U.S. patent application number 11/851765 was filed with the patent office on 2008-04-17 for uplift brassiere.
Invention is credited to Zhen Qiang Liu.
Application Number | 20080090491 11/851765 |
Document ID | / |
Family ID | 39303593 |
Filed Date | 2008-04-17 |
United States Patent
Application |
20080090491 |
Kind Code |
A1 |
Liu; Zhen Qiang |
April 17, 2008 |
UPLIFT BRASSIERE
Abstract
A molded brassiere comprising or including, a breast cup region
defined at least by (i) an interior panel that includes a foam ply
(herein after "interior foam ply") and (ii) an exterior panel that
includes a foam ply (herein after "exterior foam ply"), said
interior and exterior panels being laminated with each other
defining a breast cup region that includes two breast cups and an
intermediate bridge region extending there between, wherein the
interior and exterior panels are laminated with each other save at
least at a region where, for each breast cup, a pocket is defined
between the interior and exterior panels, the pocket being located
extending from the lower perimeter region of the breast cup towards
the neckline of the breast cup, the interior panel at said pocket
having lower curvature than said exterior panel so that said pocket
provides an air gap between said interior and exterior panels.
Inventors: |
Liu; Zhen Qiang; (Hong Kong,
HK) |
Correspondence
Address: |
OSTROLENK FABER GERB & SOFFEN
1180 AVENUE OF THE AMERICAS
NEW YORK
NY
100368403
US
|
Family ID: |
39303593 |
Appl. No.: |
11/851765 |
Filed: |
September 7, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60890097 |
Feb 15, 2007 |
|
|
|
Current U.S.
Class: |
450/39 ; 450/41;
450/54; 450/57; 450/92 |
Current CPC
Class: |
A41C 3/0014 20130101;
B32B 5/18 20130101; A41C 3/0035 20130101; B32B 5/22 20130101; A41C
3/105 20130101; A41C 5/005 20130101; B32B 27/12 20130101; A41C
3/122 20130101 |
Class at
Publication: |
450/39 ; 450/41;
450/54; 450/57; 450/92 |
International
Class: |
A41C 3/00 20060101
A41C003/00; A41C 1/14 20060101 A41C001/14; A41C 3/10 20060101
A41C003/10 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 13, 2006 |
NZ |
550597 |
Jan 25, 2007 |
NZ |
552882 |
Claims
1. A molded brassiere comprising or including, a breast cup region
defined at least by (i) an interior panel that includes a foam ply
(herein after "interior foam ply") and (ii) an exterior panel that
includes a foam ply (herein after "exterior foam ply"), said
interior and exterior panels being laminated with each other
defining a breast cup region that includes two breast cups and an
intermediate bridge region extending there between, wherein the
interior and exterior panels are laminated with each other save at
least at a region where, for each breast cup, a pocket is defined
between the interior and exterior panels, the pocket being located
extending from the lower perimeter region of the breast cup towards
the neckline of the breast cup, the interior panel thereby offering
the capacity to bulge towards the body of the wearer to thereby
encourage, in use, a general uplift of the breast.
2. A molded brassiere as claimed in claim 1 wherein the exterior
panel includes a zone of higher density foam defined by said
exterior foam ply, said zone being present adjacent said
pocket.
3. A molded brassiere as claimed in claim 1 wherein the exterior
panel includes a zone of higher density foam defined by said
exterior foam ply, said zone being present adjacent said pocket and
extending at least at its upper perimeter, beyond the upper
perimeter of the pocket.
4. A molded brassiere as claimed in claim 1 wherein the interior
panel includes a zone of higher density foam defined by said
interior foam ply, said zone being present adjacent said
pocket.
5. A molded brassiere as claimed in claim 1 wherein the interior
panel includes a zone of higher density foam defined by said
interior foam ply, said zone being present adjacent said pocket and
extending at least at its upper perimeter contiguous the upper
perimeter of the pocket.
6. A molded brassiere as claimed in claim 1 wherein a layer of
flexible material having non-stretch properties is provided
intermediate of and laminated with the said interior and exterior
panels at said bridge region, said flexible material having
non-stretch properties oriented so that across the bridge region
parallel to the cup to cup direction said core assembly is
non-stretchable.
7. A molded brassiere as claimed in claim 1 wherein the exterior
panel includes the exterior foam ply and a fabric ply laminated to
each other, the exterior foam ply positioned interior more the
fabric ply.
8. A molded brassiere as claimed in claim 1 wherein the exterior
foam ply and the interior foam ply are laminated with each other
save at least at the pocket region.
9. A molded brassiere as claimed in claim 1 wherein the exterior
foam ply and the interior foam ply are laminated to each other save
at least at the pocket region.
10. A molded brassiere as claimed in claim 1 wherein the interior
panel includes the interior foam ply and a fabric ply laminated to
each other, the interior foam ply positioned exterior more the
fabric ply.
11. A molded brassiere as claimed in claim 1 wherein an exterior
more ply of fabric material may be positioned to the exterior side
of the exterior panel.
12. A molded brassiere as claimed in claim 1 wherein an interior
more ply of fabric material may be positioned to the interior side
of the interior panel.
13. A molded brassiere as claimed in claim 1 wherein an exterior
more ply of fabric material may be positioned to the exterior side
of the exterior panel, and wherein an interior more ply of fabric
material may be positioned to the interior side of the interior
panel, and wherein at least one of the exterior and interior more
plies of fabric material layer are laminated with said interior and
exterior panels and extend beyond the perimeter of interior and
exterior panels to provide at least in part, at least that part of
the brassiere defining chest strap(s).
