion of said at least one sheet material element by means of thermoforming and comprises:

- bringing a heated plate or press close to said sheet material elements,

- exerting a pressure, by means of said plate or press, on said elements in sheet material,

- stably joining respective portions of said elements in sheet material. In a 20th aspect according to the 17th or 18th or 19th aspect, the process further comprises the step of coupling a joint element made of sheet material, for example of polyurethane, to at least one element made of sheet material, said coupling step being subsequent to the step of inserting at least one padding element inside said at least one housing and preceding the step of stably binding said at least one padding element to said at least one element made of sheet material.

In a 21st aspect according to the 17th aspect, said step of at least partial engagement of said further element in sheet material or said further portion of said at least one element in sheet material to said constraint portion of said at least one element in sheet material is made by a high frequency joining operation, for example by high frequency welding.

In a 22nd aspect according to the 21st aspect, at least partially engaging said further sheet material element or said further portion of said at least one sheet material element to said constraint portion of said at least one sheet material element provides to engage said further sheet material element to said constraint portion of said at least one sheet material element by ultrasonic welding and comprises:

- emit ultrasound, for example by means of a sonotrode,

- directing the ultrasounds towards said elements in sheet material,

- locally melting portions of said elements in sheet material.

In a 23rd aspect according to any one of the 1st to 22nd aspects, the process further comprises the step of detaching at least a scrap portion of at least one element in sheet material.

In a 24th aspect according to the 23rd aspect, the detachment of at least a scrap portion of said at least one element in sheet material occurs in correspondence with a demarcation line, for example defined by said counter-shaping step, intended to constitute at least part of a perimeter edge of the profiled cladding.

In a 25th aspect according to the 23rd or 24th aspect, the step of detaching at least a scrap portion of at least one element in sheet material is substantially contextual or simultaneous with the step of stably binding said at least one padding element to said at least one element in sheet material.

In a 26th aspect according to the 23rd or 24th or 25th aspect, the step of detaching at least a scrap portion of at least one sheet material element is subsequent to the step of stably binding said at least one padding element to said at least one element in sheet material.

In a 27th aspect according to any one of the 23rd to 26th aspects, detaching said at least one reject portion comprises cutting said at least one reject portion.

In a 28th aspect according to the 27th aspect, at least one of the mold base and a plate or press configured to cooperate with the mold base has a cutting element configured to cut said at least one sheet material element, the step of detaching at least a waste portion of at least one sheet material element comprising cutting said at least one waste portion of said at least one sheet material element by means of said cutting element. In a 29th aspect according to the 28th aspect, the step of cutting said at least one scrap portion of said at least one element in sheet material by means of said cutting element is substantially contextual or simultaneous with a relative movement step between the mold base and plate or press.

In a 30th aspect according to any one of the 1st to 29th aspects, providing at least one sheet material element comprises providing a substantially flat sheet material element made of at least one of the following: PET, PETG, polycarbonate, polypropylene, polyurethane, leather, imitation leather, natural fiber fabric, synthetic fiber fabric, leather, rubber, preferably in which providing at least one element in sheet material comprises providing an element in sheet material in plastic material, in particular thermoplastic, to example in at least one of: PET, PETG, polycarbonate, polypropylene.

In a 31st aspect, a profiled lining is provided, for example for technical and / or sports items such as helmets or masks or seat pads or backpacks or braces or overalls or technical and / or sports clothing in general, made according to the procedure in accordance with any of the aspects 1 to 30 and / or in accordance with any of the attached process claims.

In a 32 ° aspect according to the 31 ° aspect, said profiled covering comprises an element in sheet material having three-dimensional stability of shape and / or self-supporting.

In a 33rd aspect, a profiled covering is provided, for example for technical and / or sports articles such as helmets or masks or overalls or elements of technical and / or sports clothing in general, the profiled covering comprising an element in sheet material having three-dimensional stability of shape and / or being self-supporting. In a 34th aspect according to the 32nd or 33rd aspect, the element in sheet material defines a shaped body made by molding.

In a 35th aspect according to the 34th aspect, the shaped body is realized by plastic deformation, the plastic deformation conferring three-dimensional stability of shape to said at least one element in sheet material capable of making said at least one element in self-supporting sheet material .

In a 36th aspect according to any one of the 31st to 35th aspects, the profiled coating is provided with an at least one portion having at least one profiled recess or relief.

In a 37th aspect according to the 36th aspect, said recess or relief or profile is made by means of a counter-shaping step.

In a 38th aspect according to the 36th or 37th aspect, called at least a profiled recess defines a housing, the profiled lining also comprising at least one padding element housed inside the profiled recess.

In a 39th aspect according to the 38th aspect, the profiled cover is a padded profiled cover.

In a 40 ° aspect according to any one of the 31 ° to 39 ° aspects, the profiled coating has a thickness, for example a maximum thickness, of less than 80 mm, preferably less than 60 mm.

In a 41st aspect, there is a technical and / or sports item, for example a helmet or goggles or a mask or a pad or a backpack or a brace or a tracksuit or a technical and / or sports garment in general , comprising at least one profiled coating according to any of the aspects from 31 ° to 40 ° and / or according to any of the attached claims of coating and / or made according to the process according to any of the aspects from 1 to 30 ° and / or of the attached process claims.

In a 42 ° aspect, an apparatus is provided, in particular a molding apparatus, for the production of a profiled covering, for example for technical and / or sporting articles such as helmets or masks or backpacks or backpacks or braces or overalls or garments. technical and / or sports clothing in general, the equipment including:

- a mold base equipped with at least one recess or profiled relief and preferably with a support surface intended to allow the positioning of an element made of sheet material,

- a counter-mold equipped with at least one profiled relief or recess having a complementary and / or corresponding and / or substantially counter-shaped profile to the profile of said at least one profiled recess or relief of the mold base,

in which the mold base and the counter-mold are configured to cooperate with each other to mold at least one sheet material element that can be positioned between the mold base and the counter-mold in such a way that at least a portion of said at least one sheet material element assumes a shape having a profiled recess or relief with a substantially complementary profile and / or corresponding and / or counter-shaped to the profile of said at least one recess or profiled relief of the mold base.

In a 43rd aspect according to the 42nd aspect, the counter-mold is configured to counter-shape at least a portion of the sheet material element to a profile of said at least one profiled recess or relief in such a way that said at least a portion of the element in sheet material assumes a shape having a profiled recess or relief with a substantially complementary profile and / or corresponding to the profile of said at least one profiled recess or relief of the mold base.

In a 44 ° aspect according to the 42 ° or 43 ° aspect, at least one of the mold base and the counter-mold can be moved, for example movable, approaching the other in such a way as to allow relative movement between the mold and the counter-mold, said movement preferably taking place by means of hydraulic or oleodynamic or pneumatic movement members.

In a 45 ° aspect according to the 42 ° or the 43 ° or the 44 ° aspect, the apparatus further comprises a closing element configured to at least partially engage a further material element to a constraint portion of the sheet material element previously superimposed on said constraint portion of the sheet material element or a further portion of the sheet material element previously superimposed on said constraint portion of the sheet material element.

