U.S. patent application number 10/987818 was filed with the patent office on 2006-05-18 for brassiere.
Invention is credited to Bull Lau.
Application Number | 20060105673 10/987818 |
Document ID | / |
Family ID | 36387009 |
Filed Date | 2006-05-18 |
United States Patent
Application |
20060105673 |
Kind Code |
A1 |
Lau; Bull |
May 18, 2006 |
Brassiere
Abstract
A molded bra of a layered assembly of a plurality of plies of
flexible moldable material. The layered assembly generally defines
two molded breast cups a bridge intermediate of the two breast cups
and a chest band from which each of the molded breast cups are
disposed. The assembly includes an outward ply of a fabric material
presenting a first outermost surface of the bra to the convex side
of the breast cups of the bra, and an inward ply disposed to the
opposite side of the assembly where the first outermost ply is
presented and presenting a second outermost surface of the bra to
the concave side of the breast cups of the bra. The layered
assembly includes at least the inward and the outward ply at the
entire perimeter about the bra regions and wherein the outward ply
has been folded at the perimeter to provide a hem affixed to the
inward ply.
Inventors: |
Lau; Bull; (Shenzhen,
CN) |
Correspondence
Address: |
OSTROLENK FABER GERB & SOFFEN
1180 AVENUE OF THE AMERICAS
NEW YORK
NY
100368403
US
|
Family ID: |
36387009 |
Appl. No.: |
10/987818 |
Filed: |
November 12, 2004 |
Current U.S.
Class: |
450/39 |
Current CPC
Class: |
A41C 3/0014 20130101;
A41C 5/005 20130101 |
Class at
Publication: |
450/039 |
International
Class: |
A41C 3/00 20060101
A41C003/00 |
Claims
1. A molded bra defined in part by a layered assembly of a
plurality of plies of flexible moldable material, said layered
assembly generally defining bra regions of two molded breast cups a
bridge intermediate of said two breast cups and a chest band from
which each of said molded breast cups are disposed, said assembly
including a. a first of said plies (herein after "outward ply") of
a fabric material presenting a first outermost surface of said bra
to the convex side of the breast cups of said bra, and b. at least
one other of said plies (herein after "inward ply") disposed to the
opposite side of said assembly where said outward ply is presented,
presenting a second outermost surface of said bra to the concave
side of said breast cups of said bra wherein the layered assembly
includes at least the inward and outward ply at the entire
perimeter about the bra regions and wherein said outward ply has
been folded at the perimeter to provide a hem thereof affixed to
the inward ply.
2. A molded bra as claimed in claim 1 wherein said hem of said
outward ply is adhesively affixed to said inward ply.
3. A molded bra as claimed in claim 1 wherein the hem is provided
about the entire perimeter about said bra regions.
4. A molded bra as claimed in claim 1 wherein said perimeter of
said bra regions generally consists of (a) a lower perimeter
extending along the bottom edge of said chest band, (b) an outer
perimeter extending along the upper edge of at least the regions
inward of the distal ends of the chest band and transitioning to
extend adjacent or along the outer perimeter edges of each of said
breast cups, and (c) a neckline perimeter extending along the upper
edges of each of said breast cups.
5. A molded bra as claimed in claim 1 wherein the outward ply is
parallel to but not laminated with the plies of the remained of the
assembly, save for at said hem.
6. A molded bra as claimed in claim 1 wherein the assembly, at each
of the breast cups includes at least one ply of a foam
material.
7. A molded bra as claimed in claim 6 wherein the foam material
provides a flexibly rigid cup form.
8. A molded bra as claimed in claim 1 wherein the chest band, at
least at regions extending inwardly from the distal ends towards
said breast cups, includes no foam plies.
9. A molded bra as claimed in claim 1 wherein the chest band
includes no foam plies.
10. A molded bra as claimed in claim 1 wherein said outward ply and
said inward ply are coextensive with each other.
11. A molded bra as claimed in claim 1 wherein said inward ply is
of a single piece of material.
12. A molded bra as claimed in claim 1 wherein said inward ply is
of a single piece of fabric material.
13. A method of forming a hem at a perimeter of part of a chest
band of a bra of a kind including a layered assembly of a plurality
of plies of flexible moldable material said layered assembly
generally defining bra regions of two molded breast cups, a bridge
intermediate of said two breast cups and a chest band from which
each of said molded breast cups are disposed, said method
including, locating a rigid substrate intermediate of a. a chest
band region located region of a first of said plies (herein after
"outward ply") of a fabric material presenting a first outermost
surface of said bra to the convex side of the breast cups of said
bra, and b. a chest band region located region of at least one
other of said plies (herein after "inward ply") disposed to the
opposite side of said assembly where said first outermost ply is
presented, presenting a second outermost surface of said bra to the
concave side of said breast cups of said bra, said substrate
providing part of its perimeter immediately adjacent the edge of
said chest band where said hem is to be formed to define a rigid
edge for the folding there over of a hem region of said outward ply
to engage said outward ply to the inward ply, and removing the
rigid substrate from between said inward and outward plies.
14. A method as claimed in claim 13 wherein said outward ply is
engaged to said inward ply by adhesion bonding at said hem
region.
