U.S. patent application number 11/479572 was filed with the patent office on 2007-01-04 for brassiere.
Invention is credited to Zhen Qiang Liu, Theone Luk.
Application Number | 20070004315 11/479572 |
Document ID | / |
Family ID | 38544024 |
Filed Date | 2007-01-04 |
United States Patent
Application |
20070004315 |
Kind Code |
A1 |
Luk; Theone ; et
al. |
January 4, 2007 |
Brassiere
Abstract
A molded brassiere having a core of a first foam layer and a
second foam layer laminated to each other with underwire
interposed. An outer fabric layer extends beyond the core forming
at least part of the chest bands. The bridge between the cups
optionally includes a flexible non-stretchable material.
Inventors: |
Luk; Theone; (Kwai Chung,
HK) ; Liu; Zhen Qiang; (Kwai Chung, HK) |
Correspondence
Address: |
OSTROLENK FABER GERB & SOFFEN
1180 AVENUE OF THE AMERICAS
NEW YORK
NY
100368403
US
|
Family ID: |
38544024 |
Appl. No.: |
11/479572 |
Filed: |
June 30, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10864255 |
Jun 8, 2004 |
|
|
|
11479572 |
Jun 30, 2006 |
|
|
|
10349514 |
Jan 21, 2003 |
6805610 |
|
|
10864255 |
Jun 8, 2004 |
|
|
|
Current U.S.
Class: |
450/39 |
Current CPC
Class: |
A41C 3/0014 20130101;
A41C 5/005 20130101; A41C 3/10 20130101; A41C 3/00 20130101 |
Class at
Publication: |
450/039 |
International
Class: |
A41C 3/00 20060101
A41C003/00 |
Claims
1. A brassiere comprising: a core defining at least two breast cups
of the brassiere, the core comprising a first layer of foam
material, a second layer of foam material that is substantially
laminated with the first layer of foam material, and an underwire
located between the first and second layers of foam material at or
adjacent the lower peripheral part of one or each of the two breast
cups; and a first and a second covering layer, each covering layer
comprising at least a fabric ply and each covering layer being
laminated with the core on a respective side of the core to encase
the core.
2. A brassiere as claimed in claim 1 wherein the core has been
subjected to molding to form the shape of the two breast cups.
3. A brassiere as claimed in claim 1 wherein the core does not
define any chest band of the brassiere.
4. A brassiere as claimed in claim 1 wherein one or each of the
first and second layers of foam material is a continuous layer
extending across the core.
5. A brassiere as claimed in claim 1 wherein the underwire
comprises a rigid elongate member and a channel encasing the rigid
elongate member.
6. A brassiere as claimed in claim 5 wherein the channel is a
fabric material.
7. A brassiere as claimed in claim 6 wherein the first and second
layers of foam material have mutually facing surfaces and the
channel is adhered to one or each of the facing surfaces of the
first and second layers of foam material by an adhesive.
8. A brassiere as claimed in claim 1 wherein the underwire is a
non-metallic strip.
9. A brassiere as claimed in claim 1 wherein the core has a
perimeter and one or each of the first and second covering layers
extends beyond at least a portion of the perimeter of the core to
form at least part of a chest band of the brassiere.
10. A brassiere as claimed in claim 1 wherein the first covering
layer comprises a fabric ply and a foam ply, the fabric ply and the
foam ply being laminated to each other.
11. A brassiere as claimed in claim 10 wherein a surface of the
core is laminated to the foam ply of the first covering layer.
12. A brassiere as claimed in claim 1 wherein the second layer of
foam material is laminated to the first layer of foam material by
an adhesive.
13. A brassiere as claimed in claim 1 wherein the core further
defines a bridge between the two breast cups, and wherein a
flexible and substantially non-stretchable panel of material is
located between the first and second layers of foam material and
laminated with one or each of the first and the second layers of
foam material at the bridge.
14. A brassiere as claimed in claim 1 wherein the core has a
perimeter and the brassiere further comprises an outermost layer
that is at a greater distance from the body of the wearer of the
brassiere than either of the first and the second covering layers,
the outermost layer extending beyond at least a portion of the
perimeter of the core to form at least part of a chest band of the
brassiere.
15. A brassiere as claimed in claim 14 wherein the brassiere has an
inner surface and the outermost layer has a perimeter, the
outermost layer being folded at at least a portion of its perimeter
to provide a hem affixed to at least a portion of the inner surface
of the brassiere.
16. A brassiere as claimed in claim 15 wherein the hem is affixed
to at least a portion of the perimeter region of the inner surface
of the brassiere.
17. A brassiere as claimed in claim 15 wherein one of the first and
second covering layers is at least part of the inner surface of the
brassiere.
18. A brassiere as claimed in claim 15 wherein the brassiere
further comprises a strip of fabric material that is affixed to at
least a portion of the hem and at least a portion of the inner
surface of the brassiere.
19. A brassiere as claimed in claim 14 wherein the outermost layer
includes a lace fabric.