14. A molded brassiere as claimed in claim 6 wherein said interior
and exterior foam plies are laminated directly to each other save
for at said pocket and at said flexible material having non-stretch
properties.
15. A molded brassiere as claimed in claim 6 wherein said flexible
material having non stretch properties is provided extending at
said bridge region only.
16. A molded brassiere as claimed in claim 6 wherein said flexible
material having non stretch properties is captured intermediate of
said interior and exterior foam plies.
17. A molded brassiere as claimed in claim 6 wherein said flexible
material having non stretch properties is a woven fabric
material.
18. A molded brassiere as claimed in claim 6 wherein said flexible
material having non stretch properties is a woven fabric material
with bi directional non-stretch properties and is oriented such
that the non stretch orientation extends across said bridge region
to resist a pulling apart of the breast cups.
19. A molded brassiere as claimed in claim 1 wherein said interior
and exterior panels are coextensive with each other.
20. A molded brassiere as claimed in claim 1 wherein the exterior
panel includes the exterior foam ply and a fabric ply laminated to
each other, the exterior foam ply positioned interior more the
fabric ply, and wherein the interior panel includes the interior
foam ply and a fabric ply laminated to each other, the interior
foam ply positioned exterior mote the fabric ply, and wherein the
foam and fabric plies of each of the interior and exterior panels
are coextensive each other.
21. A molded brassiere as claimed in claim 13 wherein said breast
cup region is of a shape defining only the breast cups and said
bridge but not said chest strap(s).
22. A molded brassiere as claimed in claim 13 wherein said chest
strap(s) extend outwardly from each side of said breast cup
region.
23. A molded brassiere as claimed in claim 1 wherein said interior
and exterior plies of foam are co extensive each other.
24. A molded brassiere as claimed in claim 1 wherein two underwire
structures are provided intermediate of said interior and exterior
panels, one each adjacent a respective breast cup.
25. A molded brassiere as claimed in claim 24 wherein said
underwire structure comprises a rigid elongate member and a
flexible material casing about at least part of said rigid elongate
member.
26. A molded brassiere as claimed in claim 25 wherein said casing
is a fabric material.
27. A molded brassiere as claimed in claim 25 wherein said casing
is adhered to one or each of the facing surfaces of said interior
and exterior foam plies by an adhesive material.
28. A molded brassiere as claimed in claim 27 wherein said casing
is a tubular sock within which said rigid elongate member is
located, the sock having closed distal ends.
29. A molded brassiere as claimed in claim 1 wherein, in use, said
interior panel at said pocket, presses more against said breasts
than said exterior panel.
30. A method of manufacturing a molded component assembly for a
brassiere comprising: placing an exterior panel that includes a
foam ply that includes, at each region of the exterior panel at
where a breast cup is to be mold formed into said exterior panel, a
zone of increased thickness that is located extending from the to
be defined lower regions of the breast towards the neckline of the
breast cup, into a molding device and mold forming the breast
cup(s) shape into the exterior panel and to homogenise the
thickness of the foam ply at least at the breast cup(s) so that the
zone is of a higher density foam than the foam surrounding the
zone, placing an interior panel that includes a foam ply that
includes, at each region of the interior panel at where a breast
cup is to be mold formed into said interior panel, a zone of
increased thickness that is located extending from the to be
defined lower regions of the breast towards the neckline of the
breast cup, into a molding device and mold forming the breast
cup(s) shape into the interior panel and to homogenise the
thickness of the foam ply at least at the breast cup(s) so that the
zone is of a higher density foam than the foam surrounding the
zone, laminating the interior and exterior panels with each other
in a manner so that their cups(s) agree and in a manner wherein no
lamination occurs of the panels at where the zone of higher density
foam of the interior panel is located so as to define a pocket at
this zone between the interior and exterior panels.
31. A method as claimed in claim 30 wherein at least one of the
interior and exterior panels are of a size to allow two breast cups
and a bridge extending between the breast cups to be molded into
panel(s).
32. A method as claimed in claim 30 wherein the method includes the
subsequent steps of trimming said molded and laminated interior and
exterior panels to define a molded assembly which includes two cups
forms and a bridge region extending there between.
33. A method as claimed in claim 30 wherein one of the exterior
panel and interior panel also includes an underwire structure
placed, prior to lamination of the interior and exterior panels, so
as to be captured between the panels.
34. A method as claimed in claim 30 wherein one of the exterior
panels and interior panel includes a layer of flexible material
having non stretch properties placed, prior to lamination of the
interior and exterior panels, so as to become captured between the
panels.
35. A method as claimed in claim 30 wherein prior to molding of
said panels, an underwire structure is provided intermediate of
said first and second layer.
36. A method of manufacturing a molded component assembly for a
brassiere comprising: laminating (i) an exterior panel that
includes a foam ply that includes, at each region of the exterior
panel at where a breast cup is mold formed into said exterior
panel, a zone of increased foam density that is located extending
from the lower regions of the breast towards the neckline of the
breast cup with (ii) an interior panel that includes a foam ply
that includes, at each region of the interior panel at where a
breast cup is mold formed into said interior panel, a zone of
increased foam density that is located extending from the lower
regions of the breast towards the neckline of the breast cup, in a
manner so that their cups(s) agree and in a manner wherein no
lamination occurs of the panels at where the zone of higher density
foam of the interior panel is located so as to define a pocket at
this zone between the interior and exterior panels.
