Male component and respective mould unit for producing a vehicle saddle

A method for producing a vehicle saddle, comprising the following steps:

• providing a mould unit for producing a vehicle saddle, said mould unit comprising a first male part and a second female part, mutually displaceable between at least one opening position of the mould unit, wherein parts of a saddle to be moulded are arranged in said mould unit or wherein a saddle moulded in said mould unit may be removed from said mould unit, and at least one closing position of the mould unit, wherein the male part and the female part can be coupled in one or more operating positions, so as to delimit at least one mould cavity or impression between them,
• said male part including a male component or punch for a mould unit delimiting the mould cavity having a main base body made of a first material,
• wherein said male component comprises at least one insert or contact layer formed or applied over said main base body, said at least one insert or contact layer being made of a second softer or more yielding material than said first material, said at least one insert or contact layer delimiting at least one central or intermediate portion of an inner surface delimiting a surface of said male component, wherein the surface of the male component is intended to be engaged and abutted to a felt or shell (F) for a saddle (SA) to be moulded,
• wherein said main base body comprises an abutment and engagement edge for a female component of the mould unit, said abutment and engagement edge surrounding said at least one insert or contact layer, and said abutment and engagement edge comprising at least a portion in contact with the mould cavity,
• wherein said inner surface comprises an outer portion defined by the abutment and engagement edge, and said at least one central or intermediate portion enclosed in the zone delimited by the abutment and engagement edge and at least partly defined by a free surface of said at least one insert or contact layer,
• wherein the at least one insert or contact layer does not become a part of the saddle (SA) to be moulded;
• arranging the mould unit in an opening position,
• engaging a first plate and a second intermediate plate of said female part and disposing a cover or covering in a cavity, or rather in a zone thereof defined by the first plate, with a corresponding peripheral portion of the cover partially lying on a surface of the second intermediate plate distal from and not engaged with the first plate;
• actuating a third plate and/or the group consisting of the first and second intermediate plate, so as to engage the third plate against the second intermediate plate and thus mutually clamp the peripheral portion of the cover or covering;
• activating a suction or vacuum source, so as to constrain the cover to walls of said first plate defining said impression or cavity;
• pouring or inserting a material for padding of the saddle over the cover or covering;
• after engagement of a felt with a first male component, bringing the latter close to the female part and closing a corresponding mould impression with the padding material tightened between the shell and the cover, and subsequently the padding mixture or material reacts by filling the mould cavity, thus obtaining a moulded padding;
• upon completion of this first moulding step, opening the mould unit and removing the first male component from a partially formed saddle, with the felt being attached to the padding and not being removed together with the first male component;
• bringing a second male component with the insert or said first male component to which the insert has been applied in engagement and abutment against the felt and with an abutment and engagement edge in engagement and abutment against an edge of the second intermediate plate, so that at a lower, in use, edge of the saddle, between the male component and the second plate an area or zone for injecting a material to obtain a sealing edge on a perimeter of the saddle is delimited;
• injecting material into the mould unit so as to insert it into this area or zone, and then performing a second moulding step;
• upon completion of the moulding, opening the mould unit and removing the saddle, therefore proceeding, if necessary, to trim an exceeding cover.