20. A brassiere as claimed in claim 15 wherein the hem is affixed
adhesively to at least a portion of the inner surface of the
brassiere.
21. A brassiere as claimed in claim 14 wherein the outermost layer
is not laminated to at least one of the first and second covering
layers.
22. A brassiere as claimed in claim 1 wherein the core further
comprises a pouch located between the first and second layers of
foam material at or adjacent a lower portion of one or each of the
two breast cups, the pouch containing a material selected from one
of a liquid and a gel.
23. A brassiere as claimed in claim 22 wherein the pouch is
laminated to one or each of the first and second layers of foam
material.
24. A brassiere as claimed in claim 1 wherein the brassiere is
seamless.
25. A brassiere comprising: a core having a perimeter and defining
at least two molded breast cups of the brassiere, the core
comprising an outer layer of foam material, an inner layer of foam
material that is substantially laminated with the outer layer of
foam material, and an underwire interposed between the outer and
inner layers of foam material at or adjacent the lower peripheral
part of one or each of the two breast cups; an outer and an inner
covering layer, each covering layer comprising a fabric ply and a
foam ply which are substantially laminated to each other, the foam
ply of each covering layer being substantially laminated with the
core on a respective side of the core to encase the core; and
wherein one or each of the outer and inner covering layers extends
beyond at least a portion of the perimeter of the core to form at
least part of a chest band of the brassiere.
26. A brassiere as claimed in claim 25 wherein the core further
comprises a pouch located between the outer and inner layers of
foam material at or adjacent a lower portion of one or each of the
two breast cups, the pouch containing a material selected from one
of a liquid and a gel.
27. A brassiere as claimed in claim 25 wherein the brassiere
further comprises an outermost layer that is at a greater distance
from the body of the wearer of the brassiere than either of the
outer and the inner covering layers, the outermost layer extending
beyond at least a portion of the perimeter of the core to form at
least part of a chest band of the brassiere.
28. A brassiere as claimed in claim 25 wherein the brassiere is
seamless.
Description
PRIORITY CLAIM
[0001] This is a continuation-in-part of U.S. patent Ser. No.
10/864,255, filed Jun. 8, 2004, which is know U.S. Publication
Number US2004/0224604 published on Nov. 11, 2004, which is a
continuation-in-part of U.S. patent Ser. No. 10/349,514, filed Jan.
21, 2003, which is know U.S. Publication Number US 2004/0142633
published on Jul. 22, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to brassieres and in
particular to a brassiere which incorporates a seamless breast cup
construction and wherein an appealing outward appearance is
provided.
BACKGROUND TO THE INVENTION
[0003] Construction details of brassieres (hereinafter referred to
as "bras") have been developed over many years. Construction
details have evolved along with the introduction of new materials
and new processes which can be utilised for the manufacturing of
bras. As with most consumer products, manufacturers endeavour to
reduce the cost of goods sold. A reduction in cost of goods sold
can be brought about by the use of cheaper materials. For bra
technology however, a significant saving in the cost of a bra can
be achieved by eliminating the man-hours required to manufacture
the bra. Many bras that are available on the market will include
multiple panels of materials which need to be cut, and joined.
Cutting can be automated, however when it comes to stitching the
panels together, this will mostly be done by a person. The breast
cup of a bra may consist of multiple panels which each need to be
stitched together, the entire breast cup then needs to be stitched
to the chest band and to the over the shoulder straps. Perimeter
stitching or overlooking to ensure that the edges of the material
of the bra do not fray also needs to be added to the bra. Such is
also done by a person. It can hence be seen that in order to
manufacture a bra, the labour component of the overall cost can be
relatively high.
[0004] Bras that incorporate breast support pads are also known.
Such pads may be defined by foam pads incorporated within layers of
the bra so that they are not at the perimeter edges. This is a
disadvantage as it may provide a bra that is visually
unappealing.
[0005] Accordingly it is an object of the present invention to
provide a seamless breast cup construction which addresses the
above disadvantages or will at least provide the public with a
useful choice.
[0006] It is also an object of the present invention to provide a
method of manufacturing a seamless breast cup construction and
related bra incorporating such construction to reduce the labour
content of manufacturing of the bra or to at least provide the
public with a useful choice.
BRIEF DESCRIPTION OF THE INVENTION
[0007] Accordingly in a first aspect the present invention consists
in a brassiere comprising:
[0008] a core defining at least two breast cups of the brassiere,
the core comprising a first layer of foam material, a second layer
of foam material that is substantially laminated with the first
layer of foam material, and an underwire located between the first
and second layers of foam material at or adjacent the lower
peripheral part of one or each of the two breast cups; and
[0009] a first and a second covering layer, each covering layer
comprising at least a fabric ply and each covering layer being
laminated with the core on a respective side of the core to encase
the core.
[0010] Preferably the core has been subjected to molding to form
the shape of the two breast cups.
[0011] Preferably the core does not define any chest band of the
brassiere.
[0012] Preferably one or each of the first and second layers of
foam material is a continuous layer extending across the core.