In a 46th aspect according to the 45th aspect, the closure element is configured to exert a certain pressure on the constraint portion and on the further element in sheet material previously superimposed on said constraint portion or on the constraint portion and on a further portion of the element in sheet material previously superimposed on said constraint portion in such a way as to close, for example by thermoforming, the profiled product.

In a 47th aspect according to the 46th aspect, the closing element comprises a matrix and / or a plate or press.

In a 48 ° aspect according to any of the 42 ° to 47 ° aspects, the apparatus further comprises a cutting element having at least one cutting edge and configured to cut the sheet material element in such a way as to detach at least a portion of the element in sheet material. In a 49th aspect according to the 48th aspect, the cutting element is configured to cut the sheet material element along a demarcation line, for example definable by the die on the sheet material element for counter shaping, intended to at least partially constitute a perimeter edge of the profiled covering.

In a 50th aspect according to the 48th or 49th aspect, the cutting element is defined at the base of the mold or the counter-mold or the die or the plate or press or is alternatively defined in a dedicated punch.

In a 51st aspect according to any one of the 1st to 50th aspects, at least one of the mold base and the counter-mold is made of aluminum, optionally in which both the mold base and the counter-mold are made of aluminum.

In a 52nd aspect according to any one of the 1st to 51st aspects, heating elements are applied to at least one of the mold base and the counter mold.

In a 53 ° aspect according to the 52 ° aspect, the heating elements are configured to heat at least one of the mold base, the counter-mold and the element in sheet material.

In a 54th aspect according to any one of the 42 ° to 53 ° aspects, the mold base comprises connecting means, in particular pins, configured to couple with corresponding connecting means provided on the sheet material element, in order to keeping the sheet material element stably in position in particular during a molding operation performed by the apparatus.

In a 55th aspect according to any one of the 42nd to 54th aspects, the apparatus comprises a control unit configured to implement the method according to any one of the 1st to 30th aspects and / or any of the appended claims of method.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments and some aspects of the invention will be described hereinafter with reference to the accompanying drawings, provided for explanatory and therefore non-limiting purposes only, in which:

- figure 1 shows the step of preparing an element in sheet material of the process for making a profiled covering according to the present invention,

- Figure 2 is a view of a mold base that can be used in the context of a molding step of the process of making a profiled lining according to the present invention; in figure 2, the mold base is overturned with respect to the orientation it assumes in the normal condition of use,

- Figure 3 is a view of the mold base of Figure 2 in the orientation of normal conditions of use,

- Figure 4 shows a molding apparatus for the production of a profiled lining according to the present invention and a relative handling step between the mold base and the counter-mold of the process of making a profiled lining according to the present invention,

- Figure 5 shows the optional step of the process of making a profiled covering according to the present invention which provides for the introduction of padding elements in suitable recesses of the profiled covering,

Figure 6 shows the optional step of engaging two elements in sheet material of the process for making a profiled covering according to the present invention,

- figure 7 shows a step of the process for manufacturing a profiled covering according to the present invention preliminary to an optional step of detaching waste portions and also shows a padded covering made according to the process according to the present invention, in which the elements in sheet material are firmly engaged with each other,

- figure 8 shows a perspective view of an earmuff for a helmet, which constitutes an example of a padded profiled covering according to the present invention, made according to the process according to the present invention, in which it can be appreciated how the padded profiled covering has three-dimensional stability in shape and is self-supporting, - figure 9 is the section of the helmet earmuffs of figure 8, made according to the sectioning plane IX-IX, illustrating the padding inside the shell of the helmet earmuffs,

- figure 10 represents a perspective view of a gasket for goggles or a ski mask, which constitutes a further example of a padded profiled covering according to the present invention, realized according to the process according to the present invention, in which it is appreciable as the padded profiled covering has three-dimensional stability of shape and is self-supporting,

- Figure 11 represents a partially sectioned perspective view of the gasket for a goggle or a ski mask of Figure 10, illustrating the padding inside the gasket casing.

DEFINITIONS AND CONVENTIONS

It should be noted that in the present detailed description corresponding parts illustrated in the various figures are indicated with the same numerical references. The figures could illustrate the object of the invention (process, profiled coating, equipment) through non-scale representations; therefore, parts and components illustrated in the figures relating to the object of the invention could only concern schematic representations. In the context of this description, the use of terms such as "above", "above", "above", "below", "below", "below", "on the side", "side", "laterally", " horizontal "," horizontally "," vertical "," vertically "," front "," front "," rear "," rear "and similar refers, unless otherwise specified, to at least one spatial orientation that normally the object of the invention can be assumed under operating conditions or conditions of use. In this regard, see the attached figures illustrating at least one possible spatial orientation of the object of the invention (refer to the profiled lining and the components of the equipment).

Here are some definitions that can be used for the purposes of the intelligence of the present invention:

- with the terms "profiled cladding", we mean a cladding which manifests an appropriate profile or shape and / or which is equipped with an appropriate profile or shape, which can be defined on the basis of, and is functional for, the intended purpose use of the covering and, in addition or alternatively, of the technical and / or sporting article in which the profiled covering is intended to be used,

- with the terms "three-dimensional stability of shape", we mean the structural characteristic of the profiled cladding on the basis of which the profiled cladding maintains and / or retains the specific three-dimensional conformation over time, in particular this three-dimensional conformation being obtained through the molding phase of the process for producing a profiled covering according to the present invention, which is described below.

DETAILED DESCRIPTION

Method

The process according to the present invention allows the realization of a profiled covering 1. The profiled covering 1 realized according to the process described here can be used in technical and / or sporting articles such as helmets or masks or bottoms or backpacks. o braces or overalls or technical and / or sports clothing in general.

The method provides for providing at least one element in sheet material 2, preferably substantially flat. The element in sheet material 2 can be in at least one of the following materials: PET (Polyethylene terephthalate), PETG (Glycol-modified Polyethylene Terephthalate), polycarbonate, polypropylene, polyurethane, leather, imitation leather, natural fiber fabric, synthetic fiber fabric, leather, rubber. Preferably, the element in sheet material 2 is in a plastic material, in particular thermoplastic, for example in at least one of: PET, PETG, polycarbonate, polypropylene. Each of said materials has certain properties, such as its own rigidity, its own elasticity and its own density; the material of the element in sheet material 2 can be suitably chosen on the basis of the intended use of the profiled covering 1 and, in addition or alternatively, of the technical and / or sports article in which the profiled covering 1 is intended to be used. The materials used in the context of this procedure have the ability to assume, by means of molding as will be seen in greater detail below, an appropriate shape and maintain the assumed shape in a stable manner.

The element in sheet material 2 is represented in Figure 1 as it appears preliminary to the execution of the process according to the present invention. This element in sheet material 2 is for example made of fabric (rigid or elastic or bi-elastic) and has a thickness that can be of the order of a few millimeters or less or of the order of tens of millimeters, for example of about 40 -50 mm. The additional dimensions of the element in sheet 2 are defined according to the shape and / or size of the profiled coating to be obtained, in order to minimize subsequent production waste. The element in sheet material 2 represented in Figure 1 has a substantially square geometry and is suitable for example for the realization of a profiled covering that can be used in an earmuff for helmets.

