U.S. patent application number 10/623440 was filed with the patent office on 2005-01-20 for breast cup construction.
This patent application is currently assigned to Regina Miracle International Limited. Invention is credited to Luk, Theone.
Application Number | 20050014450 10/623440 |
Document ID | / |
Family ID | 33541432 |
Filed Date | 2005-01-20 |
United States Patent
Application |
20050014450 |
Kind Code |
A1 |
Luk, Theone |
January 20, 2005 |
BREAST CUP CONSTRUCTION
Abstract
Method of making a breast cup for a garment on a breast cup
defining component of moldable material, applying a flexible
covering panel of at least part of a breast cup to the convex side
of the component, applying a flexible decorative panel to the
concave side of the component, and removing a region of the panel
assembly to expose the decorative panel to the convex end.
Inventors: |
Luk, Theone; (Kwai Chung,
HK) |
Correspondence
Address: |
OSTROLENK FABER GERB & SOFFEN
1180 AVENUE OF THE AMERICAS
NEW YORK
NY
100368403
|
Assignee: |
Regina Miracle International
Limited
|
Family ID: |
33541432 |
Appl. No.: |
10/623440 |
Filed: |
July 18, 2003 |
Current U.S.
Class: |
450/39 |
Current CPC
Class: |
A41C 3/12 20130101; A41C
5/005 20130101 |
Class at
Publication: |
450/039 |
International
Class: |
A41C 003/00 |
Claims
1. A method of making a breast cup for a garment of clothing
comprising: a) providing a structure defining component of a breast
cup form and created from a flexible sheet of moldable material,
wherein the breast cup form has a convex side and a perimeter: b)
providing a flexible covering panel of an at least part breast cup
form wherein the at least part breast form corresponds to at least
part of the structure defining component, engaging the flexible
covering panel to the structure defining component to locate the
covering panel on the convex side of the breast cup form of the
structure defining component in at least a partial overlapping
condition, to thereby define a panel assembly which includes the
structure defining component and the covering panel, the panel
assembly having a perimeter a concave side and an opposite convex
side. c) affixing to the convex side of the panel assembly, a
flexible decorative panel of a material of a contrasting appearance
to the appearance of the convex side of the covering panel and in
an overlying condition to part of the panel assembly and in a first
position to locate the decorative panel inwardly of the perimeter
of the panel assembly, the decorative panel having a perimeter, d)
removing a region of the panel assembly covered by and within the
perimeter of the decorative panel to thereby expose the decorative
panel to the concave side of the panel assembly.
2. A method as claimed in claim 1 wherein the decorative panel has
a respective second perimeter; the affixing defined in step (c) is
by affixing the decorative panel at the second perimeter thereof to
the panel assembly at and about the second perimeter of the
decorative panel and wherein the removing defined in step (d) is
removal of a region of the panel assembly encompassed by the
perimeter which fixes the decorative panel.
3. A method as claimed in claim 1 wherein the affixing defined in
step (c) is by stiching the decorative panel at the second
perimeter thereof to the panel assembly at and about the second
perimeter of the decorative panel and wherein the the removing
defined in step (d) is removal of a region encompassed by the
stitching at the second perimeter of the decorative panel.
4. A method as claimed in claim 1 wherein the structure defining
component includes a means defining a visible reference point
within the perimeter of the breast cup form wherein subsequent to
step (b) and prior to step (c), relying upon the reference point to
generate a visible reference point of corresponding position
visible from the convex side of the panel assembly for the purposes
of reliance in step (c) to establish an appropriate the first
position of the decorative panel with respect to the panel
assembly.
5. A method as claimed in claim 4 wherein the visible reference
point on the convex side of the panel assembly is generated by
penetrating the panel assembly from the concave side of the panel
assembly to the convex side of the panel assembly with means
defining a visible reference point.
6. A method as claimed in claim 5 wherein the penetrating is by
stitching a line of thread through the panel assembly.
7. A method as claimed in claim 6 wherein the means defining a
visible reference point is a line of reference, the stitching being
along at least part of such the line of reference.
8. A method as claimed in claim 6 wherein the means defining a
visible reference point is an endless line of reference provided
about a region of the panel assembly, the stitching being along the
endless line, the region being of a perimeter shape commensurate
with a shape of the second perimeter of the decorative panel to
thereby allow the decorative panel to be aligned with the stitching
and subsequently affixing as defined in step (c).
9. A method as claimed in claim 4 further comprising forming of the
structure prior to step (a), and wherein the means defining a
visible reference point is generated during the forming of the
structure defining component prior to step (a).
10. A method as claimed in claim 4 further comprising forming of
the structure prior to step (a), and wherein the means defining a
visible reference point is generated during the forming of the
structure defining component prior to step (a) by embossing the
visible reference point into the convex side of the breast form of
the structure defining component.
11. A method as claimed in claim 10 wherein the structure defining
component includes a sheet of foam material and the embossing is
achieved by compression of the sheet of foam material so that the
visible reference point is defined during the forming of the
structure defining component.
12. A method as claimed in claim 4 wherein the moldable material of
the structure defining component includes at least one sheet of
foam material and the covering material comprises a sheet of fabric
material adhered to at least one major surface of the foam
material, the engaging of the structure defining component with the
covering panel being to position the covering panel on a side of
the structure defining component opposite to the at least one sheet
of fabric material.
13. A method as claimed in claim 1 wherein subsequent to step (d)
applying embroidery stitching at or proximate and inward of the
perimeter of the decorative panel to capture, within an enclosure
defined by the embroidery stitching, edges of the panel assembly
that are exposed by the removing of the region defined as step
(d).
14. A method as claimed in claim 13 wherein the decorative panel
has a perimeter edge and the embroidery stitching also captures
within the enclosure defined by the embroidery stitching the
perimeter edge of said decorative panel.
15. A method as claimed in claim 1 wherein the covering panel has a
perimeter and the engaging defined in step (b) is by affixing by
sewing of the covering panel to the structure defining component at
the perimeter of the covering panel.
16. A method as claimed in claim 1 wherein where the covering panel
is of coextensive perimeter shape to the structure defining
component, the engaging defined in step (b) is by affixing by
sewing of the covering panel to the structure defining component at
the perimeter of the structure defining component.