[0013] Preferably the underwire comprises a rigid elongate member
and a channel encasing the rigid elongate member.
[0014] Preferably the channel is a fabric material.
[0015] Preferably the first and second layers of foam material have
mutually facing surfaces and the channel is adhered to one or each
of the facing surfaces of the first and second layers of foam
material by an adhesive.
[0016] Preferably the underwire is a non-metallic strip.
[0017] Preferably the core has a perimeter and one or each of the
first and second covering layers extends beyond at least a portion
of the perimeter of the core to form at least part of a chest band
of the brassiere.
[0018] Preferably the first covering layer comprises a fabric ply
and a foam ply, the fabric ply and the foam ply being laminated to
each other.
[0019] Preferably a surface of the core is laminated to the foam
ply of the first covering layer.
[0020] Preferably the second layer of foam material is laminated to
the first layer of foam material by an adhesive.
[0021] Preferably the core further defines a bridge between the two
breast cups, and wherein a flexible and substantially
non-stretchable panel of material is located between the first and
second layers of foam material and laminated with one or each of
the first and the second layers of foam material at the bridge.
[0022] Preferably the core has a perimeter and the brassiere
further comprises an outermost layer that is more away from the
body of the wearer of the brassiere than either of the first and
the second covering layers, the outermost layer extending beyond at
least a portion of the perimeter of the core to form at least part
of a chest band of the brassiere.
[0023] Preferably the brassiere has an inner surface and the
outermost layer has a perimeter, the outermost layer being folded
at at least a portion of its perimeter to provide a hem affixed to
at least a portion of the inner surface of the brassiere.
[0024] Preferably the hem is affixed to at least a portion of the
perimeter region of the inner surface of the brassiere.
[0025] Preferably one of the first and second covering layers is at
least part of the inner surface of the brassiere.
[0026] Preferably the brassiere further comprises a strip of fabric
material that is affixed to at least a portion of the hem and at
least a portion of the inner surface of the brassiere.
[0027] Preferably the outermost layer includes a lace fabric.
[0028] Preferably the hem is affixed adhesively to at least a
portion of the inner surface of the brassiere.
[0029] Preferably the outermost layer is not laminated to at least
one of the first and second covering layers.
[0030] Preferably the core further comprises a pouch located
between the first and second layers of foam material at or adjacent
a lower portion of one or each of the two breast cups, the pouch
containing a material selected from one of a liquid and a gel.
[0031] Preferably the pouch is laminated to one or each of the
first and second layers of foam material.
[0032] In a further aspect the present invention consists in a
brassiere comprising:
[0033] a core having a perimeter and defining at least two molded
breast cups of the brassiere, the core comprising an outer layer of
foam material, an inner layer of foam material that is
substantially laminated with the outer layer of foam material, and
an underwire interposed between the outer and inner layers of foam
material at or adjacent the lower peripheral part of one or each of
the two breast cups;
[0034] an outer and an inner covering layer, each covering layer
comprising a fabric ply and a foam ply which are substantially
laminated to each other, the foam ply of each covering layer being
substantially laminated with the core on a respective side of the
core to encase the core; and
[0035] wherein one or each of the outer and inner covering layers
extends beyond at least a portion of the perimeter of the core to
form at least part of a chest band of the brassiere.
[0036] Preferably the core further comprises a pouch located
between the outer and inner layers of foam material at or adjacent
a lower portion of one or each of the two breast cups, the pouch
containing a material selected from one of a liquid and a gel.
[0037] Preferably the brassiere further comprises an outermost
layer that is at a greater distance from the body of the wearer of
the brassiere than either of the outer and the inner covering
layers, the outermost layer extending beyond at least a portion of
the perimeter of the core to form at least part of a chest band of
the brassiere.
[0038] Preferably the brassiere is seamless.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] A preferred embodiment of the present invention will now be
described with reference to the accompanying figures.
[0040] FIG. 1 is a front view of a brassiere (hereinafter referred
to as a "bra") made in accordance to methods hereinafter
described,
[0041] FIG. 2 is a plan view of two layers of precursor material,
the upper being a foam material and the lower being a fabric
material to be laminated together,
[0042] FIG. 3 is a plan view of precursor layers of material, the
upper being a foam material and the lower being a fabric
material,
[0043] FIG. 4 illustrates the layers of FIG. 2 having been
laminated together to define a precursor outer assembly by the use
of, for example, an adhesive and/or heat lamination,
[0044] FIG. 5 is a perspective view of the layers of FIG. 3 having
been laminated together to define a precursor outer assembly
wherein the lamination has been achieved by an adhesive and/or heat
lamination,
[0045] FIG. 6 is a perspective view of an underwire assembly to be
incorporated in the bra of the present invention,
[0046] FIG. 7 is a sectional view through Section AA of FIG. 6,
[0047] FIG. 8 is a sectional view through Section BB of FIG. 6,
[0048] FIG. 9 is a plan view of a precursor layer of material of
foam,
[0049] FIG. 10 is a plan view of another precursor layer of foam
material,
[0050] FIG. 11 is a plan view of a precursor fabric panel,
[0051] FIG. 12 is a sectional view through a molding device
consisting of an upper and lower mold intermediate of which an
assembly of the layers of FIGS. 9, 10 and 11 and the underwire
assembly are placed for the simultaneous molding and lamination
thereof to define a molded core assembly capturing within the
assembly the underwire assemblies underneath or adjacent of each of
the cups mold formed in the layers,
[0052] FIG. 13 is a sectional view through the two cup forms of the
assembly of layers shown in FIG. 12 after the mold forming and
lamination thereof,
[0053] FIG. 14 is a plan view of the flexible core assembly of FIG.