37. A method as claimed in claim 36 wherein the zone of the
interior panel has an upper perimeter that is lower than the
perimeter of the zone of the exterior panel.
38. A molded brassiere comprising or including, a breast cup region
defined at least by (i) an interior panel that includes a foam ply
(herein after "interior foam ply") and (ii) an exterior panel that
includes a foam ply (herein after "exterior foam ply"), said
interior and exterior panels being laminated with each other
defining a breast cup region that includes two breast cups and an
intermediate bridge region extending there between, wherein the
interior and exterior panels are laminated with each other save at
least at a region where, for each breast cup, a pocket is defined
between the interior and exterior panels, the pocket being located
extending from the lower perimeter region of the breast cup towards
the neckline of the breast cup, the interior panel at said pocket
having lower curvature than said exterior panel so that said pocket
provides an air gap between said interior and exterior panels.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims benefit of U.S. Provisional
Patent Application No. 60/890,097, filed on Feb. 15, 2007, the
disclosure of which has been incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an uplift brassiere.
BACKGROUND OF THE INVENTION
[0003] Uplift brassieres are known. Such are also known as cleavage
brassieres. Common uplift brassieres (hereinafter "bras") may
incorporate appropriately placed padding to displace breast tissue
near the bottom of a breast to thereby displace the breast tissue
upwards and thereby enhance cleavage or uplift. Pads may come in
the form of a pouch of a gel or liquid captured between layers of
the bra at the breast cups.
[0004] Pads are effective in creating an uplift of the breasts.
However the incorporation of pads between layers of the bra can be
time consuming and expensive. Two pads are required to be
manufactured, one for each breast cup. These are then required to
be handled and positioned in an appropriate location during the
manufacturing process to be captured between layers of the bra.
This added material cost and handling can increase the cost of
goods manufactured.
SUMMARY OF THE INVENTION
[0005] It is therefore an object of the present invention to
provide an uplift brassiere that does not require the incorporation
of a separate pad and/or that will at least provide the public with
a useful choice.
[0006] Accordingly in a first aspect the present invention consists
in a molded brassiere comprising or including,
[0007] a breast cup region defined at least by (i) an interior
panel that includes a foam ply (herein after "interior foam ply")
and (ii) an exterior panel that includes a foam ply (herein after
"exterior foam ply"), said interior and exterior panels being
laminated with each other defining a breast cup region that
includes two breast cups and an intermediate bridge region
extending there between, wherein the interior and exterior panels
are laminated with each other save at least at a region where, for
each breast cup, a pocket is defined between the interior and
exterior panels, the pocket being located extending from the lower
perimeter region of the breast cup towards the neckline of the
breast cup, the interior panel thereby offering the capacity to
bulge towards the body of the wearer to thereby encourage, in use,
a general uplift of the breast.
[0008] Preferably the exterior panel includes a zone of higher
density foam defined by said exterior foam ply, said zone being
present adjacent said pocket.
[0009] Preferably the exterior panel includes a zone of higher
density foam defined by said exterior foam ply, said zone being
present adjacent said pocket and extending at least at its upper
perimeter, beyond the upper perimeter of the pocket.
[0010] Preferably the interior panel includes a zone of higher
density foam defined by said interior foam ply, said zone being
present adjacent said pocket.
[0011] Preferably the interior panel includes a zone of higher
density foam defined by said interior foam ply, said zone being
present adjacent said pocket and extending at least at its upper
perimeter contiguous the upper perimeter of the pocket.
[0012] Preferably a layer of flexible material having non-stretch
properties is provided intermediate of and laminated with the said
interior and exterior panels at said bridge region, said flexible
material having non-stretch properties oriented so that across the
bridge region parallel to the cup to cup direction said core
assembly is non-stretchable.
[0013] Preferably the exterior panel includes the exterior foam ply
and a fabric ply laminated to each other, the exterior foam ply
positioned interior more the fabric ply.
[0014] Preferably the exterior foam ply and the interior foam ply
are laminated with each other save at least at the pocket
region.
[0015] Preferably the exterior foam ply and the interior foam ply
are laminated to each other save at least at the pocket region.
[0016] Preferably the interior panel includes the interior foam ply
and a fabric ply laminated to each other, the interior foam ply
positioned exterior more the fabric ply.
[0017] Preferably an exterior more ply of fabric material may be
positioned to the exterior side of the exterior panel.
[0018] Preferably an interior more ply of fabric material may be
positioned to the interior side of the interior panel.
[0019] Preferably at least one of the exterior and interior more
plies of fabric material layer are laminated with said interior and
exterior panels and extend beyond the perimeter of interior and
exterior panels to provide at least in part, at least that part of
the brassiere defining chest strap(s).
[0020] Preferably said interior and exterior foam plies laminated
directly to each other save for at said pocket and at said flexible
material having non-stretch properties.
[0021] Preferably said flexible material having non stretch
properties is provided extending at said bridge region only.
[0022] Preferably said flexible material having non stretch
properties is captured intermediate of said interior and exterior
foam plies.
[0023] Preferably said flexible material having non stretch
properties is a woven fabric material.