17. A method of making a breast cup for a garment of clothing
comprising: a) providing a structure defining component of a breast
cup form and created from a flexible sheet of moldable material, b)
engaging a flexible covering panel, of an at least part breast cup
form corresponding to at least part of the structure defining
component, to the structure defining component to locate the
covering panel on the convex side of the breast cup form of the
structure defining component in at least a partial overlapping
condition, to define a panel assembly which includes the structure
defining component and the covering panel, wherein the panel
assembly has a convex side, a concave side and a perimeter; c)
affixing to the concave side of the panel assembly, a decorative
panel of flexible decorative panel material of a contrasting
appearance to the convex side of the covering panel, in an
overlying condition to part of the panel assembly and in a position
to locate the decorative panel inwardly of the perimeter of the
panel assembly, the decorative panel having a perimeter; d)
removing a region of the panel assembly covered by and within the
perimeter of the decorative panel to thereby expose the decorative
panel to the convex side of the panel assembly.
18. A breast cup assembly for incorporation into a garment of
clothing and made in accordance with the method of claim 1.
19. A breast cup assembly comprising a structure defining component
of a breast cup form and created from a flexible sheet of moldable
material, the structure defining component having a convex side: a
flexible covering panel affixed to the structure defining component
and of an at least part breast cup form corresponding to at least
part of the structure defining component, the covering panel
located adjacent the structure defining component on the convex
side of the structure defining component and in an at least a
partial overlapping condition with the structure defining
component, to define a panel assembly which includes the structure
defining component and the covering panel, the panel assembly
having a convex side a concave side and a perimeter: a decorative
panel of flexible material of a contrasting appearance to the
convex side of the panel assembly and affixed, at either one side
selected from the convex side and concave side, to the panel
assembly in an overlying condition and located in a position
inwardly of the perimeter of the panel assembly, the decorative
panel having a perimeter: wherein an opening is provided through
the structure defining component at a region of the structure
defining component encompassed by the perimeter of the decorative
panel to there through expose the decorative panel to the opposite
of the one of the convex side and the concave side of the structure
defining component.
20. A breast cup assembly as claimed in claim 19 wherein the
structure defining component includes a molded sheet of foam
material.
21. A breast cup assembly as claimed in claim 19 wherein the
structure defining component includes molded sheet of foam material
having opposed major surfaces and there is affixed to each opposed
major surface of the molded sheet a panel of fabric.
22. A breast cup assembly as claimed in claim 19 wherein the
decorative panel is affixed to the convex side of the panel
assembly by stitching extending through the decorative panel and
the panel assembly and provided at or immediately inwardly of the
perimeter of the decorative panel and wherein the stitching at the
perimeter of the decorative panel is an embroidery and captures
within the stitching the perimeter edge of the decorative
panel.
23. A breast cup assembly as claimed in claim 19 wherein the
structure defining component and the covering panel are
coextensive.
24. A breast cup assembly as claimed in claim 19 wherein the
covering panel is a flexible fabric material.
25. A breast cup assembly as claimed in claim 19 wherein the
decorative panel is a lace material.
26. A breast cup assembly as claimed in claim 19 wherein the
structure defining component and the covering panel are coextensive
and are stitched to each other at the perimeter of the cup form and
at where the perimeter of the decorative panel is affixed to the
panel assembly.
27. A method of making a breast cup for a garment of clothing
comprising: a) providing a structure defining component of a breast
cup form and created from a flexible sheet of moldable material,
and the structure defining component having a convex side, a
concave side and a perimeter; b) affixing at a convex side region
and in an overlying condition to the structure defining component,
a decorative panel of flexible material of a contrasting appearance
to the convex side of the structure defining component, the
affixing being at a position to locate the decorative panel
inwardly of the perimeter of the structure defining component, the
decorative panel having a perimeter; c) removing a region of the
structure defining component to create an opening through the
structure defining component, the opening being at a region
corresponding to and inwardly of the perimeter of the decorative
panel to thereby expose the affixed decorative panel to the concave
side of the structure defining component.
28. A method as claimed in claim 27 wherein the affixing defined in
step (b) is or includes affixing of at least part of the perimeter
of the decorative panel to the structure defining component, the
removing to create the opening comprising cutting the structure
defining component at a region inwardly of the perimeter of the
decorative panel.
29. A method as claimed in claim 27 wherein the removing to create
the opening in the region of the structure defining component is
such that once the region is removed, the opening remains covered
by the decorative panel.
30. A method as claimed in claim 27 wherein prior to the affixing
in step (b), a flexible covering panel, of an at least part breast
cup form and corresponding to at least part of the structure
defining component, is engaged to the structure defining component
to locate the flexible covering panel on the convex side of the
breast cup form of the structure defining component in at least a
partial overlapping condition with the convex side of a of the
structure defining component, whereby the flexible covering forms
part of the structure defining component.
31. A method of making a breast cup for a garment of clothing
comprising: a) providing a structure defining component of a breast
cup form and created from a flexible sheet of mouldable material
and having a convex side a concave side and a perimeter, b)
affixing at the concave side, in an overlying condition to the
structure defining component, a decorative panel of a flexible
material having a contrasting appearance to the convex side of the
structure defining component, the affixing being at a position to
locate the decorative panel inwardly of the perimeter of the
structure defining component, the decorative panel having a
perimeter; c) removing a region of the structure defining component
to create an opening through the structure defining component, the
opening being inwardly of the perimeter of the decorative panel to
thereby expose the affixed decorative panel to the convex side of
the panel assembly.
32. A method as claimed in claim 31 wherein the affixing described
in step (b) is or includes affixing of at least part of the
perimeter of the decorative panel with to the structure defining
component, and the removing to create the opening being by cutting
the structure defining component at a region corresponding to and
being inwardly of the perimeter of the decorative panel.
33. A method as claimed in claim 31 wherein the removing to create
the opening in a region of the structure defining component is such
that once the region is removed, the opening remains covered by the
decorative panel.
34. A method as claimed in claim 31 wherein a flexible covering
panel of an at least part breast cup form and corresponding to at
least part of the structure defining component, is engaged to the
structure defining component to locate the flexible covering panel
on the convex side of the breast cup form of the structure defining
component in at least a partial overlapping condition with the
convex side surface of the structure defining component, the
flexible covering thereby forming part of the structure defining
component.
35. A method as claimed in claim 34 wherein the decorative covering
panel is affixed prior to the step (b).
36. A breast cup assembly comprising a structure defining component
of a breast cup form and created from a flexible sheet of moldable
material and having a convex side a concave side and a perimeter; a
decorative panel of a flexible material having a contrasting
appearance to the convex side of the structure defining component
and affixed at either one side selected from said convex side and
concave side of the structure defining component in an overlying
condition and located in a position inwardly of the perimeter of
the structure defining component, the decorative panel having a
perimeter; an opening through the structure defining component at a
region of the structure defining component encompassed by the
perimeter of the decorative panel to there through expose the
decorative panel to the opposite of the one of the convex side and
the concave side of the structure defining component.
37. A breast cup assembly as claimed in claim 36 wherein the
structure defining component includes a flexible covering ply of
material disposed at the convex side of the structure defining
component and against which the decorative panel is engaged.