15. A method as claimed in claim 13 wherein said hem region of said
outward ply is engaged to said inward ply by the use of an
intermediate adhesive tape.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to improvements to a bra and
related methods of its construction.
BACKGROUND TO THE INVENTION
[0002] Bras of a kind which are made from a plurality of layers or
plies of material which have been subjected to molding and trimming
are known. Molded bras offer the benefit of convenient construction
since the materials used, lend themselves conveniently to the
introduction of a three dimensional cup shape to define the breast
cups of a bra by a molding device. Such a device is normally a
molding press having appropriately shaped mold portions (an upper
and lower mold portion) intermediate of which a pre-form planar ply
or assembly of plies of materials can be placed whereupon the
molding press can then introduce the three dimensional shape into
the plies.
[0003] This process avoids the time consuming steps of creating a
three dimensional cup form by the more traditional method of
stitching together a plurality of panels of material, each cut to
an appropriate perimeter shape. Whilst speed of production is an
important factor to the manufactures of such bras, aesthetics and
comfort factors are also important as these will distinguish the
final product from competing products, at the point of sale.
[0004] Some of the materials used in the known molded forms of
bras, lend themselves to being subjected to heat (and/or adhesive)
to allow for such materials to be bonded to other material of the
bra. This allows for an assembly of plies of material of a bra to
be laminated together. It has however been an issue in respect of
bras of the molded kind, to ensure that the perimeter of the bra is
capable of being defined in a robust manner. More often than not
the perimeter of a bra includes stitching or overlooking to ensure
that the perimeter remains in tact and is not subjected to fraying
over a reasonable life span of the bra.
[0005] Stitching or overlooking can be a time consuming step in the
manufacturing of a bra. It also requires accuracy in the stitch
line in order for the appearance of the bra to remain attractive.
Furthermore stitching can be prone to becoming undone or damaged
resulting in the integrity of the perimeter of the bra being
affected. The stitching itself and the material of the bra
immediately adjacent to the stitching can also cause comfort issues
to the wearer of a bra. Discomfort to a wearer is an undesirable
result of a bra.
[0006] Accordingly it is an object of the present invention to
provide a bra which addresses the abovementioned disadvantages or
which will at least provide the public with a useful choice.
[0007] It is also an object of the present invention to provide a
method of manufacturing a bra which results in a bra which
addresses the abovementioned disadvantages or which will at least
provide the public with a useful choice.
BRIEF DESCRIPTION OF THE INVENTION
[0008] Accordingly in a first aspect the present invention consists
in a molded bra defined in part by a layered assembly of a
plurality of plies of flexible moldable material, said layered
assembly generally defining bra regions of two molded breast cups a
bridge intermediate of said two breast cups and a chest band from
which each of said molded breast cups are disposed, said assembly
including
[0009] a. a first of said plies (herein after "outward ply") of a
fabric material presenting a first outermost surface of said bra to
the convex side of the breast cups of said bra, and
[0010] b. at least one other of said plies (herein after "inward
ply") disposed to the opposite side of said assembly where said
outward ply is presented, presenting a second outermost surface of
said bra to the concave side of said breast cups of said bra
[0011] wherein the layered assembly includes at least the inward
and outward ply at the entire perimeter about the bra regions and
wherein said outward ply has been folded at the perimeter to
provide a hem thereof affixed to the inward ply.
[0012] Preferably said hem of said outward ply is adhesively
affixed to said inward ply.
[0013] Preferably the hem is provided about the entire perimeter
about said bra regions.
[0014] Preferably said perimeter of said bra regions generally
consists of (a) a lower perimeter extending along the bottom edge
of said chest band, (b) an outer perimeter extending along the
upper edge of at least the regions inward of the distal ends of the
chest band and transitioning to extend adjacent or along the outer
perimeter edges of each of said breast cups, and (c) a neckline
perimeter extending along the upper edges of each of said breast
cups.
[0015] Preferably the outward ply is parallel to but not laminated
with the plies of the remained of the assembly, save for at said
hem.
[0016] Preferably the assembly, at each of the breast cups includes
at least one ply of a foam material.
[0017] Preferably the foam material provides a flexibly rigid cup
form.
[0018] Preferably the chest band, at least at regions extending
inwardly from the distal ends towards said breast cups, includes no
foam plies.
[0019] Preferably the chest band includes no foam plies.
[0020] Preferably said outward ply and said inward ply are
coextensive with each other.
[0021] Preferably said inward ply is of a single piece of
material.
[0022] Preferably said inward ply is of a single piece of fabric
material.
[0023] In a further aspect the present invention consists in a
method of forming a hem at a perimeter of part of a chest band of a
bra of a kind including a layered assembly of a plurality of plies
of flexible moldable material said layered assembly generally
defining bra regions of two molded breast cups, a bridge
intermediate of said two breast cups and a chest band from which
each of said molded breast cups are disposed, said method
including, locating a rigid substrate intermediate of
[0024] a. a chest band region located region of a first of said
plies (herein after "outward ply") of a fabric material presenting
a first outermost surface of said bra to the convex side of the
breast cups of said bra, and
[0025] b. a chest band region located region of at least one other
of said plies (herein after "inward ply") disposed to the opposite
side of said assembly where said first outermost ply is presented,
presenting a second outermost surface of said bra to the concave
side of said breast cups of said bra,
[0026] said substrate providing part of its perimeter immediately
adjacent the edge of said chest band where said hem is to be formed
to define a rigid edge for the folding there over of a hem region
of said outward ply to engage said outward ply to the inward ply,
and removing the rigid substrate from between said inward and
outward plies.