[0024] Preferably said flexible material having non stretch
properties is a woven fabric material with bi directional
non-stretch properties and is oriented such that the non stretch
orientation extends across said bridge region to resist a pulling
apart of the breast cups.
[0025] Preferably said interior and exterior panels are coextensive
with each other.
[0026] Preferably the foam and fabric plies of each of the interior
and exterior panels are coextensive each other.
[0027] Preferably said breast cup region is of a shape defining
only the breast cups and said bridge but not said chest
strap(s).
[0028] Preferably said chest straps extend outwardly from each side
of said breast cup region.
[0029] Preferably said interior and exterior plies of foam are co
extensive each other.
[0030] Preferably two underwire structures are provided
intermediate of said interior and exterior panels, one each
adjacent a respective breast cup.
[0031] Preferably said underwire structure comprises a rigid
elongate member and a flexible material casing about at least part
of said rigid elongate member.
[0032] Preferably said casing is a fabric material.
[0033] Preferably said casing is adhered to one or each of the
facing surfaces of said first and second layers of foam by an
adhesive material.
[0034] Preferably said casing is a tubular sock within which said
rigid elongate member is located, the sock having closed distal
ends.
[0035] Preferably, in use, said interior panel at said pocket,
presses more against said breasts than said exterior panel.
[0036] In a second aspect the present invention consists in a
method of manufacturing a molded component assembly for a brassiere
comprising:
[0037] placing an exterior panel that includes a foam ply that
includes, at each region of the exterior panel at where a breast
cup is to be mold formed into said exterior panel, a zone of
increased thickness that is located extending from the to be
defined lower regions of the breast towards the neckline of the
breast cup, into a molding device and mold forming the breast
cup(s) shape into the exterior panel and to homogenise the
thickness of the foam ply at least at the breast cup(s) so that the
zone is of a higher density foam than the foam surrounding the
zone,
[0038] placing an interior panel that includes a foam ply that
includes, at each region of the interior panel at where a breast
cup is to be mold formed into said interior panel, a zone of
increased thickness that is located extending from the to be
defined lower regions of the breast towards the neckline of the
breast cup, into a molding device and mold forming the breast
cup(s) shape into the interior panel and to homogenise the
thickness of the foam ply at least at the breast cup(s) so that the
zone is of a higher density foam than the foam surrounding the
zone,
[0039] laminating the interior and exterior panels with each other
in a manner so that their cups(s) agree and in a manner wherein no
lamination occurs of the panels at where the zone of higher density
foam of the interior panel is located so as to define a pocket at
this zone between the interior and exterior panels.
[0040] Preferably at least one of the interior and exterior panels
are of a size to allow two breast cups and a bridge extending
between the breast cups to be molded into panel(s).
[0041] Preferably the method includes the subsequent steps of
trimming said molded and laminated interior and exterior panels to
define a molded assembly which includes two cups forms and a bridge
region extending there between.
[0042] Preferably one of the exterior panel and interior panel also
includes an underwire structure placed, prior to lamination of the
interior and exterior panels, so as to be captured between the
panels.
[0043] Preferably one of the exterior panels and interior panel
includes a layer of flexible material having non stretch properties
placed, prior to lamination of the interior and exterior panels, so
as to become captured between the panels.
[0044] Preferably prior to molding of said panels, an underwire
structure is provided intermediate of said first and second
layer.
[0045] In a further aspect the present invention consists in a
method of manufacturing a molded component assembly for a brassiere
comprising:
[0046] laminating (i) an exterior panel that includes a foam ply
that includes, at each region of the exterior panel at where a
breast cup is mold formed into said exterior panel, a zone of
increased foam density that is located extending from the lower
regions of the breast towards the neckline of the breast cup with
(ii) an interior panel that includes a foam ply that includes, at
each region of the interior panel at where a breast cup is mold
formed into said interior panel, a zone of increased foam density
that is located extending from the lower regions of the breast
towards the neckline of the breast cup,
[0047] in a manner so that their cups(s) agree and in a manner
wherein no lamination occurs of the panels at where the zone of
higher density foam of the interior panel is located so as to
define a pocket at this zone between the interior and exterior
panels.
[0048] Preferably the zone of the interior panel has an upper
perimeter that is lower than the perimeter of the zone of the
exterior panel.
[0049] In a further aspect the present invention consists in a
molded brassiere comprising or including,
[0050] a breast cup region defined at least by (i) an interior
panel that includes a foam ply (herein after "interior foam ply")
and (ii) an exterior panel that includes a foam ply (herein after
"exterior foam ply"), said interior and exterior panels being
laminated with each other defining a breast cup region that
includes two breast cups and an intermediate bridge region
extending there between, wherein the interior and exterior panels
are laminated with each other save at least at a region where, for
each breast cup, a pocket is defined between the interior and
exterior panels, the pocket being located extending from the lower
perimeter region of the breast cup towards the neckline of the
breast cup, the interior panel at said pocket having lower
curvature than said exterior panel so that said pocket provides an
air gap between said interior and exterior panels.
[0051] 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.
[0052] Where reference herein is made to interior and exterior or
similar terminology in relation to component parts or items of the
bra or part of the bra, it is meant to be understood to be in
relation to the body of the wearer of the bra. For example the
"interior" or "inner side" or "inner region" is a relative term to
denote that an item is more proximate the face side of the bra that
is more proximate to the body of the wearer than items of the bra
that are more distal the body of the wearer. "Inner" does not mean
"inner most" unless specified. This similarly applies to terms such
as "outer" or "exterior".