13 and wherein perimeter trimming has occurred to define a core
assembly of layers,
[0054] FIG. 15 is a sectional view through a molding device
providing upper and lower mold portions intermediate of which the
flexible core assembly of FIG. 14 is placed and relative to which
the core precursor panel assembly of FIGS. 4 and 5 are positioned
for the subsequent mold forming and lamination of the plies
together,
[0055] FIG. 16 is a plan view of the assembly of panels molded
according to the molding process of FIG. 15 and wherein excess
perimeter material has been trimmed,
[0056] FIG. 17 is a sectional view through Section CC of FIG.
16,
[0057] FIG. 18 shows a front view of part of a bra wherein the
perimeter finishing of at least part of the bra is different to
that described with reference to FIGS. 15 and 16,
[0058] FIG. 19 is a view of the components of the bra of FIG. 18
shown from the opposite direction,
[0059] FIG. 20 is a sectional view through section DD of FIG.
19,
[0060] FIG. 21 is a transparent front view of a core assembly
wherein a pouch is provided at each breast cup,
[0061] FIG. 22 is a plan view of a pouch,
[0062] FIG. 23 shows a front view of part of a bra wherein a
perimeter finishing of at least part of the bra is different to
that described with reference to FIGS. 15 and 16,
[0063] FIG. 24 is a view of the components of the bra of FIG. 23
shown from the opposite direction, and
[0064] FIG. 25 is a sectional view through section EE of FIG.
24.
DETAILED DESCRIPTION OF THE INVENTION
[0065] FIG. 1 shows a front view of a bra which has been
manufactured according to a method as herein described.
[0066] The bra 1 consists of an assembly of panels that are joined
together to define a single structure incorporating the chest bands
2 and two breast cups 3. The chest bands 2 may at their free ends
4, 5 be provided with mutually interactable catches or fasteners to
allow for the free ends 4 and 5 to be engaged together. Also
provided may be shoulder straps 6, 7 which are fixed to appropriate
regions of the chest bands and to the breast cups to allow for such
to have over the shoulder support for the wearer of a bra.
[0067] Such shoulder straps may however be optional as it is
envisaged that the bra may be of a strapless version. Indeed,
whilst reference is herein made to a bra, it is envisaged that the
assembly of panels to define such may alternatively be incorporated
into other garments such as, for example, evening dresses or
bathing suits or the like.
[0068] Where reference herein is made to inward and outward or
other similar terms, they are understood to be in relation to the
body of the wearer of the bra. For example, the "inward" or "inner"
side or region or thing is a relative term to denote that an item
or a component of the bra is more proximate or closer to the body
of the wearer of the bra than other items or components of the bra
that are at a greater distance from the body of the wearer.
"Outward" and "outer" are similarly interpreted. Additionally,
"Inner" does not mean "inner most" unless otherwise specified.
Similarly, "outer" does not mean "outer most" unless otherwise
specified. Also, "exterior" does not mean inner or outer most
unless otherwise specified.
[0069] "Seamless" is understood to mean that the bra is visibly
substantially seamless, in that the edges of the bra are finished
in a seamless or substantially seamless way, for example by
ultrasonic welding, or by folding the edge of an outer layer over
and affixing it to an inner layer by a non-stitching means, or by
some other means that is substantially without seams. Seams may,
however, be found inside the bra structure where it is not
externally visible, or in a visibly less conspicuous external place
such as the region where a shoulder strap is attached to a breast
cup, or the region where a hook or eye tape is connected to the
chest band.
[0070] Reference will now be made to a preferred method of
construction (and variations thereof) which will explain preferred
assemblies of panels which may be used to facilitate the
manufacture of the bra of FIG. 1.
[0071] FIG. 2 shows two precursor layers, panels, sheets, or plies
of material (hereinafter "layer"). The first layer 8 may be of a
foam material, preferably of a thickness of 3.1 mm.
[0072] The second layer 9 may be a fabric material such as a fabric
known by model number CMF-7440MU of Friendly Foundate Ltd. This
fabric is made of 80% Tactel and 20% lycra. The fabric layer 9 may
have a make-up of approximately 80% Tactel 40d/34f and 20% lycra
40d and of a weight of, for example, 190 g/m2.
[0073] The foam is preferably a polyurethane foam of a density of,
for example, 30-40d.