[0027] Preferably said outward ply is engaged to said inward ply by
adhesion bonding at said hem region.
[0028] Preferably said hem region of said outward ply is engaged to
said inward ply by the use of an intermediate adhesive tape.
[0029] 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. For the purposes of illustrating the
invention, there is shown in the drawings a form which is presently
preferred. It is being understood however that this invention is
not limited to the precise arrangements shown.
[0030] A preferred form and methodologies of the present invention
will now be described with reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The present invention may be considered to consist in the
foregoing and examples of which have been described with reference
to the accompanying drawings in which:
[0032] FIG. 1 is a perspective view of a bra of the present
invention,
[0033] FIG. 2 is a perspective view of a pre-form assembly of plies
of material used to define the cup formed core of the bra,
[0034] FIG. 3 is a side view of a molding press intermediate of
which the assembly of plies of FIG. 2 is positioned prior to such
being molded by the molding press,
[0035] FIG. 4 is a plan view of an assembly of plies as for example
shown in FIG. 2 wherein a molding press as per FIG. 3 has
introduced two cup forms,
[0036] FIG. 5 is a sectional view through the molded assembly of
plies of FIG. 2 illustrating the application of an adhesive to at
least part of one side of the molded assembly of plies,
[0037] FIG. 6 is a side view of a molding press illustrating the
molded assembly of plies of FIG. 5, an underwire assembly and a
further layer of material prior to all such being molded by the
molding press as shown in FIG. 6,
[0038] FIG. 7 is a plan view of an underwire assembly,
[0039] FIG. 8 is a sectional view through Section AA of FIG. 7,
[0040] FIG. 9 is a plan view of the molded assembly of plies shown
in FIG. 6 wherein the assembly of plies of FIG. 5, the underwire
assembly and the additional layer of material have been molded and
laminated together by the molding press of FIG. 6,
[0041] FIG. 10 illustrates the cutting of the cup formed core
assembly of materials from the excess material shown in FIG. 9,
[0042] FIG. 11 is a plan view of two mirror imaged cup formed core
assemblies of components,
[0043] FIG. 12 illustrates the core assembly of components of FIG.
11 located onto a lower molding press component and supported on
top of a ply of fabric material with which the core cup assembly of
components of FIG. 11 are to be laminated,
[0044] FIG. 13 is a sectional view through a vertical plane of the
assembly of materials of FIG. 13 after having been molded,
illustrating the core cup assembly components of FIG. 11 laminated
with the ply of fabric material,
[0045] FIG. 14 illustrates the introduction to the laminated
assembly of FIG. 13, a layer of a heat resistant material important
to be incorporated into the bra during its subsequent manufacturing
steps but which is preferably later removed from the components of
the bra,
[0046] FIG. 15 is a plan view of the laminated assembly of FIG. 13
and illustrating the heat resistant material shown in cross section
in FIG. 14,
[0047] FIG. 16 illustrates the perimeter cutting of the assembly of
laminated materials of FIG. 13 to be cut to the approximate
perimeter shape of the final form of half of the bra,
[0048] FIG. 17 illustrates the excess material (in particular the
ply of fabric material shown in FIG. 12 and FIG. 15) having in part
been trimmed away from the assembly of plies which in part define
the approximate perimeter of the bra as shown in FIG. 1,
[0049] FIG. 18 illustrates the bonding of two components of and
currently as shown in FIG. 17 together to thereby define an
approximate perimeter shape of the two components being bonded
together by the bridging element intermediate of the components of
an approximate shape of the perimeter of the bra shown in FIG.
1,
[0050] FIG. 19 illustrates a sectional view of part of the chest
band of the assembly of plies of FIG. 18 illustrating the
application of a catch to the distal end of the chest band,
[0051] FIG. 20 is a plan view of the assembly of plies of FIG. 18
including the application of the fastening means,
[0052] FIG. 21 is a plan view of a template used in the steps of
the manufacture of the bra of the present invention and described
in more detail hereinafter,
[0053] FIG. 22 illustrates the application of a tape like material
to the template of FIG. 21 about the base and side perimeter
regions of the perimeter shape of the bra drawn on the template and
wherein no such tape is applied to the neckline region of the bra
illustrated on the template of FIG. 21,
[0054] FIG. 23 illustrates a press to laminate the tape applied to
the template of FIG. 21 to a ply of fabric material,
[0055] FIG. 24 illustrates the tape of FIG. 22 having been
transferred to the ply of fabric material by the press of FIG.