The element in sheet material 2 can be of the monomaterial type, or comprise materials different from each other. In particular, the element in sheet material 2 can be obtained by joining a plurality of layers of the same material or advantageously of different materials. The sheet material element 2 is positioned on a mold base 3 provided with at least one recess or a profiled relief 4. The recess or profiled relief 4 can be defined at a lower surface or at an upper surface of the mold base 3. In the context of the present description, the mold base 3 can alternatively be called "mold" and substantially constitutes an anvil (molding abutment) which allows the molding of the element in sheet material 3. Hereinafter, the process will be described using a mold base 3 (for example made of aluminum) provided with a profiled recess 4 defined in correspondence with its upper surface; in this regard, see Figure 3. In further embodiments, the mold base 3 can comprise a plurality of profiled recesses 4 or at least one profiled recess 4 and at least one profiled ridge or any combination of ridges and profiled recesses 4. Figure 3 illustrates a top view of the mold base 3, illustrating the orientation it assumes under normal conditions of use; the conditions of use are shown in figures 4 to 7. As shown in the attached figures, the profiled recess 4 of the mold base 3 is concave and therefore has a concavity. The mold base can substantially comprise a suitably shaped plate 3, having a recess 4 provided with a profile; in this regard, see in particular figures 2 and 3. The profile of the profiled recess 4 corresponds to the profile that you want to print on the element in sheet material 2.

The element in sheet material 2 may comprise means of connection (not shown in the figures) to corresponding means provided on the base of the mold 3 (also not shown in the figures). In an embodiment of the present invention, the connecting means of the sheet element 2 comprise a plurality of holes advantageously obtained in correspondence with the portion of the sheet element 2 intended to become a reject portion after the execution of the process according to the present invention.

Optionally, these holes are arranged near the lateral edges of the element in sheet material 2 and have a suitably homogeneous distribution. The corresponding means of the mold base 3, on the other hand, comprise a plurality of pins, each intended to be inserted into the holes of the sheet material element 2. The coupling between the connecting means of the sheet material element 2 and the corresponding means provided on the mold base 3 (in particular between the holes of the element in sheet material 2 and the pins of the mold base 3) have the function of establishing a bond between the sheet material 2 and the mold base 3 during molding step, thus keeping the sheet material 2 stably in position during molding, thus contributing to the quality of the profiled coatings (in particular to the shape accuracy) obtained by the process according to the present invention.

The step of positioning the element in sheet material 2 is carried out in such a way that the element in sheet material 2 is arranged according to a substantially planar orientation on the base of the mold 3; in this regard, see Figure 4 illustrating the element in sheet material 2 positioned planarly on the mold base 3. The positioning step envisages facing at least one surface of the element in sheet material 2 to the concavity of the profiled recess 4 of the base of mold 3. Figure 4 illustrates a condition in which the lower surface of the element made of sheet material 2 faces the concavity of the concave profiled recess 4 of the mold base 3.

Subsequently to the positioning of the element in sheet material 2 on the mold base 3 (which can make use of the coupling between the connecting means of the element in sheet material 2 and the corresponding means provided on the mold base 3 as previously discussed), the method provides for molding the element in sheet material 2. The molding step is carried out by means of a counter-mold 5 configured to cooperate with the mold base 3 to carry out the molding step. The counter-mold 5 has an upper surface and a lower surface, at least one of which is at least partially complementary to a corresponding surface, such as the upper surface, of the mold base 3 and is configured to cooperate with it in the molding step. In the embodiment described here, the surface of the counter mold 5 configured to cooperate with the upper surface of the mold base 3 at the time of molding is the lower surface of the counter mold 5; in this regard, see figure 4. The counter-mold 5 has a portion 6, such as a relief or a recess, substantially complementary to the recess or relief 4 of the mold base 3. In embodiments in which the mold base 3 has at least one recess profiled 4, the counter-mold 5 has at least one profiled relief 6 complementary to the profiled recess 4; this is applicable, mutatis mutandis, to embodiments in which the mold base 3 and the counter-mold 5 have, on respective surfaces intended to cooperate with each other in the molding step, a plurality of recesses and profiled reliefs 4, 6. In the preferred embodiment herein described and illustrated in the figures accompanying the present description, the mold base 3 has a profiled recess 4 in correspondence with the upper surface and the counter-mold 5 has, in correspondence with its lower surface, a profiled relief 6 complementary to the profiled recess 4 of the base mold 3. As illustrated in Figure 4, the profiled relief 6 of the mold 5 defines a protrusion emerging from a planar development of the lower surface of the mold 5 and is substantially counter-shaped to the profiled recess 4 of the mold base 3. The molding step provides the relative movement between mold base 3 and counter mold 5 approaching tr to them. The preferred embodiment of the present invention envisages, in the context of the molding step, the movement of the counter-mold 5 towards the mold base 3 (see the arrow in figure 4 which defines the direction of movement of the counter-mold 5 with respect to the mold base mold 5, in this case being a substantially vertical direction).

The mold base 3 and the counter-mold 5 can therefore essentially be considered molding plates having a recess and a relief that are counter-shaped between them. In particular, the depth of the recess with respect to the support surface for the element in sheet material 2 determines the depth of the housing that will be determined within the sheet material 2 at the end of the molding phase.

The molding step determines the counter-shaping of at least a portion of the element in sheet material 2 to a profile of the profiled recess 4 of the mold base 3. The counter-shaping is made possible by inserting the profiled relief 6 of the counter-mold 5 in the profiled recess 4 of the mold base 3; upon insertion, the profiled relief 6 of the counter-mold 5 drags into the profiled recess 4 of the mold base 3 (plastically deforming them) portions of the element in sheet material interposed between the profiled relief 6 of the counter-mold 5 and the profiled recess 4 of the mold base 3. In this regard, see figure 4 illustrating the preliminary step for inserting the profiled relief 6 of the counter-mold 5 into the profiled recess 4 of the mold base 3 and figure 5, illustrating the step following the insertion of the profiled relief 6 of the counter-mold 5 in the profiled recess 4 of the mold base 3. In the embodiment of the method illustrated in the attached figures (see in particular figure 5), the counter-shaping determines the formation, on at least a portion of the element in sheet material 2, of at least one profiled recess 2a defining a housing.

Some process parameters that can be used to make a profiled covering 1 are described below; the parameters of the procedure may vary depending on the material of the element in sheet material 2. The parameters that are described below are the pressure, the time duration and the temperature; they relate to the molding phase, and in particular to the counter-shaping phase that occurs during molding. The values of the parameters that will be detailed below by way of example can be advantageously used when the element in sheet material 2 is in thermoplastic material (such as at least one of PET, PETG, polycarbonate, polypropylene). In terms of time duration, the molding phase can have a duration between 30 seconds and 150 seconds. In particular, the counter-shaping can have a duration between 30 seconds and 150 seconds. This duration can be defined as molding time or as counter-shaping time; the duration, within the aforementioned interval or within a different duration interval, can be calibrated according to the material of the element in sheet material 2 to be printed.