38. A method of making a breast cup for a garment of clothing
comprising: a) providing a structure defining component of a breast
cup form and created from a flexible sheet of moldable material and
having a convex side, a concave side and a perimeter; b) engaging a
flexible covering panel of an at least part breast cup form, having
a convex side and a perimeter corresponding to at least part of the
structure defining component, to the structure defining component
to locate the covering panel on the convex side of the breast cup
form of the structure defining component in at least a partial
overlapping condition, thereby defining a panel assembly which
includes the structure defining component and the covering panel,
the panel assembly having a concave side: c) applying to the convex
side of the covering panel a decorative panel of flexible material
of a contrasting appearance to the convex side of the covering
panel and positioning the decorative panel in an overlying
condition to the covering panel and in a position to locate the
decorative panel inwardly of the perimeter of the covering panel,
d) removing a region of the panel assembly encompassed by the
perimeter of the decorative panel to thereby expose the decorative
panel to the concave side of the panel assembly.
39. A method of making a breast cup for a garment of clothing
comprising: a) providing a structure defining component of a breast
cup form and created from a flexible sheet of moldable material,
the breast cup form having a convex side, a concave side and a
perimeter, b) engaging a flexible covering panel, of an at least
part breast cup form corresponding to at least part of the
structure defining component, to the structure defining component
to locate the covering panel on the concave side of the breast cup
form of the structure defining component in at least a partial
overlapping condition, to thereby define a panel assembly which
includes the structure defining component and the covering panel,
each of the covering panel and the panel assembly having a concave
side and a perimeter, c) applying to the concave of the covering
panel, a decorative panel of a flexible material of a contrasting
appearance to the convex side of the structure defining component,
and positioning the decorative panel in an overlying condition to
the covering panel and in a position to locate the decorative panel
inwardly of the perimeter of the covering panel, d) removing a
region of the panel assembly encompassed by the perimeter of the
decorative panel to thereby expose the decorative panel to the
concave side of the panel assembly.
Description
FIELD OF INVENTION
[0001] The present invention relates to a method of producing a
breast cup for a brassiere or other garment of clothing and in
particular although not solely to a method of producing a breast
cup which incorporates a panel of a contrasting appearance.
[0002] The present invention also relates to a breast cup for
incorporation with other components to define a brassiere or other
garment of clothing which may be defined by the methods of the
present invention.
BACKGROUND
[0003] Brassieres which incorporate a breast cup construction of a
moulded or mouldable material are becoming more prevalent. One of
the advantages that is brought about by a moulded breast cup
construction is a more simplified method of manufacture. Normally a
moulded breast cup construction will reduce the number of panels
required to define the breast cup since the three dimensional cup
form can be formed by a moulding step. Traditionally cups have been
formed by the stitching of a plurality of panels together to define
the three dimensional cup form.
[0004] However, the provision of a breast cup construction of a
basic moulded form has a reasonably plain appearance. Unlike the
traditionally multi panel sewn form of cup constructions, the
moulded cup form generally consists of a single panel of material
and in general does not incorporate significant detailing to
enhance the appearance of the breast cup. Furthermore since the
breast cup is of a moulded construction it can be difficult to add
any enhancements to the breast cup construction after it has been
formed. Furthermore, prior to forming, the pre form sheet materials
do not conveniently lend themselves to the addition of enhancements
which can, along with the pre form, be conveniently moulded to
define a suitable breast cup shape.
[0005] The traditional form of sewn panel breast cup constructions
have incorporated panels of contrasting appearance. In particular
such traditional breast cups have included a panel or panels of
lace material incorporated with a silk or other general coverage
material defining the breast cup construction.
[0006] Accordingly it is an object of the present invention to
provide a method of producing a breast cup assembly and in
particular although not solely to a method of producing a breast
cup assembly which can conveniently incorporate a panel of
contrasting appearance to thereby enhance the outward appearance of
the breast cup assembly or which will at least provide the public
with a useful choice.
BRIEF DESCRIPTION OF THE INVENTION
[0007] In a first aspect the present invention consist in a method
of making a breast cup for a garment of clothing comprising:
[0008] a) taking a structure defining component of a breast cup
form and created from a flexible sheet of mouldable material,
[0009] b) engaging a flexible panel (herein after "covering panel")
of an at least part breast cup form corresponding to at least part
of said structure defining component, to the structure defining
component to locate said covering panel on the convex side of the
breast cup form of said structure defining component in at least a
partial overlapping condition, to thereby define a panel assembly
which includes said structure defining component and said covering
panel
[0010] c) affixing to the convex side of said panel assembly, a
panel of flexible material (herein after "decorative panel") of a
contrasting appearance to the convex side of said covering panel in
an overlying condition to part of said panel assembly and in a
position to locate said decorative panel inwardly of the perimeter
of said panel assembly,
[0011] d) removing a region of the panel assembly covered by and
within the perimeter of said decorative panel to thereby expose the
decorative panel to the concave side of said panel assembly.
[0012] Preferably said affixing defined in step (c) is by affixing
said decorative panel at its perimeter to said panel assembly at
and about the perimeter of said decorative panel wherein said
removing defined in step (d) is of a region of said panel assembly
encompassed by the perimeter fixing of said decorative panel.
[0013] Preferably said affixing defined in step (c) is by stiching
said decorative panel at its perimeter to said panel assembly at
and about the perimeter of said decorative panel wherein said
removing defined in step (d) is of a region encompassed by the
perimeter stitching of said decorative panel.
[0014] Preferably said structure defining component includes a
means defining a visible reference point within the perimeter of
said breast cup form wherein subsequent to step (b) and prior to
step (c), said reference point is relied upon to generate a visible
reference point of corresponding position visible from the convex
side of said panel assembly for the purposes of reliance in step
(c) to establish the appropriate said position of said decorative
panel with respect to said panel assembly.
[0015] Preferably said visible reference point on said convex side
of said panel assembly is generated by penetrating said panel
assembly from said concave side to said convex side with a means
visible.
[0016] Preferably said penetrating is by stitching a line of thread
through said panel assembly.
[0017] Preferably said means defining a visible reference point is
a line of reference, said stitching being along at least part of
such said line.
[0018] Preferably said means defining a visible reference point is
an endless line of reference provided about a region of said panel
assembly said stitching being along said endless line, said region
being of a perimeter shape commensurate with the perimeter shape of
said decorative panel to thereby allow said decorative panel to be
aligned with said stitching for the subsequent affixing defined in
step (c).
[0019] Preferably means defining a visible reference point is
generated during the forming of said structure defining component
prior to step (a).