23,
[0056] FIG. 25 illustrates the ply of fabric material having been
trimmed along its lower and outer perimeter regions but not along
the regions to define the neckline perimeter of the bra,
[0057] FIG. 26 illustrates a molding device or press to introduce
cup forms into the ply of fabric material of FIG. 25,
[0058] FIG. 27 illustrates part of the ply of fabric material of
FIG. 25 into which cup shaped relief has been introduced,
[0059] FIG. 28 illustrates the end of the chest band to be provided
regions of the ply of fabric material of FIG. 25 into which
apertures are provided to correspond with the fastening elements of
the fasteners engaged to the end of the chest band regions of the
assembly of materials of FIG. 21,
[0060] FIG. 29 illustrates the ply of fabric material of FIG. 25
and the assembly of materials of FIG. 21 prior to their being
laminated together,
[0061] FIG. 30 is a sectional view through the assembly of FIG.
29,
[0062] FIG. 31 illustrates the assembly of the fabric ply of FIGS.
30 and 25 engaged with the assembly of FIG. 21 wherein the lower
and outer perimeter regions of the ply of fabric material of FIG.
25 have been folded over the lower and outer perimeter regions of
the assembly of FIG. 21 and the tape has been relied on for
adhering these perimeter regions of the ply of fabric material of
25 to the inside of the assembly of materials of FIG. 21,
[0063] FIG. 32 illustrates the assembly of materials of FIG. 31 but
wherein the outer ply of fabric material has been peeled back from
the core assembly of materials to expose the core cup formed
assemblies,
[0064] FIG. 33 illustrates the trimming of the excess material of
the outer ply of fabric at the neckline,
[0065] FIG. 34 is a sectional view through section BB of FIG.
33,
[0066] FIG. 35 illustrates the neckline perimeter fold of the
breast cup, and
[0067] FIG. 36 illustrates a back view of the bra in its final
form.
DETAILED DESCRIPTION OF THE INVENTION
[0068] With reference to the accompanying drawings there is shown
in FIG. 1, a bra 1 which has been manufactured according to the
methodology as hereinafter described. The bra generally consists of
a cup region 2 incorporating two breast cups 3, 4 from which there
is disposed a chest band region 5 which may include clasps 6 and
between which there is disposed over the shoulder straps 7. With
reference to FIG. 36 which is a view of the bra of FIG. 1 but from
the opposite side, there is shown a perimeter fold over or hem 8
(hereinafter referred to as a "hem") about substantially all of the
perimeter region of the bra (save for the over the shoulder straps
7). The hem is formed by the folding of part of the exterior most
ply 9 of the bra (disposed to the convex side of the breast cups
and on the same side thereof to the chest band region 5). The
exterior most ply 9 has been folded over the remaining ply or plies
of material of the bra about substantially all of the perimeter of
the bra as for example shown in FIG. 36. The hem has been created
by such folding and by an adhesive or weld affixing of that part of
the exterior most ply 9 to the interior side of the bra. No
stitching is involved in the securing of the exterior most ply 9 to
define the hem 8. As a result the breast cup and chest band region
of the bra 1 can be formed without the need for stitching to be
introduced to secure the various components of the bra together to
define the bra as for example shown in FIG. 1. Introduction of
stitching to a bra can result in the bra being expensive to
manufacture (i.e. time consuming to make) and may at a later stage
result in a degradation of the integrity of the bra as a result of
the stitching becoming undone. Stitching can also cause discomfort
to the wearer of the bra.
[0069] The fully assembled bra of the present invention is of a
kind which incorporates a ply or plies of foam material within the
breast cups 3, 4 but which does not include such foam materials
within at least a substantial part of the chest band region 5.
Preferred construction details of the bra of FIGS. 1 and 36 will
hereinafter be described in conjunction with the explanation of the
preferred methodology for the manufacture of the bra.
[0070] The hem 8 is preferably only of a width W sufficient to
securely and permanently engage the exterior most ply 9 of the bra
to the inside face of the bra. The hem may for example be between
4-12 mm in width. It preferably extends along the perimeter of the
bra which may be defined as the outer perimeter line 10, the lower
perimeter line 11 and the neckline perimeter 12 of the bra. Indeed
the hem 8 is preferably continuous across the entire neckline 12
for both breast cups 3, 4 extending over the bridge region 14
between the adjacent breast cups 3, 4.
[0071] For further details of the assembly of preferred materials
to define the bra of the present invention reference will now be
made to the preferred method of its manufacture.
[0072] With reference to FIG. 2 there is shown a precursor assembly
of plies of material (the precursor core assembly 15). The
precursor core assembly 15 preferably consists of a foam ply 16
laminated to a fabric ply 17. Such lamination may have occurred by
heat welding and/or by adhesive. The precursor core assembly is
introduced into a molding press consisting of a male mold portion
18 and a female mold portion 19 as for example shown in FIG. 3. The
male and female mold portions 18, 19 include complimentary shaped
relief of a kind which is of a breast cup shaped form. The
precursor core assembly 15 is subjected to pressure and preferably
heat by the male and female mold portions 18, 19 to introduce a
breast cup form into the precursor core assembly 15. The precursor
core assembly 15 is placed relative to the molding press so that
the fabric ply 17 is disposed to the convex side of the cup form to
be molded into the precursor core assembly 15. The foam ply of the
precursor core assembly is preferably of a thickness of for example
9 mm and may for example be a polyurethane or memory foam. The
fabric ply 17 is preferably of a material such as nylon or spandex.