As regards the pressure, the molding step can be carried out at a pressure between 5 bar and 8 bar, for example substantially equal to 7 bar. Optionally, the pressure is substantially constant during the molding step. In particular, the counter-shaping can be made at a pressure between 5 bar and 8 bar, for example substantially equal to 7 bar. Optionally, the pressure is substantially constant during the counter-shaping phase. This pressure can be defined as molding pressure or as counter-shaping pressure; the pressure, within the aforementioned range or within a different pressure range, can be calibrated according to the material of the element in sheet material 2 to be printed. The molding phase can be carried out at a temperature between 50 ° C and 170 ° C. In particular, the counter-shaping can be carried out at a temperature between 50 ° C and 170 ° C. This temperature can be defined as the molding temperature or as the counter-shaping temperature; the temperature, within the aforementioned range or within a different temperature range, can be calibrated according to the material of the element in sheet material 2 to be printed.

Generally speaking, the parameters of the process according to the present invention which are most significantly affected by the characteristics of the material (or materials) of the sheet material element 2 are the time duration and the temperature, while the pressure is less sensitive to variations. of the material (or materials) of the element in sheet material 2 (the Applicant has in particular verified that a molding pressure of about 7 bar allows to carry out the method according to the present invention with a very wide range of constituent materials of the sheet material element 2).

The process can also provide, either prior to or simultaneously with the molding step, a heating phase of at least one of the mold base 3, the sheet material element 2 and the counter-mold 5. The heating phase can allow to reach a predetermined temperature, for example by at least one of the mold base 3, the sheet material element 2 and the counter-mold 5, this predetermined temperature being preferably located within the previously described temperature range. In particular, the heating step can allow the achievement of a desired temperature of the sheet material element 2. The heating can be carried out by means of heating elements, such as at least one electric resistance, integrated in the mold base 3 and, in addition or alternatively, in the counter-mold 5 or by means of external heating elements, and connected, to the mold base 3 and, in addition or alternatively, to the counter-mold 5. For example, the process can provide for the heating of the mold base 3, which determines the heating of the element made of sheet material 2 positioned above it (see Figure 4). Alternatively, the process can provide for the heating of the counter-mold 5 which determines, upon contact of the counter-mold 5 with the element in sheet material 2, the heating of the element in sheet material 2. Alternatively, the step of heating can be carried out by heating a molding environment, such as a molding chamber in which the mold base 3, the sheet material element 2 and the counter-mold 5 are displaced at the time of molding.

The element in printed sheet material 2 is self-supporting and has its own three-dimensional stability of the shape acquired by counter-shaping during the molding phase; moreover, the element in printed sheet material 2 is able to maintain the three-dimensional stability of the acquired shape. Basically, after being printed, the element in sheet material 2 substantially constitutes a frame or skeleton of the profiled covering 1 self-supporting and with three-dimensional stability of shape; the element in printed sheet material 2 therefore confers the characteristics of three-dimensional stability of shape and self-supporting capacity to the profiled covering 1. The element in sheet material 2 in particular maintains its own shape and / or profile assumed by the step of molding even in the absence of external stresses, thereby distinguishing itself from the technical solutions known to date.

The molding phase determines the plastic deformation of the element in sheet material 2 which allows the portion or portions of the element in sheet material 2 that have been counter-shaped to assume and maintain the profile obtained by molding. In the plastic deformation step, the profiled recess 4 of the mold base 3 acts as a deformation abutment (anvil). The maintenance of the three-dimensional stability of shape by the profiled coating 1 is made possible by the plastic deformation suffered by the element in sheet material 2.

Following the molding step, the process can optionally provide for a cooling step of the element in sheet material 2. The cooling can be carried out without the aid of cooling elements (for example by natural convection) or can be assisted by elements cooling devices operating on the element in sheet material 2; an example of possible cooling elements is represented by a blower capable of generating an air flow which, suitably directed, allows the forced convection cooling of the element in printed sheet material 2. The cooling step can be provided in the embodiment of the process which provides, either before or simultaneously with the molding, the heating step described above; alternatively, the cooling phase can be provided independently of the heating phase (and vice versa).

The process also allows the production of padded profiled coverings 1; for this purpose, the process can provide for a step of filling or padding the profiled covering 1 made in accordance with what has been previously described. The padding step provides for the insertion of at least one padding element 7 inside a housing defined by the counter-shaped portion 2a of the element in sheet material and is illustrated by way of example in Figure 5. The padding element 7 can be a single-material or multi-material element. Specifically, the padding element 7 is made of a material with a high capacity to absorb or mitigate any shocks, such as a cell material. The padding step can advantageously allow to increase the comfort of use of the profiled covering 1 and, in some applications, to increase the shock absorption characteristics of the padded profiled covering 1 or of the technical and / or sports article in the which the padded profiled covering 1 is intended to be used. In the embodiment of the procedure referred to in the attached figures, the padding step takes place at the housing defined by the profiled recess 2a of the element in sheet material 2; in this regard, see Figure 5 and see also Figure 6, illustrating padding elements 7 housed in the profiled recess 2a. Figure 5 schematically shows two separate padding elements 7; however, the padding step can provide for the insertion of any number of padding elements 7. In the rest of the present description, reference will be made, for simplicity of treatment, to a padding element 7. In the context of the procedure, the phase padding is optional; being the profiled covering 1, due to the molding phase, self-supporting and endowed with three-dimensional stability of shape, it is already ready for use in specific technical and / or sports articles, for example in technical and / or sports articles that do not necessarily require padding. Conversely, the process can advantageously provide for the padding step if the intended use of the profiled covering 1 provides for the need to pad the profiled covering 1 itself; the intended use of the profiled covering 1 can be defined according to the technical and / or sporting article in which the profiled covering 1 is used. The padding can for example be provided in the production of profiled coatings 1 intended to be used in technical and / or sports articles designed to be subjected to shocks and to absorb shocks, such as helmets; an example of a padded profiled covering 1 for helmets that can be made according to the method described here is constituted by an earmuff (see Figures 8 and 9). A further example of a padded profiled covering 1 made according to the process according to the present invention is represented by a gasket for goggles or a ski mask (see Figures 10 and 11). Following the padding phase, the procedure can also provide for stably binding the padding element 7 previously inserted in the housing to the element in printed sheet material 2. Advantageously, the binding step of the padding element 7 is carried out without the aid of seams; in this way, it is possible to avoid residual stresses due to the seams in the profile covering 1.

The step of stably binding the padding element 7 involves overlapping a further element in sheet material 8; the step of overlapping the further element in sheet material 8 to the element in sheet material 2 previously printed is illustrated in Figure 6. In the context of the present invention, the element in sheet material prepared and counter-shaped can be defined as the first element in sheet material 2 and the further element in sheet material used in the context of the constraint step of the padding element 7 can be defined as the second element in sheet material 8. The first element in sheet material 2 and the second element in sheet material 8 can share the same constituent material (for example in one of the plastic or thermoplastic materials previously described) or they can be made of materials compatible with each other, for example compatible with each other in such a way that they can be mutually engaged without the use of seams or glues or any filler material, in accordance with the modalities ch and will be described below (thermoforming or high frequency joining operation). Alternatively, the method can provide for the provision of a second element made of sheet material 8 made of a material different from the first element made of sheet material 2; for example, the material of the second sheet material element 8 may be different from the material of the first sheet material element 2 in terms of density and / or stiffness and / or elasticity and / or composition. This embodiment of the method allows the production of composite padded profiled coverings 1, that is to say padded profiled coverings 1 in which the first element in sheet material 2 and the second element in sheet material 8 are made of different materials.