[0053] By seamless is meant the bra is visibly substantially
seamless, in that the edges of the bra are finished in a 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 visibly less conspicuous
externally at places such as the region where the shoulder strap is
attached to a bra cup region, or the region where hook or eye tape
is connected to the chest bands.
[0054] As used herein the term "and/or" means "and" or "or", or
both.
[0055] As used herein "(s)" following a noun means the plural
and/or singular forms of the noun.
[0056] The term "comprising" as used in this specification means
"consisting at least in part of". When interpreting statements in
this specification which include that term, the features, prefaced
by that term in each statement, all need to be present but other
features can also be present. Related terms such as "comprise" and
"comprised" are to be interpreted in the same manner.
BRIEF DESCRIPTION OF DRAWINGS
[0057] A preferred form of the present invention will now be
described with reference to the accompanying drawings in which:
[0058] FIG. 1 is a perspective view of a pre-molding stage interior
panel assembly,
[0059] FIG. 2 is a perspective view of a pre-molding stage exterior
panel assembly,
[0060] FIG. 3 is a plan view of the exterior panel assembly showing
variation in thickness of the foam ply,
[0061] FIG. 4 is a sectional view through section AA of FIG. 3,
[0062] FIG. 5 is a plan view of the interior panel assembly to
illustrate variation in thickness,
[0063] FIG. 6 is a sectional view through section BB of FIG. 5,
[0064] FIG. 7 is a sectional view through a molding device
illustrating the positioning of the exterior panel assembly prior
to mold forming of the exterior panel assembly,
[0065] FIG. 8 is a plan view of the molded exterior panel assembly
including the positioning of an optional underwire assembly at each
breast cup,
[0066] FIG. 9 is a close up view of the bridge region of the panel
assembly of FIG. 8 illustrating the positioning of a bridge
panel,
[0067] FIG. 10 is a plan view of the exterior panel illustrating
the positioning of additional panel or panels of material,
[0068] FIG. 11 is a plan view of part of the exterior panel
assembly illustrating the positioning of further optional panels of
material,
[0069] FIG. 11a is a sectional view through the assembled panel
assembly illustrating the approximate position of the underwire
assembly,
[0070] FIG. 12 is a sectional view through section CC illustrating
an example of approximate positioning of panels and components at
section CC,
[0071] FIG. 13 is a sectional view through a molding device
illustrating the positioning of the internal panel assembly prior
to mold forming,
[0072] FIG. 14 is a plan view of the molded external panel assembly
illustrating the zone of higher density foam previously having been
the zone of increased thickness of the pre-molded precursor
interior panel assembly,
[0073] FIG. 15 is a sectional view through a molding and/or
laminating device including the illustration of the positioning of
the interior and exterior molded panels prior to their bonding,
preferably by lamination, together,
[0074] FIG. 16 is a front view of components defining at least part
of the breast cup region for incorporation with other bra
components, illustrating the pocket that may be formed between the
internal and external panel assemblies,
[0075] FIG. 17 is a sectional view through section EE of FIG.
16,
[0076] FIG. 18 is a sectional view through section FF of FIG.
16,
[0077] FIG. 19 illustrates a variation to the formation of the
present invention wherein each breast cup may be separately defined
and incorporate the features and optional features herein described
wherein each component can then be fastened together at the bridge
region,
[0078] FIG. 20 illustrates the incorporation of the components
defining the breast cup or breast cup region and other components
capable of being engaged or fastened therewith to define a bra,
and
[0079] FIG. 21 is a plan view of a bra of the present
invention.
[0080] With reference to FIG. 21 there is shown a bra 100 that may
generally be defined by a breast cup region 102, chest bands 103
and 104 and shoulder straps 105 and 106. The shoulder straps 106
and 105 may extend between the breast cup region 102 and each of
the chest bands 103 and 104 respectively.
[0081] Such over the shoulder straps may however be optional as it
is envisaged that the bra may also be of a strapless version.
Indeed whilst reference is herein made to a bra, it is envisaged
that the assembly of panels component parts and items to define
such, may alternatively be incorporated into other garments such
as, for example, evening dresses or bathing suits or similar.
[0082] At the ends of each of the chest bands may be fasteners 107
and 108 that are mutually cooperative to allow for the bra to be
fastened about the chest of a wearer.
[0083] The bra may be seamless and made from materials at least
some of which are molded or moldable and that are engaged to each
other preferably at least in part by lamination.
[0084] As can be seen with reference to FIG. 20 the components
defining the breast cup region 102 may be fastened to the
components defining the chest band 103 and the shoulder strap 106.
Such fastening may occur by adhesive and/or ultrasonic welding or
other forms of welding and/or by stitching. Stitching is not the
preferred form of joining. In the most preferred form the bra of
the present invention is a seamless bra that incorporates little or
no stitching at all and preferably no visible stitching.
[0085] The breast cup region 102 preferably defines two breast cups
109 and 110 that are adjacent to each other and between which may
extend an intermediate bridge region 111. At least some of the
material components defining the breast cups 109 and 110 are
continuous over the entire breast cup region 102, including across
the bridge region 111. Alternatively some or all of the material
components may only be present at least part of the breast cups 109
and 110.
[0086] In the preferred form, at least one of the material
components of the breast cup region 102 is continuous over the
breast cup region 102 and preferably also over the bridge region.