The precursor core assembly 15 may include further plies of
material disposed to either or both of the foam and fabric plies
16, 17. With reference to FIG. 4 there is shown the molded form of
the precursor core assembly 15 into which two breast cup forms 20
have been introduced. The molding press of FIG. 3 may include two
complimentary shaped surface relief features in its male and female
mold portions 18, 19 to introduce into a single precursor core
assembly 15 as for example shown in FIG. 4 the breast cup forms 20
are substantially of a mirror image shape. The then molded
precursor core assembly 15A (whether the breast cup forms 20 are
cut from the remainder of the material or before such cutting
occurs) is subjected to the application of an adhesive. Such an
adhesive may be spray applied via a spray nozzle 21 to apply
adhesive to at least the breast cup forms 20 of the then molded
precursor core assembly 15A. This adhesive is applied to the
concave side of the breast cup forms. The purpose of the
application of the adhesive is to allow for lamination of further
components of the bra to the breast cup forms 20. With reference to
FIG. 6 there is illustrated a molding press consisting of a male
mold portion 22 and female mold portion 23. Laminated to the then
molded precursor core assembly 15A is a further ply of material
such as a second foam ply 24. This second foam ply 24 may include
further plies of material pre-laminated therewith but in the
preferred form is only a single ply of material. However any such
additional plies of material may include a further fabric ply
either to the upper or lower side of the second foam ply 24. This
lamination allows the formation of a cup form which is structurally
consistent in shape.
[0073] Captured between the second foam ply 24 (and any other plies
that may be associated therewith) is preferably an underwire
assembly 25. The underwire assembly 25 is shown in plan view in
FIG. 7 and in sectional view in FIG. 8. The underwire assembly
preferably consists of a sock of material 26 within which there is
located a flexible but rigid elongate member 27 such as a plastic
or metal wire. The underwire assembly 25 is of a curved plan shape.
It is located intermediate of the second foam ply 24 and the then
molded precursor core assembly 15A at a location corresponding to
the breast cup form 20 being the lower region of the breast cup
form where such an underwire assembly 25 would normally be provided
as part of a bra. Molding of the components (as shown in FIG. 6 by
the molding press) may require the application of heat over a
sufficient dwell time to ensure that a lamination of the components
occurs. FIG. 9 illustrates the then assembled laminated and molded
components of FIG. 6.
[0074] The excess material of the then molded precursor core
assembly 15A and the then molded and laminated second foam ply 24
may then be cut to be removed from the breast cup form 20 to define
the assembly as shown in FIG. 11. The assembly of FIG. 11 is the
breast cup core assembly 28. FIG. 11 illustrates two breast cup
core assemblies 28 being a mirror image of each other each to be
incorporated into other components to form a bra of the present
invention. The breast cup core assembly includes a breast cup form
20 and may also include a flange 29 extending for example about the
lower and outer perimeter regions of the breast cup core assembly.
The breast cup core assembly includes a lower perimeter region 30,
outer perimeter region 31 and neckline perimeter region 32. The
core assembly may be of varying thickness.
[0075] The next step in the manufacture of the bra of the present
invention is to take one or for example both breast cup core
assemblies 28 and laminate to their concave side, a ply of fabric
material (the interior most ply 33). With reference to FIG. 12,
there can be seen part of a mold press including a perimeter frame
34 to hold the interior most ply 33 onto a male molding portion
which includes male surface relief corresponding substantially to
the breast cup form or forms of the breast cup core assemblies 28
placed thereon. An upper female relief molding portion of the
molding press in part shown in FIG. 12 (the upper portion not being
shown) can then apply heat and pressure to the breast cup core
assembly or assemblies 28 to press these and laminate these with
the interior most ply 33. In one form the interior most ply 33 may
be molded and laminated to a breast cup core assembly 28
individually or simultaneously. The simultaneous lamination is for
example demonstrated with reference to FIG. 12.
[0076] The interior most ply 33 is preferably of a material such as
nylon or spandex.
[0077] A vertical cross section through the then molded assembly of
the breast cup core assemblies 28 and the interior most ply 33 is
for example shown in FIG. 13. The interior most ply 33 is of a size
sufficient to also allow for part of the interior most ply 33 to
define part of the chest band region 5 of the bra.
[0078] At this stage a wing shaped heat resistant panel (heat
resistant wing panel 35) may be placed onto the interior most ply
33 and in part over the flange 29. The heat resistant wing panel 35
is preferably of a plan shape corresponding to the wing portion of
the chest band region 5 of the bra. It is positioned onto the
interior most ply 33 in a location where the chest band region 5 of
the bra is to be provided in part by the interior most ply 33. The
heat resistant wing panel is placed onto the same side of the
interior most ply 33 as where the breast cup core assembly 28 is
provided. The heat resistant wing panel 35 is provided to prevent
any bonding of any other of the layers of the bra provided at this
region to the interior most ply 33 on that side thereof where the
heat resistant wing panel 35 is located.