As an alternative to the superimposition of a second element in sheet material 8 to the first element in sheet material 2, the step of stably securing the padding element 7 can provide for superimposing a further portion of the previously printed element in sheet material 2 to a constraint portion of the element made of sheet material in such a way as to cover both the previously counter-shaped portion 2a and the padding element 7 housed therein. In essence, this embodiment provides for folding the element made of sheet material 2 onto itself in such a way as to overlap a virgin portion of the element made of sheet material 2, that is to say a portion of the element made of sheet material 2 not deformed by means of the previous molding step, to the previously counter-shaped portion 2a of the element in sheet material 2 housing the padding element 7. In the continuation of the description, the embodiment which foresees to superimpose a second element in sheet material 8 to the first sheet material element 2 (see Figure 6). After the overlapping of the first element in sheet material 2 and of the second element in sheet material 8, the constraint step involves engaging the first element in sheet material 2 and the second element in sheet material 8 together. engagement between the first element made of sheet material 2 and the second element made of sheet material 8 forms an envelope of the padded profiled covering 1, inside which one or more padding elements 7 constituting the padding of the profiled upholstered cover 1 are arranged; in this regard, see Figures 9 and 11. Advantageously, the engagement step involves a portion of the first element made of sheet material 2 surrounding the profiled recess 2a, this portion effectively acting as a connecting flange of the first element made of material in sheet 2 with the second element made of sheet material 8. In Figures 6 and 7, the second element made of sheet material is shown without reliefs, recesses and housings. However, the possibility that not only the first element in sheet material 2, but also the second element in sheet material 8 is a profiled covering is not precluded within the scope of the present invention.

The engagement phase can be accomplished by thermoforming. The thermoforming can provide for the approach of a closing device 9, such as a heated plate or press, to the first element in sheet material 2 and to the second element in sheet material 8 (see figure 6) and to apply pressure , after having contacted at least the second element in sheet material 8 arranged above the first element in sheet material 2, on the second element in sheet material 8 and on the first element in sheet material 2. In this pressure step, realized by means of an advantageously heated plate or press 9 (which may possibly coincide with the counter-mold 5 used for molding), a matrix (which may possibly coincide with the mold base 3 used for molding, as shown for illustrative but not limiting purposes in figure 6) acts as an abutment or anvil. The pressure exerted by the heated plate or press 9 determines the stable union of respective portions of the first element made of sheet material 2 and of the second element made of sheet material 8.

Prior to thermoforming, the process can provide for coupling a joint element in sheet material, for example in polyurethane, to at least one of the first element in sheet material 2 and the second element in sheet material 8. The coupling step it can be subsequent to the step of inserting at least one padding element 7 and preceding the step of stably binding the padding element 7 to the element in sheet material 2, 8.

As an alternative to thermoforming, the engagement step between the first element in sheet material 2 and the second element in sheet material 8 can be achieved by means of a high-frequency joining operation, for example by high-frequency welding. The high-frequency welding can be, for example, an ultrasonic welding and can be carried out by emitting, for example by means of a sonotrode, ultrasounds of a suitable frequency (suitable according to the material or materials to be welded) in the direction of the first element in sheet material 2 and of the second element in sheet material 8 in such a way as to locally melt respective portions of the elements in sheet material 2, 8 and consequently allow the stable union of the elements in sheet material 2, 8.

The present invention can further contemplate an embodiment in which the engagement step is achieved by gluing between the first element in sheet material 2 and the second element in sheet material 8.

The method can also provide for the detachment of at least a scrap portion 10 of the element in sheet material 2. In the embodiment in which the padding is provided and in which a first element in sheet material 2 and a second element are provided in sheet material 8, the method can provide for detaching respective waste portions 10 of the first element in sheet material 2 and of the second element in sheet material 8; Figure 7 illustrates waste portions 10 to be detached of the first element in sheet material 2 and of the second element in sheet material 8.

The detachment step can be carried out in correspondence with a demarcation line intended to constitute, after the detachment of at least one scrap portion 10, at least part of a perimeter edge of the profiled covering 1 (padded or unpadded); the demarcation line can be defined in advance, for example by means of the counter-shaping step. The detachment phase can be carried out by cutting. The cutting of the scrap portion 10 can be achieved by means of one or more cutting elements (with respective cutting edge) provided by the mold base 3 and, in addition or alternatively, by the plate or press 9. Preferably, the mold base 3 comprises at least one cutting element configured to cut at least one element in sheet material 2, 8 (this cutting element may be a fixed element of the mold base or a movable element of the mold base); this cutting element can cut waste portions 10 of at least one element in sheet material 2, 8 or of both elements in sheet material 2, 8 when the plate or press 9 approaches the mold base 2. The cutting of the waste portions 10 can take place simultaneously with the molding of the first element in sheet material 2 or advantageously simultaneously with the engagement between the first element in sheet material 2 and the second element in sheet material 8. Alternatively, the cutting of the sheets reject portions 10 can take place in a step subsequent to the molding and engagement steps, for example by means of a punch movable with respect to the mold base and equipped with at least one cutting edge. This punch represents a device that is separate and distinct from the mold base 3, the counter-mold 5, the die and the plate or press 9. In the embodiment of the method which provides a first element in sheet material 2 and a second element in sheet material 8, the step of cutting the waste portions 10 can therefore be carried out simultaneously or subsequently to the step of engagement of the first element in sheet material 2 and of the second element in sheet material 8. Following the detachment of waste portions 10, a padded profiled covering 1 such as the one illustrated in figure 8 is obtained.

Advantageously, in accordance with what has been described above, the process allows to realize profiled coverings (padded or unpadded) 1 of any shape or profile; this is possible by providing a mold base 3 and a counter-mold 5 specifically shaped and dimensioned to the shape or profile of the coating 1 to be obtained.

Profiled lining

The present invention also relates to a profiled covering 1. The profiled covering 1 is preferably made in accordance with the process described above. The profiled covering 1 according to the present invention is self-supporting and has its own three-dimensional stability of shape, which has been acquired, as previously described, by counter-shaping during the molding step. The profiled covering 1 can also comprise at least one padding element 7 housed inside the profiled recess 2a; in this embodiment, the profiled covering 1 is padded and has a first element in sheet material 2 and a second element in sheet material 8 (in the same material or in different materials) engaged to each other to define a casing of the profiled lining 1. The casing of the profiled lining 1 defines a seat, inside which the padding is arranged, which comprises one or more padding elements 7 housed inside at least one profiled recess 2a or of respective profiled recesses 2a defined in correspondence with the first sheet material element 2. The profiled recess 2a or the profiled recesses 2a can be made by molding in accordance with what has been previously described with reference to the method. A first example and a second example of padded profiled coverings 1 made in accordance with the process according to the present invention are illustrated respectively in Figures 8-9 and in Figures 10-11. The padded profiled coverings 1 of figures 8-9 and figures 10-11 are self-supporting and have their own three-dimensional shape stability. With reference to Figure 8, the profiled padded cover illustrated therein is an earmuff for helmet 1. Figure 9 represents a section of the earmuff 1 of Figure 8 and illustrates the first element in sheet material 2 and the second element in sheet material 8 forming the shell of the earmuffs 1 and the padding housed inside the shell 1. As regards Figures 10 and 11, the profiled padded coating illustrated therein is a gasket 1 for goggles or a ski mask. Figure 11 represents the gasket 1 for a goggle or a ski mask as in figure 10, from which a portion has been removed in order to illustrate the padding housed inside the casing defined by the first element in sheet material 2 and the second element in sheet material 8.