[0074] With reference to FIG. 4, the foam panel 8 and the fabric
panel 9 are laminated together (preferably but not necessarily over
their entire contiguous surfaces) to provide a first covering panel
assembly 10. It is to be understood that the first covering panel
assembly is not necessarily an outermost or innermost layer of the
bra. There may be other layer(s) or panel(s) covering the first
covering panel assembly 10.
[0075] The first covering panel assembly 10 is also referred to as
the outer panel assembly 10. "Outer" refers to the panel assembly
10 being at a greater distance from the body of the wearer of the
bra than a core assembly 33 that will be described hereinafter.
[0076] The outer panel assembly 10 comprises the layer of foam 8
substantially laminated to the layer of fabric 9. The layers 8, 9
are preferably substantially co-extensive with each other and may
have been laminated together using an adhesive such as glue HM-1 of
Forbo Swift Adhesives SA. This glue will stick the fabric and foam
together when dry without heating. It is sprayed onto at least one
of the facing surfaces of the foam or fabric layers 8, 9. The
surface of foam layer 8 that is not facing fabric layer 9 is also
sprayed with a glue such as RM-30 of Ultra Energy Adhesive Trading
Co., Ltd. This glue will dry without sticking but will stick when
heated in the mold during the molding process shown in FIG. 15 and
described hereinbelow. As an alternative to the foam layer 8 and
fabric layer 9 being co-extensive, the foam layer may be smaller in
size and positioned inward of the entire perimeter of the fabric
layer 9.
[0077] Where a foam layer 8 is present in the outer panel assembly
10, it is at least of a size to overlap at least a substantial
part, if not all, of a core assembly 33 that will be described
hereinafter.
[0078] A variation to the aforesaid outer panel assembly 10 is
possible where the outer panel assembly 10 comprises only one ply
of material.
[0079] With reference to FIG. 3, there are shown a foam panel 11
and a fabric panel 12 which, like the foam panel 8 and fabric panel
9, are laminated (preferably but not necessarily over their entire
contiguous surfaces) together to define a second covering panel
assembly 13 as shown in FIG. 5. It is to be understood that the
second covering panel assembly 13 is not necessarily an outermost
or innermost layer of the bra. There may be other layer(s) or
panel(s) covering the second covering panel assembly 13.
[0080] The second covering panel assembly 13 is also referred to as
the inner panel assembly 13. "Inner" refers to the panel assembly
13 being at a smaller distance from the body of the wearer of the
bra than the core assembly 33 and the outer panel assembly 10. The
foam panel 11 is preferably of a foam such as EWA35 of Inoac
Corporation which is a polyurethane and is of a thickness of 1.7
mm.
[0081] The fabric panel 12 is preferably of the same material as
that of the fabric panel 9. The surface of foam panel 11 that is
not facing fabric panel 12 may also be sprayed with a glue such as
RM-30 of Ultra Energy Adhesive Trading Co., Ltd. As a variation to
the inner panel assembly 13 as hereinbefore described, it may
instead comprise only a single ply of fabric material. Where a foam
panel 11 is present in the inner panel assembly 13, it is at least
of a size to overlap at least part, if not all, of the core
assembly 33.
[0082] The bra (and its core assembly 33 which will hereinafter be
described) may incorporate an underwire structure 25. The underwire
structure 25 may consist of a substantially rigid but to a certain
extent flexible wire 20 which may be of a diameter of, for example,
2 mm as shown in FIG. 7. The wire may be made from a metallic
material such as stainless steel. In that case, the wire is
preferably captured within a sock or a channel 21. The sock or
channel may be closed at each end 22, 23 as, for example, shown in
FIG. 8. The sock or channel may be made from a fabric material or a
material such as TRICOT. The closure of the end of the sock or
channel 22, 23 may be achieved by using an ultrasonic machine to
bond the sock or channel closed. The underwire structure 25 is then
ready for subsequent incorporation.
[0083] As a variation to using a metallic underwire, the underwire
structure 25 may alternatively be made up totally of non-metallic
material. For example, the underwire structure can be the sock or
channel 21 as described hereinbefore alone without the wire 20.
Thus, a non-metallic underwire structure can for example be a
fabric channel as conventionally used to encase a steel underwire
for a conventional bra. After being subjected to molding with the
foam layers 29 and 30, which will hereinafter be described, the
conventional fabric channel embedded by the foam layers 29 and 30
will harden to a state whereby it will become a comfortable
substitute for the conventional steel underwire. A non-metallic
underwire structure is preferably of a strip form, substantially
planar, and resiliently bendable. Compared with a metallic
underwire, a non-metallic underwire structure enhances the softness
of the bra making it more comfortable to wear. Any non-metallic
resiliently bendable strip can be used as the underwire structure
25.
[0084] With reference to FIG. 9, there is shown a plan view of a
layer of foam material 29. This may form the outer layer of a core
assembly 33 for the bra. The foam layer 29 is preferably of a
polyurethane foam/memory foam such as, for example, EL58-4S of
Inoac Corporation which is a polyurethane/memory foam and is of a
thickness of, for example, 6 mm.