[0079] The heat resistant wing panel 35 is made from a heat
resistant material which is of a kind which may be transparent and
non-elastic. It may for example be a plastic film material with
some integral rigidity. It is preferably slightly sticky or
adhesive on one side (that side to engage with the interior most
ply 33) and not adhesive on the other side. The plastic material
will not melt below a temperature of for example 180 degrees
Celsius. As this temperature will not be reached during the process
of manufacturing of the bra, the heat resistant material will not
permanently bond with the plies of material immediately adjacent
thereto. As will be explained further on, this material will be
removed from the bra by hand but is provided for the purposes of
allowing more convenient working of the material for the subsequent
steps of the manufacturing of the bra.
[0080] The interior most ply 33 may then be trimmed by for example
a scissors to cutaway excess material of the interior most ply 33
by cutting along the perimeter line of the heat resistant wing
panel 35 and at least part of the perimeter of the breast cup core
assembly. Such cutting is for example demonstrated in FIG. 16.
[0081] The result of such cutting may define an assembly as for
example shown in FIG. 17. The assembly of FIG. 17 is to engage with
a mirror image and like assembly at the bridge region 14 of the
bra. However in an alternative form creating such bridging may not
necessarily need to be an additional step and the interior most ply
33 may remain joined at the bridge region with a like assembly. It
may be that both breast cups are laminated to an interior most ply
33 and remain engaged together rather than separating as herein
described. However where separated the assembly 36 is engaged to a
like assembly as for example shown in FIG. 18. Such engagement is
by connecting the interior most plies 33 of each of the assemblies
36 together and/or by the provision of a bridging panel 37 to bond
the two assemblies 36 together in a condition to dispose the breast
cup core assemblies 28 in an appropriate location for their use
subsequently as part of the bra. The bridging panel 37 may be of a
flexible but non-stretch material to ensure that the breast cup
core assemblies 28 cannot move outwardly from each other.
[0082] From here the next step is preferably to apply the clasps or
catches or taches to the distal ends of the interior most ply 33 of
the bra. Preferably the clasps 38 are adhered by an adhesive and/or
heat and/or ultrasonic welding to the interior most ply 33. As can
be seen with reference to FIG. 19 the clasps 38 are not affixed to
the heat resistant wing panel 35. On one of the distal ends of the
chest band region 5 of the interior most ply 33 the clasp is
provided to the same side of the interior most ply 33 as the heat
resistant wing panel 35.
[0083] The next stage in the method of manufacturing the bra of the
present invention is to prepare the exterior most ply for the
bra.
[0084] Whilst reference herein has been made to the interior most
ply and the exterior most ply, the terms interior and exterior in
this regard relate to the plies of material which are outermost on
the bra. Reference to the interior most ply is not a ply located
within the assembly of materials but is the ply of material which
is to be adjacent most the body of the wearer. The outer most ply
is the ply of material of the assembly of the bra which in a
substantial part, is distal most from the body of the wearer.
[0085] Preparation of the exterior most ply 9 involves the use of a
template 40. The template 40 may for example be a substrate of a
paper or card like material. Drawn or depicted on the template 40
is an outline of at least the lower perimeter line 11 and outer
perimeter line 10 of the final form of the bra. This is as for
example shown in FIG. 21. A margin 41 may be drawn about the outer
and lower perimeter lines 10, 11 drawn on the template 40. The
margin is preferably of a width of a tape 42 to be applied to the
template 40 outwardly and immediately adjacent the outer and lower
perimeter lines 10, 11. The tape 42 is applied to the margin drawn
on the template 40 to follow the outer and lower perimeter lines
10, 11. Such tape is not provided to a region of the template
corresponding to the neckline perimeter 12 of the bra. The tape 42
preferably consists of multiple layers and indeed such multiple
layers may be applied simultaneously or sequentially. Essentially
the tape 42 consists of a first layer of material to be applied
directly to the template. It is a heat resistant plaster 43.
[0086] This material is sticky on the side facing the template 40
so that it can adhere to the template 40. Applied over the heat
resistant plaster 43 is an assembly of layers the first consisting
of an adhesive coated tape and the second band of elastic material.
The adhesive coated tape is provided at the assembly of this
additional layer of tape away from the heat resistant plaster 43.
The band of elastic material is provided to adhere to the heat
resistant plaster 43. This may be by a suitable adhesive which can
result in the sticking of this additional assembly of tape to the
heat resistant plaster yet be able to be removed therefrom at a
later stage. Glue is applied on the non-sticky side of the heat
resistant material so that the elastic band can temporarily stay on
the heat resistant material. One side of the adhesive coated tape
is sticking on the elastic band. The whole of the template 40 (with
the heat resistant plaster, the elastic band and the adhesive
coated tape on top of it) is then placed on the thermal pressing
machine as is shown in part in FIG. 23 (operating at around 120
degrees Celsius). The exterior most ply 9 is then placed on top of
the template 40.