[0020] Preferably said means defining a visible reference point is
generated during the forming of said structure defining component
prior to step (a) by embossing the visible reference point into the
convex side surface of said structure defining component.
[0021] Preferably said structure defining component includes a
sheet of foam material and said embossing is achieved by the
enhanced compression of said sheet of foam material at where said
visible reference point is defined during the forming of said
structure defining component.
[0022] Preferably said structure defining component includes a
sheet of foam material with which there is adhered from at least
one major surface thereof a sheet of fabric material, said engaging
of said structure defining component with said covering panel being
to position said covering panel on the side of said structure
defining component opposite to said at least one sheet of fabric
material.
[0023] Preferably subsequent to step (d) embroidery stitching is
applied at or proximate and inward of the perimeter of said
decorative panel to capture within the enclosure of said embroidery
stitching the edges of said panel assembly exposed by the removing
of said region defined as step (d).
[0024] Preferably said embroidery stitching also captures within
the enclosure of said embroidery stitching the perimeter edge of
said decorative panel.
[0025] Preferably said engaging defined in step (b) is by affixing
by sewing of the covering panel to said structure defining
component at the perimeter of said covering panel.
[0026] Preferably where said covering panel is of coextensive
perimeter shape to the structure defining component, said engaging
defined in step (b) is by affixing by sewing of the covering panel
to structure defining component at the perimeter of said structure
defining component.
[0027] In a further aspect the present invention consist in a
method of making a breast cup for a garment of clothing
comprising:
[0028] a) taking a structure defining component of a breast cup
form and created from a flexible sheet of mouldable material,
[0029] b) engaging a flexible panel (herein after "covering panel")
of an at least part breast cup form corresponding to at least part
of said structure defining component, to the structure defining
component to locate said covering panel on the convex side of the
breast cup form of said structure defining component in at least a
partial overlapping condition, to define a panel assembly which
includes said structure defining component and said covering
panel
[0030] c) affixing to the concave side of said panel assembly, a
panel of flexible material (herein after "decorative panel") of a
contrasting appearance to the convex side of said covering panel in
an overlying condition to part of said panel assembly and in a
position to locate said decorative panel inwardly of the perimeter
of said panel assembly,
[0031] d) removing a region of the panel assembly covered by and
within the perimeter of said decorative panel to thereby expose the
decorative panel to the convex side of said panel assembly.
[0032] In a further aspect the present invention consist in a
breast cup assembly for incorporation into a garment of clothing
and made in accordance to any on of the methods as herein
described
[0033] In a further aspect the present invention consist in a
breast cup assembly comprising
[0034] a structure defining component of a breast cup form and
created from a flexible sheet of mouldable material,
[0035] a flexible panel (herein after "covering panel") affixed to
said structure defining component and of an at least part breast
cup form corresponding to at least part of said structure defining
component, said covering panel located adjacent the structure
defining component on the convex side of said structure defining
component and in an at least a partial overlapping condition with
said structure defining component, to define a panel assembly which
includes said structure defining component and said covering
panel
[0036] a panel of flexible material (herein after "decorative
panel") of a contrasting appearance to the convex side of said
panel assembly and affixed with, at either one side selected from
said convex side and concave side, said panel assembly in an
overlying condition and located in a position inwardly of the
perimeter of said panel assembly,
[0037] wherein an opening is provided through said structure
defining component at a region of the structure defining component
encompassed by the perimeter of said decorative panel to there
through expose the decorative panel to the opposite of said one of
said convex side and concave side of said structure defining
component.
[0038] Preferably said structure defining component includes a
moulded sheet of foam material.
[0039] Preferably said structure defining component includes a
moulded sheet of foam material with which there is affixed to each
opposed major surface, a panel of fabric.
[0040] Preferably said decorative panel is affixed to the convex
side of said panel assembly by stitching extending through said
decorative panel and said panel assembly and provided at or
immediately inwardly of the perimeter of said decorative panel and
wherein the said or a stitching at the perimeter of said decorative
panel is of an embroidery kind and captures within such stitching
the perimeter edge of said decorative panel.
[0041] Preferably said structure defining component and said
covering panel are coextensive.
[0042] Preferably said covering panel is a flexible fabric
material.
[0043] Preferably said decorative panel is a lace material.
[0044] Preferably said structure defining component and said
covering panel are coextensive and are stitched to each other at
the perimeter of said cup and at where said perimeter of said
decorative panel is affixed to said panel assembly.
[0045] In a further aspect the present invention consist in a
method of making a breast cup for a garment of clothing
comprising:
[0046] a) taking a structure defining component of a breast cup
form and created from a flexible sheet of mouldable material,
[0047] b) affixing at a convex side region and in an overlying
condition to said structure defining component, a panel of flexible
material (herein after "decorative panel") of a contrasting
appearance to the convex side of said structure defining component,
said affixing being of a position to locate said decorative panel
inwardly of the perimeter of said structure defining component,
[0048] c) removing a region of said structure defining component to
create an opening through said structure defining component, said
opening of a region corresponding to and inwardly of the perimeter
of said decorative panel to thereby expose the affixed decorative
panel to the concave side of said structure defining component.
[0049] Preferably said affixing defined in step (b) is or includes
affixing of at least part of the perimeter of said decorative panel
with said structure defining component, said removing to create
said opening being by cutting said structure defining component at
a region inwardly of the perimeter of said decorative panel.
[0050] Preferably said removing to create said opening in said
region of said structure defining component is such that once said
region is removed, said opening remains covered by said decorative
panel
[0051] Preferably prior the affixing as described in step (b), a
flexible covering panel of an at least part breast cup form
corresponding to at least part of said structure defining
component, is engaged to said structure defining component to
locate said flexible covering panel on the convex side of the
breast cup form of said structure defining component in at least a
partial overlapping condition with the convex side surface of said
structure defining component, said flexible covering thereby
forming part of the structure defining component.
[0052] In a further aspect the present invention consist in a
method of making a breast cup for a garment of clothing
comprising:
[0053] a) taking a structure defining component of a breast cup
form and created from a flexible sheet of mouldable material,
[0054] b) affixing at a concave side region and in an overlying
condition to said structure defining component, a panel of flexible
material (herein after "decorative panel") of a contrasting
appearance to the convex side of said structure defining component,
said affixing being of a position to locate said decorative panel
inwardly of the perimeter of said structure defining component,
[0055] c) removing a region of said structure defining component to
create an opening through said structure defining component, said
opening being inwardly of the perimeter of said decorative panel to
thereby expose the affixed decorative panel to the convex side of
said panel assembly.