[0085] The core assembly 33 is also referred to simply as the
core.
[0086] FIG. 10 is a plan view of a layer of foam 30 which may form
the inner layer of the core 33. The foam layer 30 is made of a
polyurethane foam/memory foam such as, for example, EL58-4S of
Inoac Corporation. It is preferably of a thickness of approximately
6 mm. The foam layers 29 and 30 are laminated together such as by
the method hereinafter described.
[0087] In FIG. 11 there is shown a plan view of a layer or panel of
fabric material 31 which may optionally be incorporated as part of
the core 33.
[0088] The fabric layer 31 is for example fabric 7118 of Goldspring
Co. Ltd. It is preferably a piece of gauze which is 100% nylon.
This layer is included in the core 33 between the two foam layers
29 and 30 of the core. The fabric layer 31 may be provided to be
interposed between the foam layers 29 and 30 at a bridge region 41
of the core 33, the bridge being intermediate of the two breast
cups 39 and 40. The fabric layer 31 is to be laminated into the
core 33, and is preferably located between the two breast cups 39
and 40. It provides resistance against the elasticity which may
otherwise be resultant at the bridge region 41 between the breast
cups. It reduces the elasticity of the core 33 at the region
between the breast cups. The layer 31 is substantially
non-stretchable but is flexible in a manner to allow it to bend. It
may consist of a single ply or multi ply assembly. It is desirable
to ensure that the breast cups remain at a substantially constant
disposition relative to each other. In the most preferred form,
such a fabric layer 31 does not extend to the region below the
breast cups, and merely extends at the region which bridges the
breast cups 39, 40. At such bridge region 41, the foam layers 29
and 30 are also provided.
[0089] Each of the sides of the panels or layers 31, 29 and 30 that
are to be laminated (and also the sock or channel 21 of the
underwire structure 25 which is preferably provided) are sprayed
with an adhesive whereupon they are assembled but still remaining
in a planar form. Two underwire structures 25, preferably provided,
are positioned between the foam layers 29 and 30 at appropriate
location (preferably the lower peripheral part) of the breast cups
to be formed. The cup forms are then molded into the assembly of
layers and components to define the core 33. Additional, or
substitute, plies or components may optionally be incorporated into
the core 33 before molding.
[0090] Molding of the core 33 may then occur by the mold portions
34, 35. The mold portions 34, 35 have surface relief provided
thereto for the purposes of molding and introducing two cup forms
into the layers of the core 33. The upper mold 34 is preferably of
a temperature of 180.degree. C. to 200.degree. C. and the lower
mold is preferably of 180.degree. C. to 200.degree. C. The dwell
time holding the mold portions together is preferably 120
seconds.
[0091] With reference to FIG. 13, there is shown a cross sectional
view of the molded core 33. FIG. 14 illustrates the core 33 after
having its perimeter trimmed to define a core cup assembly wherein
two cup forms 39-40 are provided and interconnected over the bridge
region 41. The core 33 here is provided as a single unit. All of
the layers of the core 33, except for the fabric layer 31, are
preferably substantially coextensive and laminated with each other
(except for the layer 31). Where underwire structures are provided
at appropriate location (preferably the lower peripheral part) of
the breast cups of the core, the foam panels 29 and 30 preferably
remain substantially coextensive and laminated with each other.
[0092] The core 33 may then be engaged with the inner and outer
panel assemblies 13 and 10. This may be achieved by a molding
device consisting of two mold portions 45, 46 which each have
surface relief features defining two cup forms. One or both of the
panel assemblies 10 and 13 are preferably of a size which are
sufficiently large to allow the assemblies 10 and 13 to provide the
chest bands 2 extending from the breast cup regions 3. Such
sufficient size may be provided by one or more layers of one or
both of the inner and outer panel assemblies 13, 10. Alternatively,
both the inner and outer panel assemblies 13, 10 extend only
sufficiently to encase the core 33 and separate chest bands may be
affixed to the core. Preferably, at least the foam panel 8 of the
outer panel assembly 10 is of a size and shape sufficient to
overlap the core 33. In this way, the perimeter of the core 33 is
covered by the foam panel 8 and this helps improve visual
concealment of this perimeter that may otherwise show through to
the exterior of the bra.
[0093] In the molding of the core 33 with the inner and outer panel
assemblies 10 and 13, the top mold is preferably at a temperature
of approximately 180.degree. and the bottom mold is preferably
approximately 170.degree.. The dwell time is preferably 120
seconds. While heat is applied to ensure lamination between the
core 33 and the panels 10 and 13, the core 33 may be sprayed with
an adhesive such as glue RM-30 of Ultra Energy Adhesive Trading Co.
on both faces of the core.