Technical and / or sports article

The present invention also relates to a technical and / or sports article comprising at least one profiled covering 1 in accordance with what has been described above. Preferably, the profiled coating 1 or the plurality of profiled coatings 1 of the technical and / or sports article are made by the process according to the present invention. The profiled covering 1 of the article can be padded or unpadded. Providing at least one padded profiled covering 1 is particularly advantageous for technical and / or sports articles intended to be subjected, in use, to impacts (such as helmets); in this case, the padding element 7 or the padding elements 7 of the padded profiled cover 1 allow to increase the shock absorption capacity of the technical and / or sports article. Possible examples of technical and / or sporting articles according to the present invention are a helmet or a pair of glasses or a mask or a pad or a backpack or a brace or a suit; the invention may also provide for other technical and / or sports items, such as additional items of technical and / or sports clothing in general (for example knee pads, sleeves, braces, wrist guards, shoulder protectors, headphones, chin guards and the like).

The technical and / or sports article according to the present invention is typically configured to be worn by a user. In particular, the technical and / or sports article includes at least one element suitable for wearing, a profiled covering being applied to at least one surface of this element, in particular by gluing or stitching or welding or connection with velcro or buttons.

Equipment

The object of the present invention is also an apparatus 100. The apparatus 100 is configured to implement the method previously described and / or in accordance with any of the attached claims. The apparatus 100 is also configured to create a profiled cover 1 (padded or unpadded) in accordance with the present invention and of the type previously described. The equipment is preferably a molding equipment 100.

The apparatus 100 comprises a mold base 2 equipped with at least one recess or profiled relief 4 and a support surface intended to allow the positioning of an element in sheet material 2 in accordance with the respective step of the procedure described above. As described above, in accordance with the embodiment of the attached figures, the mold base 3 has a profiled recess 4 defined at its upper surface. The mold base 3 is configured to operate in accordance with what has been previously described with reference to the process for making a profiled lining 1.

The apparatus 100 also comprises a counter-mold 5 equipped with at least one profiled relief or recess 6 having a complementary profile and substantially counter-shaped to the profile of the profiled recess or relief 4 of the mold base 3. As described above, according to the embodiment referred to in to the attached figures, the counter-mold 5 has a profiled relief 6 defined in correspondence with its own lower surface. The counter-mold 5 is configured to operate in accordance with what has been previously described with reference to the process for making a profiled covering 1.

In terms of materials, the mold base 3 and the counter mold 5 are preferably made of aluminum.

The apparatus 100 is also configured to allow the positioning of at least one element in sheet material 2 between the mold base 3 and the counter-mold 5 (in this regard, connection means, in particular pins, configured on the mold base 2 can be provided to couple with corresponding connection means provided on the sheet material element 2, in order to keep the sheet material element 2) stably in the correct position. The mold base 3 and the counter-mold 5 are configured to cooperate with each other to mold an element in sheet material 2 in accordance with what has been previously described with reference to the process for making a profiled covering 1. In particular, the mold base 3 and the counter-mold 5 are configured to cooperate with each other to mold at least one element in sheet material 2 positioned between the mold base 3 and the counter-mold 5 in such a way that at least a portion of the element in sheet material 2 assumes a shape having a profiled recess or relief 2a with a profile substantially counter-shaped to the profile of the profiled recess or relief 4 of the mold base 3. In the embodiment of the attached figures, the mold base 3 and the counter-mold 5 are configured to cooperate with each other to mold at least one element in sheet material 2 positioned between the mold base 3 and the counter-mold 5, in such a way that at least one portion one of the element in sheet material 2 assumes a shape having a profiled recess 2a with a profile substantially counter-shaped to the profile of the profiled recess 4 of the mold base 3; the assumption of this profile by the portion 2a of the element in sheet material 2 is possible through the action of the profiled relief 6 of the counter-mold 5.

The mold base 3 and the counter mold 5 are also configured to be moved relatively to each other. In particular, the mold base 3 and the counter-mold 5 are configured to be moved towards each other. The preferred embodiment of the apparatus 100 provides, in order to carry out the molding step, the movement of the counter-mold 5 towards the base of the mold 3 (see Figure 4). To allow the displacement of the counter-mold 5, the apparatus 100 preferably comprises at least one hydraulic cylinder (however, different moving members of the counter-mold 5, for example hydraulic or pneumatic organs, are not to be excluded).

The apparatus 100 may further comprise heating elements configured to heat at least one of the mold base 3, the counter mold 5 and the sheet material element 2. As previously described, the heating elements can be integrated in at least one of the mold base 3 and counter-mold 5 or they can be external at the base of the mold 3 or counter-mold 5 and connected to at least one of the mold base 3 and the counter-mold 5 to heat them. Alternatively, the heating elements can be configured to heat a molding environment, such as a molding chamber of the apparatus 100 in which the mold base 3, the sheet material element 2 and the counter mold 5 are located at the act of stamping. The heating elements, which can for example comprise at least an electric resistance or an induction heater or a gas burner, operate substantially in accordance with what has been described above with reference to the process for making a profiled lining.

The mold base 3 and the counter mold 5 can be provided in a molding station of the equipment 100; the molding station is schematically illustrated in figure 4.

The apparatus 100 can also comprise a padding station configured to insert, for example in accordance with what has been described above with reference to the process for making a padded profiled cover 1, of at least one padding element 7 inside the housing one or more profiled recesses 2a (made by molding) of the element in sheet material 2. The stuffing station is schematically illustrated in figure 5.

According to an embodiment, the apparatus 100 can also be configured to allow the positioning of a further portion of the element in sheet material 2 or of a second element in sheet material 8 between a matrix (which may possibly coincide with the mold base 3) and a press or plate 9 (which may possibly coincide with the counter-mold 5) and to allow their engagement, for example in accordance with what has been described above with reference to the process for making a profiled coating 1. L The apparatus 100 is advantageously configured to allow the engagement of a second element in sheet material 8 to the first element in sheet material 2 previously printed. The apparatus 100 is preferably configured to position the second sheet material element 8 with respect to the first sheet material element 2 by superimposing the second sheet material element 8 over the first sheet material element 2 so as to cover the portion 2a of the first element in sheet material 2 previously counter-shaped (the profiled recess 2a) and the padding element 7 housed therein.

In accordance with the embodiment illustrated in the attached figures, the apparatus 100 can also be configured to engage the first element in sheet material 2 and the second element in sheet material 8 with each other by thermoforming; for this purpose, the apparatus 100 can comprise a closing element 9. In this embodiment, the closing element comprises a heated plate or press 9 configured to be moved towards the first element in sheet material 2 and the second element in sheet material 8 (see figure 6). The heated platen or press 9 is further configured to exert pressure on the second sheet material element 8 and on the first sheet material element 2. During the pressure exercise by the heated platen or press 9, the mold base 3 acts as a striker or anvil. In accordance with what has been described above with reference to the process, the heated plate or press 9 is configured to stably join respective portions of the first element in sheet material 2 and of the second element in sheet material 8. The thermoforming described here can take place in correspondence with of a thermoforming station of the apparatus 100, which is schematically illustrated in Figure 6.