[0056] Preferably said affixing described in step (b) is or
includes affixing of at least part of the perimeter of said
decorative panel with said structure defining component, said
removing to create said opening being by cutting said structure
defining component at a region corresponding to and being inwardly
of the perimeter of said decorative panel.
[0057] Preferably said removing to create said opening in a region
of said structure defining component is such that once said region
is removed, said opening remains covered by said decorative
panel
[0058] Preferably a flexible covering panel of an at least part
breast cup form corresponding to at least part of said structure
defining component, is engaged to said structure defining component
to locate said flexible covering panel on the convex side of the
breast cup form of said structure defining component in at least a
partial overlapping condition with the convex side surface of said
structure defining component, said flexible covering thereby
forming part of the structure defining component.
[0059] Preferably said flexible covering panel is affixing prior to
the step described as step (b).
[0060] In a further aspect the present invention consist in a
breast cup assembly comprising
[0061] a structure defining component of a breast cup form and
created from a flexible sheet of mouldable material,
[0062] a panel of flexible material (herein after "decorative
panel") of a contrasting appearance to the convex side of said
structure defining component affixed with, at either one side
selected from said convex side and concave side, said structure
defining component in an overlying condition and located in a
position inwardly of the perimeter of said structure defining
component,
[0063] wherein an opening is provided through said structure
defining component at a region of the structure defining component
encompassed by the perimeter of said decorative panel to there
through expose the decorative panel to the opposite of said one of
said convex side and concave side of said structure defining
component.
[0064] Preferably said structure defining component includes a
flexible covering ply of material disposed to the convex side of
said structure defining component and against which said decorative
panel is engaged.
[0065] In a further aspect the present invention consist in method
of making a breast cup for a garment of clothing comprising:
[0066] a) taking a structure defining component of a breast cup
form and created from a flexible sheet of mouldable material,
[0067] b) engaging a flexible panel (herein after "covering panel")
of an at least part breast cup form corresponding to at least part
of said structure defining component, to the structure defining
component to locate said covering panel on the convex side of the
breast cup form of said structure defining component in at least a
partial overlapping condition, to thereby define a panel assembly
which includes said structure defining component and said covering
panel, said covering panel including on the convex side of said
covering panel, a panel of flexible material (herein after
"decorative panel") of a contrasting appearance to the convex side
of said covering panel, positioned in an overlying condition to
said covering panel and in a position to locate said decorative
panel inwardly of the perimeter of said covering panel,
[0068] d) removing a region of the panel assembly within a
corresponding region of said panel assembly encompassed by the
perimeter of said decorative panel to thereby expose the decorative
panel to the concave side of said panel assembly.
[0069] In a further aspect the present invention consist in a
method of making a breast cup for a garment of clothing
comprising:
[0070] a) taking a structure defining component of a breast cup
form and created from a flexible sheet of mouldable material,
[0071] b) engaging a flexible panel (herein after "covering panel")
of an at least part breast cup form corresponding to at least part
of said structure defining component, to the structure defining
component to locate said covering panel on the concave side of the
breast cup form of said structure defining component in at least a
partial overlapping condition, to thereby define a panel assembly
which includes said structure defining component and said covering
panel, said covering panel including on the concave of said
covering panel, a panel of flexible material (herein after
"decorative panel") of a contrasting appearance to the convex side
of said structure defining component, positioned in an overlying
condition to said covering panel and in a position to locate said
decorative panel inwardly of the perimeter of said covering
panel,
[0072] d) removing a region of the panel assembly within a
corresponding region of said panel assembly encompassed by the
perimeter of said decorative panel to thereby expose the decorative
panel to the concave side of said panel assembly.
[0073] This invention may also be said broadly to consist in the
parts, elements and features referred to or indicated in the
specification of the application, individually or collectively, and
any or all combinations of any two or more of said parts, elements
or features, and where specific integers are mentioned herein which
have known equivalents in the art to which this invention relates,
such known equivalents are deemed to be incorporated herein as if
individually set forth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] FIGS. 1-14 illustrate the preferred steps to the method of
the invention for defining the breast cup construction of FIG. 15,
wherein
[0075] FIG. 1 is a perspective view of a sheet of material to
provide the structure defining component of the breast cup
construction prior to being moulded,
[0076] FIG. 2 is a side sectional view of a moulding device to
mould two cup forms in the sheet of FIG. 1,
[0077] FIG. 3 is a plan view of part of the sheet of FIG. 1 after
moulding in the moulding device of FIG. 2,
[0078] FIG. 4 is a detailed side sectional view of the upper mould
portion of the mould of FIG. 2,
[0079] FIG. 5 is a perspective view of a cover sheet to be
incorporated with the structure defining breast cup portions,
[0080] FIG. 6 is a side view of a moulding device for moulding a
breast cup form in the sheet of material of FIG. 5,
[0081] FIG. 7 is a perspective view of the sheet of FIG. 5 engaged
with a framing device which may be utilised for supporting the
sheet of FIG. 5 during the moulding phase provided by the moulding
device of FIG. 6,
[0082] FIG. 8 is a plan view of the moulded form of FIG. 1 wherein
the moulded cup forms are to be cut from the remaining portions of
the sheet,
[0083] FIG. 9 is a sectional view through a breast cup construction
assembly comprising of the structure defining breast cup component
and the breast cup component defined from the sheet of FIG. 5
engaged together,
[0084] FIG. 10 illustrates a sewing of the structure defining
breast cup component and the breast cup defined from FIG. 5
together to define an outline by stitching on the convex side of
the breast cup assembly,
[0085] FIG. 11 illustrates the sewing of a panel of contrasting
appearance on to the convex side of the breast cup assembly,
[0086] FIG. 12 is a front view of the breast cup assembly defined
by the step of FIG. 11,
[0087] FIG. 13 illustrates the removal of a region of the breast
cup assembly to thereby expose the panel of contrasting appearance
on the concave side,
[0088] FIG. 14 illustrates an embroidery step for enhancing the
appearance of the breast cup assembly, but which may have
alternatively been previously defined with reference to the step of
FIG. 11,
[0089] FIG. 15 is a front view of a breast cup construction of the
present invention,
[0090] FIG. 15A which is a brassiere which incorporates breast cup
constructions as defined with reference to FIG. 15,
[0091] FIG. 16 is a sectional view of the structure defining
component of the breast cup assembly engaged with the covering
sheet prior to being manipulated to define the preferred
relationship between the structure defining component and the
covering sheet,
[0092] FIG. 17 is a sectional view wherein the cover sheet and the
structure defining component of FIG. 16 have been manipulated to
define the preferred form of their relationship which will lead to
the constructional relationship as shown in FIG. 9, and
[0093] FIG. 18 is an alternative to the breast cup assembly of FIG.
15.