[0094] In the most preferred form of the present invention, the
core 33 comprises an underwire structure 25 interposed between two
foam layers 29 and 30. The outer and inner panel assemblies 10 and
13 are substantially laminated with the core 33 on respective side
(the outer and the inner side respectively) of the core. One or
each of the outer and inner panel assemblies extends beyond at
least a portion of the perimeter or boundary of the core 33 to form
at least part of the chest bands 2. Additional layer(s) of material
may optionally be applied, whether affixed or not, to the outer
side of the outer panel assembly 10 and/or to the inner side of the
inner panel assembly 13. The outermost layer of the bra extends
beyond at least a portion of the perimeter or boundary of the core
33 to form at least part of the chest bands 2.
[0095] In a variation of the invention, one or both of the panel
assemblies 10 and 13 may be formed to an appropriate molded shape
prior to being engaged with the core 33. For example, the outer
panel assembly 10 may be mold formed to an appropriate shape and
subsequently engaged to the core 33. In this alternative
arrangement, one or both of the panel assemblies 10 and 13 may or
may not be fully laminated with the core 33. For example, the outer
panel assembly 10 so formed may, instead of being fully surface
laminated with the core 33, be engaged at least partly by edge
engagement. For example, with reference to FIGS. 18 and 19, it can
be seen that the outer panel assembly 10 is affixed to the core 33
by a hem 71. The affixing can be direct or indirect. The latter,
i.e., indirect affixing, occurs when the hem 71 is affixed to, for
example, the inner panel assembly 13. The affixing of the hem 71 is
preferably by means of adhesive.
[0096] In FIG. 19, it can be seen that a hem 71 is provided by the
outer panel assembly 10 that has been folded about part of the edge
of the inner panel assembly 13. The hem 71 may be provided about
the entire perimeter or about only part of the perimeter as for
example shown in FIG. 19. Provision of the hem 71 is one mode of
edge finishing of the bra of the present invention. An alternative
mode is where the edge of the bra is ultrasonically welded. Any
combination of ultrasonic welding and hem finishing may also be
utilized. In the example of FIGS. 18 to 20, the outer panel
assembly 10 defines the hem 71 at part of the perimeter, while
ultrasonic welding is used to define the remainder of the
perimeter.
[0097] In this variation, the outer panel assembly 10 preferably
remains loose with respect to the core 33 except at the hem 71
and/or the ultrasonically welded part of the perimeter. However,
the outer panel assembly 10 may be laminated to the core 33 or part
thereof, and/or to the inner panel assembly 13. For example,
lamination of the outer panel assembly 10 may occur with the inner
panel assembly 13 at the chest bands 2, leaving the outer panel
assembly 10 loose with respect to the core 33 at the breast cups 39
and 40. In the preferred form as described with reference to FIGS.
18 to 20, the outer panel assembly 10 is preferably of a single ply
of fabric.
[0098] In the embodiment where the panel assemblies 10 and 13 are
laminated with the core 33 on its respective sides, simultaneous
molding and lamination of the core 33 with the panel assemblies 10
and 13 preferably occurs. The assembly of the panel assemblies 10
and 13 and the core 33 molded to the appropriate form can, after
such molding and lamination, be trimmed to assume a form as, for
example, shown in FIG. 16. Such trimming may occur manually or may
be done ultrasonically by an ultrasonic machine such as device
EGR-053 of Ever Green Ultrasonic Co., Ltd. and a trimming roller
28. The ultrasonic trimming device cuts and bonds the edge together
at the same time. The core 33 is preferably of a perimeter smaller
and inward of the trimmed perimeter of at least the outer panel
assembly 10 and preferably also of the inner panel assembly 13.
Accordingly the core 33 is captured within the panel assemblies 10,
13.
[0099] Where the variation as described with reference to FIGS. 18
to 20 occurs, the core 33 and the inner panel assembly 13 may be
laminated together in the molding process as shown with reference
to FIG. 15 and the outer panel assembly 10 may subsequently be
affixed to the core 33. The outer panel assembly 10 may have been
subjected to independent mold forming prior to affixing. Prior to
the affixing of the outer panel assembly 10, the inner panel
assembly 13 and/or the core assembly 33 may be perimeter trimmed to
the appropriate shape and form. In this variation, the core 33 may
have at least part of its perimeter coincident with part of the
perimeter of the inner panel assembly 13, with the hem 71 covering
any such coincident perimeter as a result of the hem being defined
about such coincident perimeter.
[0100] FIG. 17 shows the peripheral region 50 of the bra through
Section CC. It can be seen that the panel assemblies 10 and 13 are
engaged to each other at the periphery and captured within the core
33. FIG. 20 shows a section through section DD of FIG. 19.
[0101] The peripheral components such as the fasteners 4, 5 and the
shoulder straps may be fixed to the assembly shown in FIG. 16. The
shoulder straps may be length adjustable and the fasteners may
allow for adjustment of the band size of the bra. Such peripheral
components are preferably engaged to the assembly shown in FIG. 16
by means of ultrasonic welding.