However in alternative forms each of the breast cups 109 and 110
may be separately predefined as for example shown in FIG. 19 and
may be affixed together at the bridging region 111 to define, once
assembled, the breast cup region 102.
[0087] Additional components, layers or plies of material may be
provided with the materials defining the breast cup region to those
herein defined.
[0088] Variations to the bra shown in FIG. 21 may include where the
chest bands 104 and 103 are unitary and may extend along the lower
perimeter of the breast cup region 102. The bra may be a front
opening bra where mutually cooperative fasteners are positioned at
the bridge region 111 to allow the bra to be opened and fastened at
that region.
[0089] The bra 100 preferably includes at least the lower regions
of each of the breast cups 109 and 110, a zone 112 defined by
materials component structure and/or materials characteristics that
will facilitate, when the bra is being worn, in a displacement of
breast tissue at least such lower regions to encourage uplift of
the breast that may thereby enhance breast uplift and/or cleavage
appearance. Each zone 112 is shown in phantom in FIG. 21 at each
breast cup 109 and 110. Each zone 112 includes a pocket 33 formed
between layers of the material components defining the breast cups
109 and 110. The zone 112 is generally provided at the lower
regions of each of the breast cups 109, 110 to facilitate
displacement of breast tissue from this region of the bra.
[0090] The pocket or pockets 33 may be defined in the bra as a
result of the construction of the bra. The pocket or pockets, with
an air gap across, at the zones 112 may be created only once the
bra is being worn by the user, again as a result of the
construction of the bra.
[0091] The steps in the manufacture of the bra or in manufacture of
components for a bra which allow for such a pocket to be defined,
will now be described by way of example.
DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION
[0092] With reference to FIG. 1, there is shown a precursor
interior panel assembly 1. The precursor exterior panel assembly 1
preferably consists of a foam ply 2 and a fabric ply 3. The
interior panel assembly 1 preferably consists of at least the two
plies 2 and 3 and may consist of additional plies such as further
fabric ply or plies and/or foam ply or plies. Preferably the fabric
ply 3 is laminated to the foam ply 2 in a coextensive manner.
[0093] In FIG. 2 there is shown an exterior panel assembly 4. The
exterior panel assembly 4 preferably consists of coextensive plies
5 and 6. Ply 5 is preferably a foam ply and ply 6 is preferably a
fabric ply. Similarly to the interior panel assembly 1, the
exterior panel assembly 4 may include further plies of material.
Such plies may or may not be coextensive with the plies 5 and/or
6.
[0094] The interior panel assembly 1 and exterior panel assembly 2
are to be laminated with each other such that the foam plies 2 and
5 are proximate most each other and the fabric plies 3 and 6 face
away from each other.
[0095] The precursor interior panel assembly 1 is preferably of a
constant thickness. The precursor exterior panel assembly 4 is
preferably of a constant thickness. However prior to their
lamination together one or both of the panel assemblies 1, 4 is
preferably modified. Such modification is to introduce a variation
in thickness in the panel assembly 1 and/or 4 at appropriate
regions that, with subsequent processing, will lead to a variation
in density.
[0096] With reference to FIG. 3, the exterior panel assembly 4 is
shown with its foam ply 5 face up. Shown in phantom is an outline
of a breast cup region to be formed. The panel assembly 4 has been
modified by shaving or skiving or similar known foam thickness
reducing techniques in order to introduce zones 8 at the breast cup
region 7 of the foam ply 5. Two discrete zones 8 are shown although
at this stage these may instead be joined across the bridge
region.
[0097] The zone 8 at each breast cup region 109 and 110 is
preferably of a plateau shape. The plateau region 8 is of a greater
thickness than the surrounding panel region or regions. With
reference to FIG. 4 it can be seen that the zone 8 is a plateau
like shaped zone or at least a zone having increased thickness to
the remainder of the foam ply 5 of the external panel assembly
4.
[0098] The region of increased thickness may include a gradual
transition between the thinner regions of the foam ply 5 and the
zone of increased thickness 8 at least about some perimeter regions
of the plateau. As can be seen with reference to FIG. 4 the
preferred plateau shaped zone 8 includes transition between it and
the thinner regions of the foam ply 5. Formation of the zone 8
preferably occurs by a shaving or skiving of foam removing the
portions shown in phantom in FIG. 4. Alternatively the thickness
variation may be achieved by lamination of a foam plateau panel
onto the foam ply 5 to build up the effective thickness of the
foam.
[0099] In addition or alternatively, the interior panel assembly 1
may be modified in a similar manner to introduce zones 11. The
zones 11 where both the exterior and interior panel assemblies are
modified to introduce the zones 8/11, are preferably of a shape and
size that is scaled down from the plan shape of the zones 8 of the
exterior panel assembly 4. Such scaling is preferably in both axes
of the Cartesian plane and is preferably done so that the zones 11
do not extend beyond the boundary of the zones 8 once the external
and internal panel assemblies are laminated with each other.
[0100] FIG. 6 is a cross-section through section BB of FIG. 5
showing the zone or zones of increased thickness at section BB.
[0101] The exterior panel assembly 4 with its modified thickness
may be introduced into a molding device consisting of upper and
lower mold portions 14/15 for the introduction of the breast cups
shape. The exterior panel assembly 4 is positioned in the molding
device such that the foam ply 5 will be positioned on the concave
side of the molded panel assembly and the fabric ply 6 is on the
convex side.