DETAILED DESCRIPTION OF THE INVENTION
[0094] With reference to FIG. 15, the present invention includes a
method to define a breast cup assembly similar to the kind as shown
in FIG. 15. The breast cup assembly 1 is substantially of a breast
cup shape and made substantially from mouldable materials.
[0095] The breast cup assembly includes a three dimensional body
form bounded by a neckline perimeter region 2, a base perimeter
region 3 and an underarm perimeter region 4. At or proximate to the
junction between the neckline perimeter region 2 and underarm
perimeter region 4 at point 5, will be where the breast cup
assembly 1 will be incorporated with the strap of the bra as for
example shown in FIG. 15A. However, it is envisaged by the inventor
that the methods and breast cup assembly 1 defined by the methods
of the present invention may be incorporated in a strapless bra and
certainly the configuration of the perimeter of the breast cup
assembly is not to be considered limited to those shown in the
accompanying drawings. It is also envisaged that the breast cup
assembly may be incorporated as part of a different kind of garment
of clothing such as for example, lingerie, swimwear or a female
dress in general. Accordingly whilst in the most preferred form
reference will herein be made to a breast cup assembly particularly
for its application as part of a bra, it is to be appreciated that
the breast cup assembly need not necessarily be provided for the
purposes of defining a component in underwear. The breast cup
assembly may indeed be incorporated into a garment which is
outerwear.
[0096] The breast cup assembly 1 as shown in FIG. 15 includes a
panel 6 of contrasting appearance to the general cup defining panel
assembly 7 of the breast cup assembly 1. The panel of contrasting
appearance 6 may be a panel of different material and may be of a
single ply or of a multi-ply. With reference to FIG. 14 which is a
sectional view through part of the breast cup assembly of FIG. 15,
it can be seen that the panel of contrasting appearance 6 is
exposed on the convex side 15 and the concave side 16 of the breast
cup assembly. A panel 6 which is made of a multi-ply construction
may expose to the convex side a material of one colour or texture
and to the concave side a material of another colour or texture.
However, in the most preferred form the panel 6 is a panel of lace
material. The lace material will have a partially see through
effect and provides a decorative effect to the convex side 15 of
the breast cup assembly. The configuration as shown in FIG. 14
where part of the generally cup defining panel assembly 7 is
removed, the see through effect of the lace material can be
enhanced particularly when a bra incorporating the breast cup
assembly of the present invention is being worn, when the colour of
the skin will be exposed in regions through the lace material.
[0097] The preferred form of constructing the breast cup of FIG. 15
will now be described with reference to the drawings.
[0098] FIG. 1 illustrates a sheet 10 of flexible and mouldable
material which is used to define the structure defining component
31 to the breast cup assembly 1. A sheet 10 is of a perimeter size
sufficient for at least one cup form to be moulded therein. In the
most preferred form the sheet is of a perimeter sufficient to allow
for two matching cup forms (left and right side) to be formed in
the sheet simultaneously by a two cup moulding machine, as for
example shown in part in FIG. 2. The sheet 10 preferably consists
of three layers of material. The first layer 11 is a sheet layer of
foam 11 such as, for example polyurethane. In its pre-moulded form,
the sheet of foam 11 is for example of a thickness of 5 mm. The
sheet of foam 11 has engaged to each of its opposed major surfaces,
layers of thin flexible sheet such as a fabric material 12, 13. The
layers of fabric material 12, 13 are adhered preferably directly to
the opposing major surfaces of the sheet of foam 11. Such adhesion
may be by heat welding and/or adhesive affixing. The sheet 10 is
preferably cut from a bulk supply of material to define the sheet
and accordingly the fabric layers 12, 13 are substantially
co-extensive with the sheet of foam 11. The layers of fabric 12, 13
are preferably of a woven fabric, however alternatively the layers
12, 13 are of a non-woven kind. All plies of the sheet 10 are of a
synthetic and mouldable material.
[0099] In an alternative form of the sheet 10 of FIG. 1, a fabric
layer may be applied only to one major surface of the sheet of foam
11. Whilst such a form is less desirable it is envisaged that the
breast cup assembly 1 and the methods of forming the breast cup
assembly 1 may utilise such a single side fabric covered sheet of
foam assembly. Reference will briefly be made to such an
alternative form hereinafter as the methods of construction of the
present invention are described.
[0100] The sheet 10 has a moulded cup form or forms introduced
therein by a moulding device as, for example, in part shown in FIG.
2. The moulding device includes an upper mould portion 17 and a
lower mould portion 18. It can be seen in the arrangement of FIG. 2
that the upper mould portion includes convex moulding surfaces and
the lower mould portion includes substantially complimentary shaped
concave moulding surfaces to introduce two, three dimensional cup
forms into the sheet 10 of the FIG. 1.
[0101] Preferably although not essentially, the moulding step to
define the moulded cup form(s) in the sheet 10 of FIG. 1 also
includes the provision of an embossed or depressed relief to the
concave side of the moulded cup form(s). Such embossing is
preferably provided by an upstanding region 19 of at least one of
the convex cup moulding surfaces of the upper mould 17.
[0102] Preferably where both cups to be incorporated into the bra
are to include the panel 6 as shown in FIG. 15 then both convex up
stands of the upper mould portion should include the upstanding
surface 19. Since the panel 6 is to be incorporated into the cup
form within the boundaries 2, 3, 4 of the perimeter of the cup, the
embossing defining upstanding portion 19 provide an embossed region
which preferably defines an enclosed region to the concave side of
the cup shapes formed in the sheet 10.
[0103] With reference to FIG. 3, the embossed region 20 is defined
by the moulding device within the perimeter defined by edges 2, 3
and 4 of the cup forms of the sheet 10. In the examples shown in
FIG. 3, the embossing is of a track like form which defines the
perimeter to the region 22 bounded by the embossing. Such a track
form is for example, able to be defined by an upstanding track like
region 19 of the upper mould 17 as shown in FIG. 4.
[0104] In an alternative form the entire region 22 is embossed or
depressed and such may be provided by an upstanding region which is
entirely upstanding from the cup defining surface 25 of the upper
mould portion 17. In effect the embossing step reduces the
thickness of the panel 10 by compressing the sheet 10 and in
particular the foam 11 of the sheet at regions of embossing to an
extent greater than the remaining regions of the sheet 10 within
the moulded breast cup form. The embossed relief is for example
shown in FIG. 9. The provision of the embossed relief to the
concave side of the breast cup form of the sheet 10 is not
essential but is preferred for the purposes of allowing for
duplicated and repeatable placement of the panel 6 with the convex
side of the cup form. The purposes of the embossing to allow for
such consistent placement will become apparent as the steps to the
method are further explained.