[0102] While reference has herein been made to the outer and inner
panel assemblies 10 and 13 as comprising a layer of foam 8, 11 and
a layer of fabric 9, 12, it may well be that either or both of the
assemblies 10, 13 comprise only the fabric layer 9, 12. Indeed in
the variation as described with reference to FIGS. 18 to 20 where a
fully or partially hemmed perimeter is defined by the outer panel
assembly 10, the assembly 10 is then a single ply of fabric
material. The single ply of fabric material is preferably the ply 9
of fabric material previously described.
[0103] A further variation of the present invention is where the
core 33 comprises only a single layer of foam material. In such a
construction there may or may not be an underwire and/or the
substantially non-stretchable layer 31 present. Alternatively, such
components may be provided and interposed between one of the panel
assemblies 10 or 13 and the core 33 consisting of a single layer of
foam. Preferably, such components as the underwire assembly and/or
the panel of substantially non-stretchable layer 31 are disposed
between the single-foam core 33 and the inner panel assembly
13.
[0104] With reference to FIG. 23, there is shown a further
variation of the present invention. Here, the primary structure of
the bra is substantially as shown with respect to FIGS. 2 to 17,
but an additional ply of material is provided on the outer side of
the bra. The additional ply is the outermost ply 79 of the bra. The
outermost ply 79 is preferably present for at least a substantial
portion of the bra. The outermost ply 79 preferably overlaps the
outer panel assembly 10 at least at the breast cups 39 and 40 and
the bridge 41. The outermost ply 79 also preferably overlaps the
outer panel assembly 10 at the chest bands 2. In the most preferred
form, the outermost ply 79 defines the entire outermost surface of
the bra of the present invention. However, a variation to that is
as shown with reference to FIG. 24, in which the outermost ply 79
is shown not extending across the entire length of the chest bands
2 of the bra. The outermost ply 79 is preferably engaged by its hem
71 to a semi-finished or finished bra structure that is produced
substantially with reference to FIGS. 2 to 17. The hem 71 is
provided about the entire perimeter or a portion of the perimeter
of the bra. With reference to FIG. 24, it can be seen that the hem
71 is provided about the lower region of the bra as well as around
part of the underarm 80 and the neckline 81. The hem 71 is
preferably affixed to the inner panel assembly 13. The hem 71 is
preferably adhesively affixed to the inner panel assembly 13. It is
preferably affixed to the fabric layer 12 of the inner panel
assembly 13.
[0105] The outermost ply 79 is preferably not laminated or
otherwise affixed to the outer panel assembly 10 and this has been
shown in FIG. 25, in which a gap 82 may exist between the outermost
ply 79 and the outer panel assembly 10. In such case, the outermost
ply 79 is loose with respect to the outer panel assembly 10 or
indeed the core 33.
[0106] The outermost ply 79 is preferably fabric. It can be or can
include a lace, or may include sections that are lace.
Alternatively, or in addition, the outermost ply 79 may include
non-laced fabric or other materials.
[0107] In an embodiment where the outermost ply 79 is lace or
substantially lace, it may require a perimeter strip 86 at or
covering the hem 71 to facilitate the bonding of the hem 71 with
the inner panel assembly 13. The strip 86 is preferably of a fabric
material, or it can be other tape which allows for adhesive and/or
heat bonding to occur. The strip 86 can be applied to cover or
overlap the hem 71, with or without at the same time overlapping a
portion of the fabric layer 12 of the inner panel assembly 13, to
facilitate bonding of the hem 71 to the inner panel assembly 13.
FIG. 25 has not shown the strip 86 extending to cover also a
portion of the inner panel assembly 13, but it is possible and
preferable to have the strip 86 covering not only the hem, but also
extending to cover and overlap a portion of the inner panel
assembly.
[0108] The outer panel assembly 10 preferably provides its foam
layer 8 to overlap at least the perimeter of the core 33, in order
to reduce the visibility of the perimeter of the core assembly 33
to the exterior of the bra. Similarly the inner panel assembly 13
preferably provides its foam layer 11 to overlap at least the
perimeter of the core 33.
[0109] With reference to FIG. 21, there is shown a further item
that may be included intermediate of the two foam layers 29 and 30
of the core assembly or core 33. In FIG. 21 the core assembly 33
incorporates a pouch 72 that may include a liquid. The pouch is
shown in more detail in FIG. 22 wherein the pouch includes a
containment region 73 that is sealed by the perimeter seal 74. The
containment region 73 may include a liquid. Examples of suitable
liquid include water, oil, gel, or any liquid having preferably a
greater viscosity than water. The pouch 72 is preferably
incorporated between the foam layers 29 and 30 of the core assembly
33. It can be provided to enhance the appearance of the bra or the
appearance of the breasts of the wearer of the bra. The volume of
the containment region 73 and/or the volume of liquid contained
therein can be so set as to achieve the result desired by
individual tastes. In the embodiment as shown in FIGS. 21 and 22 an
underwire assembly 25 is included positioned adjacent and below the
pouch 72.
[0110] While the present invention has been described with
reference to particular embodiments thereof, it will be understood
that such embodiments are susceptible of modifications and
variations without departing from the scope of the present
invention and that the invention will include all embodiments
falling within the scope of the appended claims.
* * * * *