The apparatus 100 can also be configured to couple a joint element in sheet material, for example in polyurethane, to at least one of the first element in sheet material 2 and the second element in sheet material 8 prior to thermoforming. This coupling can be carried out by means of a coupling station of the apparatus 100, which can for example be provided upstream of the thermoforming station. Alternatively, the coupling station can coincide with the thermoforming station; in other words, the thermoforming station can also be configured to perform the coupling between the junction element in sheet material and at least one element in sheet material 2, 8.

In an alternative embodiment, the apparatus 100 can be configured to engage the first sheet material element 2 and the second sheet material element 8 to each other by a high frequency bonding operation, for example by high-frequency welding. frequency. The apparatus 100 can be configured to emit ultrasounds of suitable frequency (suitable according to the material or materials to be welded) in the direction of the first element in sheet material 2 and of the second element in sheet material 8 in such a way as to locally melt respective portions of the elements in sheet material 2, 8 and consequently allow the stable union of the elements in sheet material 2, 8. For example, the apparatus 100 can be configured to perform an ultrasonic welding. For this purpose, the equipment 100 can comprise a sonotrode configured to emit ultrasounds of a suitable frequency.

The apparatus 100 can also be configured to detach at least a scrap portion 10 from the element in sheet material 2. In the embodiment of the invention which provides a first element in sheet material 2 and a second element in sheet material 8 , the apparatus 100 can be configured to detach at least a scrap portion 10 from at least one sheet material element 2, 8 or both of the sheet material elements 2, 8. The apparatus 100 can be configured to allow the detachment of at least a scrap portion 10 in correspondence with a demarcation line intended to constitute at least part of a perimeter edge of the profiled covering 1. For this purpose, the apparatus 100 can comprise at least one cutting element, which can be integrated into the mold base 3 and / or in the counter-mold 5 or in the die and / or in the plate or press 9. The cutting element can develop perimetrically for at least one a portion of a perimeter of the mold base 3 or of the counter mold 5 or both. The cutting element can alternatively develop perimeter for at least a portion of a perimeter of the die or plate or press 9 or both. Preferably, the mold base 3 (or alternatively the matrix) comprises at least one cutting element configured to cut at least one element in sheet material 2, 8; this cutting element can be configured to cut waste portions 10 of at least one element in sheet material 2, 8 or of both elements in sheet material 2, 8 when the counter-mold 5 approaches the mold base 3 (or of the plate or press 9 to the die). In the embodiment which provides a first element in sheet material 2 and a second element in sheet material 8, the cutting element is configured to cut waste portions 10 from the first element in sheet material 2 and from the second element in material in sheet 8. The apparatus 100 can be configured to cut the waste portions 10 at the same time as molding, by providing a cutting element integrated in the mold base 3 or in the counter-mold 5, or after molding, for example during molding. engagement between the first element in sheet material 2 and the second element in sheet material 8 by providing a cutting element integrated in the plate or press 9 or in the die. Alternatively, a dedicated punch can be adopted for cutting, separate and distinct from the mold base 3, the counter-mold 5, the plate or press 9 and the die.

The apparatus 100 can also comprise a control unit configured to implement the process in accordance with what has been described above and / or with any of the attached claims. The control unit is configured to implement the procedure in order to create a profiled cover 1 (padded or unpadded) of the type described above.

ADVANTAGES OF THE INVENTION

The present invention allows to obtain self-supporting profiled coverings 1 (padded or unpadded) having, and capable of maintaining, three-dimensional stability of shape.

The process according to the invention allows the realization of profiled coatings 1 of substantially any shape, that is to say with a very wide range of profiles or shapes. In particular, the method according to the invention makes it possible to produce profiled coatings 1 whose three-dimensional structure can have characteristic dimensions, such as width, length, depth and thickness, which are different in the same profiled coating (see for example the thickness of the profiled coating in figure 8 , which changes between different portions of the same coating). This is possible by appropriately preparing and configuring the mold base 3 and counter mold 5.

The process according to the invention also allows you to create profiled coatings 1 free from residual stresses; this is possible both because of the absence of seams and because of the peculiar molding which, being carried out mechanically by means of the joint action of a mold base 3 and a counter-mold 5 suitably shaped, allows to counter-shape and deform in an optimal way the element made of sheet material 2, in such a way that it assumes and stably maintains a certain profile or a certain shape.

The process according to the invention also allows to realize profiled coatings 1 of high quality and finish, which are not obtainable by the known methods of manufacturing the coatings.

The process according to the invention allows to realize profiled coatings 1 in a short time and with low costs.

The method according to the invention is also capable of reducing or even eliminating the defects or non-conformities in the realization of the profiled coatings 1. In addition to the above, the method according to the invention is advantageously able to minimize the waste of material. in the realization of the profiled coverings 1. This is possible by appropriately preparing and configuring the mold base 3 and the counter-mold 5 and suitably dimensioning the element in sheet material 2 according to the profile to be molded and, if necessary, the additional material element in sheet 8.

The advantages of the process described above are also shared by the apparatus 100 according to the invention.

The process and the apparatus 100 according to the invention also allow the creation of profiled coatings 1 whose quality is repeatable and homogeneous. The method and the apparatus 100 according to the invention also advantageously make it possible to produce profiled coatings 1 whose profiles are able to adapt, depending on the intended use of the profiled coatings 1 and / or the technical and / or sports article in which the profiled coatings 1 will be used, to specific desired profiles, such as profiles of specific parts of the body of a user.

The invention allows to obtain profiled coatings 1 with a solid and robust structure, which are self-supporting and are advantageously characterized by a three-dimensional stability of shape.

The profiled coatings 1 according to the invention are also free of residual stresses. The invention makes it possible to obtain technical and / or sports articles capable of guaranteeing, by means of at least one profiled covering 1, an optimal comfort of use for a user. Comfort can be further improved by providing, in the profiled cover 1 of the technical and / or sports article, at least one padding element 7.

The invention allows the creation of technical and / or sports articles with improved shock absorption performance; this is possible by providing, in the profiled covering 1, at least one padding element 7.

The invention also allows to specifically optimize and conform technical and / or sports articles, according to their respective intended use, on the basis of specific desired profiles, such as profiles of specific parts of the body of a user of the technical article and / or sporty; this is possible by suitably shaping, by molding, the element in sheet material 2 of the profiled covering 1.