[0105] Once the cup form(s) are moulded in the sheet 10 the cup
form(s) may be cut from the remainder of the sheet 10 as for
example shown in FIG. 8.
[0106] In the most preferred form the cup forms are cut from the
remainder of the sheet 10 prior to the engagement of a covering
panel 30 to the structure defining component 31 of the cup forms
defined from the then moulded sheet 10. However it may be possible
to engage the covering panel 30 to the structure defining component
31 whilst still engaged to the remainder of the foam sheet 10.
However, preferably the covering panel 30 is engaged to the
structure defining component 31 once the structure defining
components are removed from the remainder of the sheet 10.
[0107] The covering panel 30 is preferably disposed from the convex
side of the structure defining component 31. The cover panel 30 is
preferably defined from a sheet of mouldable flexible material as
for example shown in FIG. 5. The flexible sheet 30 is preferably of
a single ply material such as a fabric material. It is preferably
made from a synthetic material such as a nylon/lycra blend of 86%
nylon and 14% lycra.
[0108] In order to ensure that the covering panel (covering fabric)
30 can conveniently conform to the three dimensional cup shape of
the structure defining component 31, the covering fabric 35 is
preferably moulded to a three dimensional cup form substantially
commensurate with the three dimensional cup form of the structure
defining component 31 to which it is to be engaged. The covering
fabric may for example be moulded in a moulding device as for
example in part shown in FIG. 6, the device providing two moulded
cup forms into a single sheet of covering fabric 35. For the
purposes of such moulding step the fabric sheet 35 may need to be
engaged with a frame 36 which will hold the perimeter of the fabric
sheet 35 in position during the moulding process to prevent the
fabric sheet 35 from wrinkling during the moulding step.
[0109] The cup forms defined in the fabric sheet 35 may then be
applied to the convex side of the structure defining component 31
and affixed thereto. It may cover the entire convex side or part of
the convex side (see FIG. 18). Such a fixing may be achieved in one
of several manners the details of which will be hereinafter
described.
[0110] The cup forms formed in the fabric sheet 35 may be cut prior
to being affixed to the structure defining component 31 or
after.
[0111] The purpose of affixing the covering fabric 30 to the
structure defining component 31 is to ensure that they remain in
register together.
[0112] In the version of the method of the present invention where
the embossing step is provided, the embossing is effectively
provided for the purposes of aiding the positioning of the panel 6
in a repeatable manner with the structure defining component and
cover fabric assembly (hereinafter the "panel assembly 90").
[0113] The purpose of providing the embossed region on the concave
side of the structure defining component 31 is to allow for a means
of reference to be generated on the convex side of the panel
assembly which will allow for the placement of the panel 6 to be
positioned in the desired position. The way in which the reference
is provided to the convex side is preferably by stitching panel 6
to the panel assembly 90 as shown in FIG. 10 together along the
perimeter to the bounded area 22, bounded by the embossed region
20. Such stitching 49 is preferably applied by the use of a sewing
machine which can apply a straight line stitching following the
outer perimeter of the embossed relief, in the concave side of the
panel assembly.
[0114] A sewing machine operator can manipulate the assembly of
panels to position this relative to the sewing machine to provide
stitching through the panel assembly 90 along the perimeter of the
embossed region 20. Such stitching will penetrate through all of
the panels and will present a line of stitching 49 exposed to the
convex side of the panel assembly 90. A panel 6 is preferably cut
to a shape matching the shape of the line of stitching can then be
positioned against the convex side of the assembly, its position
gaining reference from the line of stitching visible 49 to the
convex side of the panel assembly 90 to thereby accurately position
the panel 6 in the desired location.
[0115] Whilst in the preferred form such stitching 49 is provided
through the layers of the panel assembly 90 to define an enclosed
region which proximately corresponds to the enclosed region 22
defined by the embossing on the concave side, it will be
appreciated that since the primary purpose of providing the
stitching is to provide reference points to the convex side such
stitching need not be continuous. Indeed it is envisaged by the
inventor that the stitching may provide two reference points
visible from the convex side. Such two reference points can be
sufficient to allow for the correct positioning of the panel 6 in
the desired location against the convex side of the panel assembly
90.
[0116] In an alternative form of the present invention however the
embossing may not be provided for the purposes of generating the
cup assembly 1 of FIG. 15. It may be that approximate positioning
by line of sight by the operator of a sewing machine may be
sufficient to generate a desired result. However for mass
production the repeatability of positioning is preferred and
accordingly the embossing and stitch through steps to define the
reference stitching 49 is preferred. It is however anticipated by
the inventor that alternative forms of defining a reference point
on the convex side of the panel assembly is achievable. However, it
is most preferred that any means for defining the reference points
are introduced at the moulding steps and not on the perform sheet
10. This is because during the moulding step movement of the
material as a result of the moulding may not be predictable.
Accordingly any screen printing or other marking provided on a
surface of the sheet 10 may not end in a repeatable position on the
cup form once the sheet has been rolled. Accordingly it is believed
by the inventor to be most reliable to introduce a means for
defining the reference (i.e.; the embossing) during the moulding
phase.
[0117] The affixing of the panel 6 to the convex side 15 of the
assembly is preferably also achieved by stitching. Such stitching
50 is preferably at and about the entire perimeter of the panel 6
as, for example, shown in FIG. 11. Since this stitching 50 is going
to be a visible part of the final construction of the breast cup
assembly and the brassiere incorporating such, the stitching 50 is
preferably of an aesthetic kind such as, for example, of an
embroidered or overlocking kind. The embroidered type of stitching
that is preferably utilised for the stitching 50 is of a kind which
defines a beaded like line of stitching. Such stitching will extend
to the perimeter of the panel 6 and cover the perimeter of the
panel 6 so that the perimeter of the panel 6 will be captured
within the embroidered like stitching and not be visible. Such is
for example, shown in FIG. 14. The stitching 50 may however be of a
different kind or may not be of a final finishing kind and
reference to the stitching 50 will hereinafter be again referred to
once some further aspects of the invention have been described.
[0118] In the most preferred form and as has so far been described,
the panel 6 is preferably affixed to the convex side of the panel
assembly 90. Such is desirable as, once incorporated, the panel 6
will have the appearance of being substantially at the convex
surface of the cup assembly. However in an alternative form the
panel 6 may be affixed to the concave side of the assembly. In such
an example the panel 6 is provided to the concave side. If
reference points for the positioning of such panel are to be
provided, the steps of embossing may need to be provided to the
convex side.