[0087] The tape is of a kind which is adhesive on each side. The
adhesive applied on both sides of the tape will melt when heated
during the process of the manufacture of this bra enabling two
plies of material of the bra to be bonded together by the adhesive
coated tape. The adhesive coated tape is preferably also slightly
elastic and can therefore provide mild elasticity to the material
that is bonded. One example of an adhesive coated tape of this kind
will result in the adhesive melting slightly at around 120 degrees
Celsius. However at around 150 to 160 degrees Celsius the adhesive
will completely melt and provide strongest adhesion ability.
Normally the adhesive coated tape is supplied from the manufacture
where one side of the tape is pre-covered with a non-stick paper
which is peeled away for the purpose of exposing the adhesive
coated tape for subsequent heat bonding.
[0088] The elastic band with which the adhesive coated tape is
engaged, is of a kind which may for example be one commonly used in
garments or bras. The adhesive tape on both sides of the elastic
band allows the exterior most ply to be attached to the interior
most ply with the elastic band between the two plies along the
perimeter of the bra. No stitching is required to affix the elastic
band in the bra.
[0089] With reference to FIG. 23 there is shown a sectional view of
a heating press illustrating the template 40 onto which there is
provided the heat resistant plaster 43 and the assembly of plies of
tape 44 consisting of the adhesive coated tape and the elastic
band. The adhesive coated tape is here provided intermediate of the
exterior most ply and the elastic band. Also shown is a ply of
fabric material being that which defines the exterior most ply 9.
The press consisting of a lower press portion 45 and an upper press
portion 46 can apply pressure to the exterior most ply 9 for it to
be pressed against the template 40. With the application of heat
and sufficient dwell time, a bonding of the adhesive coated tape to
the exterior most ply 9 will occur. The transfer is as for example
shown in FIG. 24 where the exterior most ply 9 has transferred onto
it the assembly 44 at locations corresponding to the outer and
lower perimeter lines 10 and 11.
[0090] The exterior most ply 9 may be of a material such as nylon
or spandex or lycra.
[0091] The exterior most ply 9 is thereafter trimmed about the tape
portions now present (being the second adhesive coating over the
elastic band and the then bonded adhesive coating between the
elastic band and the fabric) to the outer and lower perimeter line
disposed regions thereof. Prior to the application of the exterior
most ply 9 to the other components of the bra, the exterior most
ply 9 has introduced therein, molded relief provided by a molding
device of a kind as for example shown in FIG. 26. The exterior most
ply 9 is clamped between two plates 47-48 which includes two
apertures 49 to allow the penetration through each of the apertures
49 of molding bullets 50. These molding bullets 50 penetrate
through the apertures 49 to an extent as required to introduce into
the exterior most ply 9 molded relief Such relief corresponds to
and to allow for the exterior most ply 9 to then be engaged to the
other components with the breast cup forms. The molded relief 51 is
shown in a non-form defining manner in FIG. 27. The molding bullets
50 are preferably heated to a suitable temperature and in
combination with a dwell time, ensure that a permanent deformation
of the exterior most ply 9 occurs at the regions thereof to
correspond with the breast cup forms.
[0092] At some stage the exterior most ply 9 may have introduced
therewith apertures 58 at a region of the exterior most ply 9 to
correspond with the distal ends of the chest band region 5. The
assembly 36 and the then molded and in part trimmed exterior most
ply 9A as shown in FIGS. 29 and 30 are affixed together. Such
affixing is such that the exterior most ply 9A is positioned to the
convex side of the assembly 36. The exterior most ply 9 is provided
to the convex side of the assembly 36 with the tape 42 provided on
that side of the exterior most ply facing the assembly 36. Such a
relationship is for example shown in FIG. 30. The positioning of
the exterior most ply 9 to the assembly 36 is such that the tape
applied perimeter or perimeters of the exterior most ply 9 fall
outside of the corresponding perimeter of the assembly 36. As a
result the tape applied perimeter of the exterior most ply 9A can
be manipulated to fold about the adjacent perimeter of the assembly
36. It is such folding and subsequent application of pressure and
heat to the perimeter of the exterior most ply at where the tape 42
is applied which will result in an affixing of the assembly 36 with
the exterior most ply 9A.
[0093] With reference to FIG. 31, there is shown a part of the bra
of the present invention wherein the exterior most ply 9 has had
its tape 42 carrying hem 8 (not shown) folded over the outer and
lower perimeter lines 10 and 11 of the assembly 36. In addition to
the folding a heating of the hem and application of pressure has
occurred by for example an iron which activates the tape 42 (in
fact the adhesive coated tape thereof) to bond the hem portion of
the exterior most ply 9 to the interior most ply 33 of the assembly
36. With sufficient pressure and heat and dwell time (the heat
being in the vicinity of 150 degrees Celsius) strong bonding of the
hem 8 of the exterior most ply 9 will occur to the interior most
ply 33 at the outer and lower perimeter lines 10, 11.