Claims (10)

CLAIMS 1. Process for making a profiled lining (1), for example for technical and / or sports items such as helmets or masks or seat pads or backpacks or braces or overalls or technical and / or sports clothing in general, comprising the following steps : - providing at least one sheet element (2) preferably substantially flat, - positioning said at least one sheet element (2) on a mold base (3) provided with at least one recess or profiled relief (4) and - printing said at least one sheet element (2), in which the step of molding said at least one sheet element (2) comprises a counter-shaping, by means of a counter-mold (5) configured to cooperate with the mold base (3), of at least a portion (2a) of said at least one element in sheet (2) to a profile of said at least one recess or profiled relief (4) of said mold base (3), at the end of said counter-shaping said at least one sheet element (2) exhibiting three-dimensional stability of shape and / or being self-supporting. Process according to claim 1, wherein the counter-shaped portion (2a) of said at least one sheet element (2) defines at least one housing, the process further comprising the steps of: - insert at least one padding element (7) inside said at least one housing e - tie stably and without the aid of seams said at least one padding element (7) to said at least one sheet element (2). Method according to claim 1 or 2, wherein the positioning of said at least one sheet element (2) provides for facing at least one surface of said at least one sheet element (2) to said at least one profiled recess or relief (4 ) of said mold base (3), and in which: - said at least one profiled recess (4) of the mold base (3) has a concavity or said at least one profiled relief of the mold base has a convexity, and - facing at least one surface of said at least one sheet element (2) to said at least one profiled recess or relief (4) comprises facing a surface of said at least one sheet element (2) to the concavity of said at least one profiled recess (4 ) of the mold base (3) or to the convexity of said at least one profiled relief of the mold base. Process according to claim 1 or 2 or 3, wherein the step of printing said at least one sheet element (2) comprises: - providing a counter-mold (5) configured to cooperate with the mold base (3) and equipped with at least one profiled relief or recess (6) having a complementary and / or corresponding and / or substantially counter-shaped profile to the profile of said at least one recess or profiled relief (4) of the mold base (3) e - relatively moving the mold base (3) and the counter-mold (5) in mutual approach, the counter-shaping of said at least one portion (2a) of said at least one sheet element (2) being contextual or simultaneous with the relative movement of the mold base ( 3) and the counter-mold (5) and / or taking place during the relative movement of the mold base (3) and the counter-mold (5). Process according to any one of the preceding claims, wherein the counter-shaping of said at least one portion (2a) of said at least one sheet element (2) comprises a plastic deformation, by means of said counter-mold (5), of said at least one portion ( 2a), in such a way that said at least one portion (2a) assumes the profile of said at least one profiled relief or recess (6) of the counter-mold (5), in the plastic deformation said at least one profiled recess or relief (4) of the base of mold (3) acting as an abutment for deformation or anvil, the plastic deformation conferring three-dimensional stability of shape to said at least one sheet element (2) so as to make said at least one sheet element (2) self-supporting, optionally in which the counter-shaping of at least a portion (2a) of said at least one sheet element (2) to a profile of said at least one recess or profiled relief (4) provides for counter-shaping, by means of said counter-mold (5), at least a portion (2a) of said at least one sheet element to a profile of said at least one profiled recess (4) of the mold base, and in which: - the step of preparing a counter-mold (5) provides for the provision of a counter-mold (5) configured to cooperate with the mold base (3) and equipped with at least one profiled relief (6) having a complementary and / or corresponding profile and / or substantially counter-shaped to the profile of said at least one profiled recess (4) of the mold base (3) and / or - the relative handling phase of the mold base (3) and the counter-mold (5) involves moving the counter-mold (5) towards the mold base (3) and / or - the plastic deformation of said at least one portion (2a) of said at least one sheet element (2) provides for plastically deforming, by means of said counter-mold (5), said at least one portion (2a) of said at least one sheet element (2 ) in such a way that said at least one portion (2a) assumes the profile of said at least one profiled relief (6) of the counter mold (5), in the plastic deformation said at least one profiled recess (4) of the mold base (3) acting by finding of deformation or anvil and / or - the counter-shaping phase lasts between 30 seconds and 150 seconds and / or - the counter-shaping phase is carried out at a temperature between 50 ° C and 180 ° C, preferably at a temperature between 50 ° C and 170 ° C, and / or - the counter-shaping phase is carried out at a pressure between 5 bar and 8 bar, preferably at a pressure between 5 bar and 7 bar, even more preferably at about 7 bar and / or - said at least one sheet element is made of at least one material between: PET, PETG, polycarbonate, polypropylene, polyurethane, leather, imitation leather, natural fiber fabric, synthetic fiber fabric, leather, rubber. Process according to any one of claims 2 to 5, wherein the step of stably binding said at least one stuffing element (7) to said at least one sheet element (2) comprises: - superimposing a further sheet element (8) or a further portion of said at least one sheet element (2) to a constraint portion of said at least one sheet element (2) in such a way as to cover said previously counter-shaped portion (2a ) and said at least one padding element (7) e - at least partially engaging said further sheet element (8) or said further portion of said at least one sheet element (2) to said constraint portion of said at least one sheet element (2), in particular in which said engagement step at least part of said further sheet element (8) or said further portion of said at least one sheet element (2) to said constraint portion of said at least one sheet element (2) is made by means of a high frequency joining operation, for example by high frequency welding, or in particular in which said step of at least partial engagement of said further sheet element (8) or said further portion of said at least one sheet element (2) to said bonding portion of said at least one sheet element (2) is made by thermoforming, optionally in which the process further comprises the step of coupling a jointing element in sheet, for example in polyurethane, to at least one element in sheet (2, 8), said coupling step being subsequent to the step of inserting at least one padding element (7) inside said at least one housing and prior to the step of stably binding said at least one padding element (7) to said at least one sheet element (2). 7. Process according to any one of the preceding claims, further comprising the step of detaching at least a reject portion (10) of said at least one sheet element (2), detaching at least a reject portion of said at least one sheet element (2) occurring in correspondence with a demarcation line, for example defined by means of said counter-shaping step, intended in particular to constitute at least part of a perimeter edge of the profiled covering, optionally in which the step of detaching at least a scrap portion of at least one sheet element (2, 8) is substantially contextual or simultaneous with the step of stably binding said at least one padding element (7) to said at least one sheet element ( 2), in particular in which at least one of the mold base (3) and the counter-mold (5) has a cutting element configured to cut said at least one sheet element (2, 8), the step of detaching at least a scrap portion of at least a sheet element comprising cutting said at least one reject portion of said at least one sheet element (2, 8) by means of said cutting element. 8. Profiled lining (1), for example for technical and / or sports items such as helmets or masks or chamois or backpacks or braces or overalls or technical and / or sports clothing in general, made according to the procedure in accordance with any of the preceding claims, said profiled covering (1) comprising a sheet element (2) having three-dimensional stability of shape and / or being self-supporting and being provided with at least one portion (2a) having at least one profiled recess or relief. 9. Molding equipment for the production of a profiled covering, for example for technical and / or sports items such as helmets or masks or chamois or backpacks or braces or overalls or technical and / or sports clothing in general, the equipment of molding including: - a mold base (3) equipped with at least one profiled recess or relief (4) and - a counter-mold (5) equipped with at least one profiled relief or recess having a complementary profile and / or corresponding and / or substantially counter-shaped to the profile said at least one recess or profiled relief of the mold base (3), in which the mold base (3) and the counter-mold (5) are configured to cooperate with each other to mold a sheet element (2) which can be positioned between said mold base (3) and said counter-mold (5) so that at least a portion of said at least one sheet element (2) assumes a shape having a profiled recess or relief with a substantially complementary profile and / or corresponding to the profile of said at least one profiled recess or relief of said mold base (3). 10. Technical and / or sporting article, for example a helmet or goggles or a mask or a pad or a backpack or a brace or a suit or a technical and / or sporting garment in general, comprising at least one profiled lining ( 1) according to claim 8 and / or realized according to the method according to any one of claims 1 to 7 and / or realized by means of the apparatus according to claim 9.