[0119] With reference to FIG. 11, it can be seen that the structure
defining component 31 defined from the panel 10 is of an
alternative kind wherein only a single layer of fabric material 12
is provided to the foam panel 11. Whilst it is envisaged that this
is one form of construction of the assembly of the present
invention it is less desirable since the foam may be subjected to
weathering wherein its colour may vary from the colour at
manufacture. In particular foam has a tendency to "yellow" and
should the covering fabric 30 not be of a construction which may
prevent such yellowing and prevent such yellowing from being
visible from the convex side of the cup construction, the
discolouring of the foam will be an undesirable effect to the
appearance of the final breast cup assembly.
[0120] Accordingly the most preferred form is where the foam has a
fabric panel on both sides and in particular so as to provide a two
layer panel assembly to the convex side of the cup
construction.
[0121] As an alternative the covering fabric may be absent from the
panel assembly and the breast cup assembly may only include the
structure defining component formed from the sheet 10 without
another layer provided external thereof. The panel 6 may then be
affixed direct to the layer 13 of the structure defining component.
A variation to this is where the panel is affixed to the fabric
panel 12 on the concave side. The structure defining component is
then cut to create the opening to expose the panel 6 to the other
side.
[0122] Once the assembly as for example shown in FIG. 11 has been
defined, material to the concave side of the panel 6 may be removed
so as to provide a single panel thickness through this area. The
fabric layer 12, the foam layer 11, the optional fabric layer 13
and the covering fabric 30 are removed within the region bounded by
the perimeter of the panel 6 and intermediate of the stitching 50
about the panel 6. In the example and in the preferred form where
the panel 6 is of a lace material such removal of the layers will
expose the lace to the concave side of the construction which will
have an enhanced and more desirable visual effect. Such an effect
will be provided by a partial see through from the convex side to
the concave side and when the breast cup assembly 1 incorporated
with a brassiere is worn against the skin of a person, the skin of
the person will be visible in part through the panel 6. Where the
panel 6 is affixed to the concave side of the assembly the same
material removed for the preferred configuration of FIG. 11 may
occur, however such removal is achieved from the convex side.
[0123] In the configuration of FIG. 11 the material is removed by
cutting the material away from the concave side of the panel
assembly 90.
[0124] As can be seen with reference to FIG. 15 the panel 6 is
provided within the bounds of the cup construction (boundaries 2, 3
and 4). The panel is bounded by stitching 50 which retains the
panel 6 to the main body 7 of the cup construction. The cutting
away of the material may be achieved by the use of scissors. Such
cutting may be along the regions of the assembly within the bounds
of the stitching 50 and such cutting may be assisted by it being
along part of the embossed region 20.
[0125] Once the material has been removed, edges of the material
will be exposed and such is visually appealing. Accordingly a
second line of stitching is introduced to capture within the bounds
of the stitching, the edges of the exposed plies of material
resulting from the cutting away of the section as described above.
The stitching is preferably along the line of stitching 50 and is
preferably of an embroided kind so that it will capture within its
bounds, the edges of the cut away fabric. Accordingly two sets of
stitching may be provided along the line of stitching 50 shown in
the drawings. The first line of stitching being to attach the panel
6 to the panel assembly 90 and the second provided for the purposes
of capturing the edges exposed by the cutaway sections.
[0126] The assembly in the condition as for example shown with
reference to FIGS. 13 and 15, can then be incorporated with other
components to define a brassiere 60 as for example shown in FIG.
15A.
[0127] The covering fabric 30 is preferably engaged to the
components of the sheet 10 by perimeter stitching 65. However in
addition to such stitching to affix the covering fabric adhesive
may be applied between the covering fabric and the structure
defining component 31. Such adhesive may be applied everywhere save
for the region of the assembly where the material is to be cut away
to expose the panel 6 to the concave side of the cup
construction.
[0128] In order to create a cup assembly which is aesthetically
appealing, the covering fabric 30 is engaged to the structure
defining component 31 in a manner to provide blind stitching at
least along the neckline perimeter 2.
[0129] With reference to FIGS. 16 and 17 such blind stitching may
be achieved by the engagement of the covering fabric 30 with the
structure defining component 31 along the perimeter 2 by reversing
the covering fabric 30 from the side it is affixed to of the
structure defining component 31 to the convex side. A blind
stitching configuration will then be provided along the perimeter
2. Since this perimeter 2 will be that part of the breast cup
construction which will be a substantially free edge and may be
more exposed to be seen than the other edges e, it is desirable for
such blind stitching to be provided at this edge. It may however be
feasible for such blind stitching to also be provided along the
perimeter edge 4.
[0130] The moulding of the sheet 10 in the moulding device of FIG.
2 may for example occur where the upper mould is of approximately
101.degree. C. and the lower mould is approximately under
95.degree. C. The moulding time for such temperatures and the
preferred materials will be for a period of about 120 seconds. The
moulding of the fabric panel 35 preferably occurs where the
temperatures of the upper mould is approximately 208.degree. C. and
the lower mould is 215.degree. C. The moulding or dwell time is
approximately 80 seconds.
[0131] An alternative to the method of constructing the cup
assembly of the present invention will now be described. Such an
alternative is not an alternative to all the steps but to part of
the process of affixing the panel 6 with the covering fabric 30. It
is anticipated that the provision of the panel 6 to the panel
assembly 90 may occur at a step prior to the covering fabric 30
being engaged to the structure defining component 31. The panel 6
may be affixed to the covering fabric 30 pre or post moulding of
the fabric sheet 35 to define the covering fabric 30. The panel 6
may be affixed to the fabric sheet 35 by sewing subsequent to which
the assembly is placed in a moulding device to define the covering
fabric with the panel engaged thereto. However such may create
difficulties with respect to the position of the panel 6 and the
maintaining of the structural integrity of the fabric sheet 35 to
define the covering fabric 30. Since the covering fabric 30 is of a
thin material the provision of the panel 6 to the covering fabric
after moulding but prior to its engagement with the structured
defining component may also not be sufficient to allow for
convenient engagement thereto of the panel 6. However since it is
anticipated that such a step in the process of the provision of the
cup assembly may be achievable, the methods of the present
invention includes this alternative step to the construction of the
cup assembly.
[0132] The covering fabric 30 is preferably provided coextensive
with the structure defining component 31. However with reference to
FIG. 18 it can be seen that the covering fabric 30 may not be
coextensive with the structure defining component and there may be
a seam of embroided stitching 91 extending between the edge of the
covering fabric 30 and the upper surface 13 of the structure
defining component 31. In such a configuration, the covering fabric
30 is however provided to the structure defining component where
the panel 6 is to be provided. Panel 6 will hence be captured also
within the boundaries of the fabric panel 30. Whilst reference is
made to the provision of a decorative panel 6 to the breast cup, it
is envisaged that more than one discrete panel 6 may be provided to
each cup assembly.
* * * * *