[0102] A molded exterior panel assembly 4 is shown in FIG. 8
wherein the panel assembly 4 has the breast cups of the breast cup
region formed therein. As a result of molding of the shaved
exterior panel, (a) breast cups are formed at the breast cup
region, and (b) the thickness of the foam layer 5 should be
approximately constant since the molding will even the thickness or
at least cause any difference in the thickness to not be readily
noticeable. A change in foam density will result with a higher
density being defined at the zones 8.
[0103] After the forming of the three dimensional breast cups,
underwire assemblies may be placed on the foam ply 5 at or
immediately adjacent the lower regions of the breast cups. The
underwire assembly may consist of a plastic strip and/or a metal
wire that may or may not be encased within a sock such as a fabric
sock. Preferably two underwires 16 are provided, one for each
breast cup.
[0104] The placement and securing of the underwire 16 and other
components may occur before the breast cup region 102 is trimmed
from the remaining peripheral portions of the exterior panel 4 or
after.
[0105] With reference to FIG. 9, a flexible but preferably
non-stretch bridge panel 17 is placed to extend across the bridge
111 and at least partially onto each of the breast cups 109 and 110
of the exterior panel assembly 4. The underwire 16 may extend
between the foam ply 5 and the bridge panel 17 as shown on the left
hand side, or may sit on top of the bridge panel 17 such that the
bridge panel 17 is between the underwire 16 and the foam ply 5.
[0106] The underwire or underwire structure 16 is preferably held
in place with the panel 4 by the use of an adhesive. Such an
adhesive may be provided to at least tack the underwire in
place.
[0107] With reference to FIG. 10 there is shown a further assembled
layer of material provided to cover the underwire structure 16 and
preferably at least in part also the flexible but non-stretch
material bridge panel 17. This additional material is optional. It
is preferably is of a gauze material. The gauze 19 is preferably of
a W shape extending over the underwires and across the bridge 111.
Alternatively the gauze may terminate at the boundaries of the
bridge panel 17 and may not necessarily extend across the bridge
111.
[0108] The gauze may also be applied by the use of an adhesive such
as an adhesive spray or adhesive tacking, to locate the gauze in
position relative to the external panel 4.
[0109] With reference to FIG. 11, a panel 20 may also be placed
over the underwire structure 16. The panel 20 is preferably a foam
panel that extends beyond the boundary of the underwire structure.
Preferably the foam panel is of a smaller shape and size than the
gauze panel 19.
[0110] In other embodiments of this invention, the components 16,
17, 19 and 20 may be placed in different order than those described
herein with reference to the drawings.
[0111] With reference to FIG. 12 showing in cross-section the
structure through section CC of FIG. 11, it can be seen that the
underwire structure 16 is captured between gauze layers 19, foam
layer 20, and the exterior panel assembly 2 including at the bridge
region, the bridge panel 17.
[0112] Alternatively, the same set of materials 16, 17, 19 and 20
can be glued onto the foam layer 2 of the interior panel assembly 1
before lamination with the exterior panel 4.
[0113] FIG. 13 shows the interior panel assembly 1 located
intermediate of a molding device consisting of upper and lower
molds 28/27 prior to mold closure and forming of three dimensional
breast cups to define a modified panel 1 as shown in FIG. 14.
Similarly, as a result of molding of the interior panel, (a) breast
cups are formed at the breast cup region, and (b) the thickness of
the foam layer 2 should be approximately constant since the molding
will even the thickness or at least cause any difference in the
thickness to not be readily noticeable. This will result in an
interior molded panel of varying density, with a higher density
defined at zones 11.
[0114] Modified panels 1 and 4 are then able to be laminated
together in an overlying manner as for example shown in
cross-sectional side view in FIG. 15. Panel assembly 4, preferably
carrying (if such optional components are provided) the foam panel
20, bridge panel 17, underwire structures 16 and gauze panel 19,
can be laminated together with the exterior panel 1 such that the
breast cup regions of the panel are aligned with each other.
Lamination of the panels 1 and 4 may occur by adhesion, heat and/or
adhesion bonding and may require the application of pressure such
as by way of pressures plate that may for example be between mold
portions 127 and 128 as shown.
[0115] There are hence preferably two molding actions (as described
with reference to FIGS. 7 and 13) and one laminating action (as
described with reference to FIG. 15).
[0116] Lamination of the panels 1 and 4 in their condition
described with reference to FIG. 15 is preferably over the entire
surfaces of the respective breast cups of the panels save for at
the regions where the pocket is to be created. With reference to
FIGS. 16, 17 and 18 it can be seen that lamination has not occurred
at the regions 8 and 11 of the interior and exterior panels 1 and
4. This results in a pocket 33 being defined between the panel 1
and 4 at and immediately adjacent and above each underwire
structure 16. The underwire structure 16 is preferably positioned
immediately below the perimeter of the denser foam area at the
exterior panel (i.e. the original plateau area 8 at the foam layer
of the pre-molded exterior panel 4).
[0117] Save for the upper perimeter of the original plateau area(s)
8 of the exterior panel 4, the perimeter of the original plateau
area at the exterior panel 4 may be laminated at the perimeter of
the original plateau area 11 at the interior panel 1. Since the
original plateau area(s) 8 at the exterior panel 4 covers
preferably more than half of the original plateau area 11 of the
interior panel 1, the upper perimeter of the original plateau area
11 at the interior panel 1 is laminated with the original plateau
area 8 of the exterior panel 4 (at around the middle part of the
original plateau area of the exterior layer).