[0094] No bonding of the exterior most ply 9 occurs with other
regions of the assembly 36 at this stage. As such the exterior most
ply 9 can be peeled back from the assembly 36 as for example shown
in FIG. 32. Such partial peeling away of the exterior most ply 9 at
least from the core assembly proximate region of the assembly 36
will allow for an exposure of the heat resistant wing panels 35 to
occur. Since the heat resistant wing panels 35 are not permanently
bonded to any of the bra, such exposure will allow for the heat
resistant wing panels 35 to be removed. Pulling out of the cavity
defined between the exterior most ply 9 and the assembly 36 at the
wing regions of the chest band region 5 will allow for the heat
resistant wing panel 35 to be removed. Since the wing regions of
the chest band region 5 are suitably tapered, such removal can
occur quite conveniently.
[0095] Since the wing regions of the chest band 5 do not
incorporate any material of significant rigidity (i.e. they
preferably do not incorporate any foam material) it would be
difficult to manipulate the wing panel regions of the various plies
of material of the bra for the purposes of the steps of assembly of
the bra. It is for this reason that the heat resistant wing panel
35 is employed during the assembly of the present invention. The
heat resistant wing panel is of a material which although flexible
has some structural rigidity. Such structural rigidity allows for
the outer perimeter line 10 and lower perimeter line 11 at the wing
regions of the bra to be and remain clearly defined. It also
provides a significantly rigid edge along the part of the outer and
lower perimeter lines 10, 11 of the bra at the wing region of the
chest band region 5 for the purposes of allowing the folding of the
hem 8 and the bonding of the hem 8 to the interior most ply 33.
Without the heat resistant wing panel 35 being provided during the
assembly of the bra it would make it very difficult to accurately
define the outer and lower perimeter line at the chest band region
of the bra. This is not so for the perimeter defined by the breast
cups since these consist of a number of layers which create a more
rigid edge for the exterior most ply to fold about. It will also
make it difficult for the hem to be folded about the outer and
lower perimeter line defined by the assembly 36. The assembly 36
without the heat resistant wing panel 35 would not provide an edge
for the folding of the hem 8 thereabout which is sufficiently
defined and rigid for such purposes of folding.
[0096] However it is undesirable for the heat resistant wing panel
to remain with the bra after its assembly. As such there is a need
for the wing panel to be able to be exposed for its removal. It is
for this region that the neckline perimeter of the bra is also not
simultaneously bonded at its hemline when the outer and lower
perimeter line disposed hem 8 of the exterior most plies are
affixed. A subsequent affixing of the hem 8 at the neckline of the
breast cup forms allows prior to such affixing, the removal of the
heat resistant wing panel.
[0097] However as mentioned earlier in the specification it is
desirable that substantially the entire perimeter of the bra has a
hem provided. As such, once the heat resistant wing panel has been
removed it is then possible for the hem 8 at the neckline perimeter
12 of the bra to be affixed. A trimming of excess material of the
exterior most ply 9 can occur to follow substantially the neckline
perimeter of the assembly 36. However again a margin beyond the
neckline perimeter 12A of the assembly 36 may be provided to the
neckline edge 12B of the exterior most ply 9. This margin is
preferably the same as the margin of the hem 8 to be provided at
the neckline perimeter of the bra. A material like that of the tape
42 which is or includes the adhesive coated tape can be applied to
the neckline perimeter 12B of the exterior most ply for its
subsequent folding of the hem 8 of the exterior most ply 9 about
the neckline perimeter 12A of the assembly 36. The application of
the adhesive coated tape to the hem region 8 of the exterior most
ply 9 at the neckline perimeter may also include the application of
an elastic band like that incorporated in the outer and lower
perimeter lines 10 and 11 of the bra.
[0098] A further reason for not applying any adhesive coated tape
to the neckline perimeter of the exterior most ply prior to the
exterior most ply having been molded by the bullet molder, is that
the neckline perimeter would be very proximate to the regions of
the exterior most ply 9 at where the surface relief is molded into
the exterior most ply 9 by the bullet molder. As such the neckline
perimeter of region of the exterior most ply during such molding
will be subjected to heat and if an adhesive coated tape were
applied at this point in time the effectiveness of the adhesive
coated tape for subsequent use may be affected.
[0099] A pre-folded condition is as for example shown in FIG. 34
whereas a subsequently folded condition is shown in FIG. 35. Such
folding and bonding of the hem at the neck perimeter line 12 may
include the use of an iron or a device to apply heat and pressure
for the purposes of activating the adhesive coating tape for the
bonding of the hem 8 at this region. A further advantage that is
obtained from a subsequently defined hem 8 at the neckline
perimeter 12 of the bra is that any variations, deviations or
inaccuracies in the location of the exterior most ply 9 to the
assembly 36 can be taken into consideration at the subsequent
trimming of the neckline perimeter region of the exterior most ply
9. Such subsequent trimming can ensure that a taught exterior most
ply 9 is provided over the assembly 36 of the bra. Were the
neckline perimeter 12 of the exterior most ply 9 trimmed at the
stage where the exterior most ply 9 has its outer perimeter line 10
and lower perimeter line 11 trimmed (see FIG. 25) any manufacturing
deviations may then not have been able to be taken into account.
However once the substantial part of the hem 8 has been formed at
the outer and lower perimeter lines 10, 11 any such variations can
be accounted for at the trimming stage of the exterior most ply 9
to define its neckline perimeter 12B.
* * * * *