[0118] Each of the two molding actions (i.e. the molding action in
FIG. 7 and the molding action in FIG. 13) causes a predetermined
shape to be formed at each bra cup region of the corresponding
panel. The subsequent laminating action (i.e. the laminating action
in FIG. 15) simply laminates the two panels together (except at the
pocket 33 of each bra cup region) and does not change the
predetermined shape already formed during the corresponding molding
action.
[0119] Preferably the predetermined shape formed at each breast cup
region of the exterior panel by the molding of the shaved exterior
panel in FIG. 7 is the shape of a complete breast cup. Preferably
the predetermined shape formed at each breast cup region of the
interior panel by the molding of the shaved interior panel in FIG.
13 consists of the shape of a partial breast cup (at the area not
covering the pocket 33) and the shape of the pocket 33 (at the area
covering the pocket 33).
[0120] Since the predetermined shape at each breast cup region of
the molded exterior panel and the predetermined shape at each
breast cup region of the molded interior panel preferably does not
change during the laminating action in FIG. 15, the shape of the
corresponding breast cup region of each panel will be contiguous to
each other except at the area covering the pocket 33.
[0121] Thus the shape of the pocket 33 is formed by the molding
action in FIG. 13, rather than by the laminating action in FIG.
15.
[0122] The plateau 8 of the foam ply 5 of the pre-molded exterior
panel 4 has the main function of keeping the breast cup region 102
in its intended shape particularly from an external view point.
Since the density of the foam at where the plateau 8 was defined
and after being molded, will be higher the foam thereat will be
harder than the foam at the remaining part of the breast cup region
102. As such, when the bra is being worn, any change of shape of
the breast cup region 102 will be resisted. This means that the
outward aesthetic appearance can to a large extend be
maintained.
[0123] The higher density foam sections of the exterior panel and
the inner panel are stiffer than the lower density sections of the
same panels. The stiffness tends to attribute to the maintenance of
the pocket shape as much as possible when the bra is worn. The
higher density foam sections at both the exterior panel and the
inner panel (rather than just at one of the panels only) are
desired primarily for providing a shape-keeping effect to the
pocket. Therefore, it is not expected that an exterior most ply can
provide a better shape-keeping effect to the pocket 33, although
such exterior most ply may obscure any visually undesired
deformation of the exterior and/or interior panels.
[0124] A change of shape of the breast cup region 102 may be caused
by different forces applied on the bra when the bra is being
worn.
[0125] Further, after lamination of the exterior panel 4 and the
interior panel 1 together (FIG. 15), the upper perimeter of the
pocket 33 is defined by a joining of the interior panel foam ply 2
with the exterior panel foam ply 5. As the original plateau of the
foam ply 2 is smaller, the upper perimeter can be created at where
a lower density part of the foam ply 1 joins the higher density
part of the foam ply 5. A shape a shown in FIG. 17 may be created.
A shelf like configuration for the breast may be defined. The
interior panel 1 may apply a pulling down force on the exterior
panel 4 when the interior panel at the pocket region 33 is
supporting the breast of the wearer.
[0126] As the denser foam area at the exterior panel 4 is
relatively hard it may provide a shape-keeping function for the
brassiere.
[0127] The foam close to the neckline of the exterior panel may be
of a lower density because there is not much force being applied
thereon when the bra is being worn.
[0128] When the bra is worn, the breast cup region at the pocket 33
is pressed by the breast, thereby creating a force pushing both
ends of the underwire (which was in its natural shape before the
bra is worn) towards each other and also creating a force pulling
the back straps towards this region. However, since the underwire
and any other elastic components of the bra surrounding the chest
and back of the wearer tend to return to their natural shapes, the
shape of the pocket can be maintained as much as possible and
thereby providing good support of the breast.
[0129] The denser foam area at the interior panel 1 (i.e. the
original plateau area 11 at the foam layer of the pre-molded
interior panel 1) may keep the pocket 33 in shape as much as
possible since its higher density regions make the foam harder.
There is no need to have the denser foam area of the interior panel
bigger than the denser foam area of the exterior panel because any
change of shape of the breast cup region at the interior panel when
the bra is being worn should not be visible.
[0130] Because of (a) the stretching of the non-laminated area of
each bra cup region of the interior layer towards the laminated
area of the bra cup region of the core assembly and (b) the
stretching of the said non-laminated area generally between two
ends of the underwire structure resulting from the stiffness of the
underwire structure, the non-laminated area of each bra cup region
of the interior layer bulges towards the skin of the wearer,
creating a hollow uplifting bra pad.
[0131] Given that the pocket does not include a pouch or pad, it
will be lighter than a bra that does.
[0132] The fabric material used may be of a material 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.
[0133] The foam used is preferably a polyurethane foam of a
precursor density of, for example, 30-40d.
[0134] Adhesive used may be of a kind such as RM-30 of Ultra Energy
Adhesive Trading Co., Ltd.
[0135] The bridge fabric may be 7118 of Goldspring Co. Ltd. It is
preferably a piece of gauze which is 100% nylon.
[0136] One or all the molding processes occur preferably at an
upper mold 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 for example 120
seconds.
* * * * *