U.S. patent application number 11/674970 was filed with the patent office on 2008-04-24 for brassiere.
Invention is credited to Zhen Qiang Liu.
Application Number | 20080096465 11/674970 |
Document ID | / |
Family ID | 39318501 |
Filed Date | 2008-04-24 |
United States Patent
Application |
20080096465 |
Kind Code |
A1 |
Liu; Zhen Qiang |
April 24, 2008 |
BRASSIERE
Abstract
A molded brassiere, a core assembly of a first layer of molded
foam material laminated with a second layer of molded foam
material, defining two breast cup regions and an intermediate
bridge region. At least one layer of flexible material having
non-stretch properties adjacent one of or intermediate of and
laminated with the layers of molded foam material at the bridge
region, and oriented so that across the bridge region parallel to
the cup to cup direction the material is non-stretchable. A first
and second layer of the fabric is laminated with the core assembly
on the respective interior and exterior side and preferably encases
the core assembly. A third layer joined at least to the first layer
at or near the lowermost perimeter of the core assembly is wrapped
over that perimeter and extends towards the remaining perimeter
thereof.
Inventors: |
Liu; Zhen Qiang; (Hong Kong,
CN) |
Correspondence
Address: |
OSTROLENK FABER GERB & SOFFEN
1180 AVENUE OF THE AMERICAS
NEW YORK
NY
100368403
US
|
Family ID: |
39318501 |
Appl. No.: |
11/674970 |
Filed: |
February 14, 2007 |
Current U.S.
Class: |
450/39 |
Current CPC
Class: |
A41C 3/0014 20130101;
A41C 5/005 20130101 |
Class at
Publication: |
450/39 |
International
Class: |
A41C 3/10 20060101
A41C003/10 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 18, 2006 |
NZ |
550632 |
Jan 25, 2007 |
NZ |
552881 |
Claims
1. A moulded brassiere, including a core assembly of at least a
first layer of moulded foam material preferably laminated with a
second layer of moulded foam material, said core assembly defining
two breast cup regions and an intermediate bridge region extending
there between, and wherein at least one layer of flexible material
having non-stretch properties is provided adjacent one of or
intermediate of and laminated with said first and second layer of
moulded foam material 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; and a first and second layer, each of at least a
fabric material, is disposed outside of and each laminated with
said core assembly on a respective interior and exterior side of
said core assembly to preferably encase said core assembly, and a
third layer joined at least to said first layer at or near the
lower most perimeter of said core assembly, said third layer
wrapped over the lower most perimeter and extending to or towards
the remaining perimeter of said core assembly.
2. A moulded brassiere including, a core assembly of at least a
first layer of moulded foam material preferably laminated with a
second layer of moulded foam material, said core assembly defining
two breast cup regions and an intermediate bridge region extending
there between and wherein at least one layer of flexible material
having non-stretch properties is provided adjacent one of or
intermediate of and laminated with said first and second layer of
moulded foam material 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, and a first and second layer, each of at least a
fabric material, disposed outside of said core assembly on the
respective interior and exterior sides of said core assembly, said
first layer laminated to the interior side of said core assembly,
said second layer joined at its lower edge at the lower perimeter
of the core assembly, to said first layer and folded over to wrap
around said core assembly to the exterior side of said core
assembly, the join between said first and second exterior layers
located toward the bottom periphery of said moulded brassiere,
having no raw edges or sewing presenting exteriorly.
3. A moulded brassiere according to claim 1, wherein there is an
intermediate fabric layer between said core assembly and at least
one of said first and second layers of fabric that is/are laminated
with said core assembly.
4. A moulded brassiere according to claim 1, 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
parallel to the cup to cup direction of said core assembly.
5. A moulded brassiere according to claim 1, wherein said layer of
flexible material having non stretch properties is captured
intermediate of said first and second layer of moulded foam
material.
6. A moulded brassiere according to claim 1, wherein said first and
second layers of foam are coextensive with each other and both
define the perimeter of the said core assembly.
7. A moulded brassiere according to claim 1, wherein said core
assembly is of a shape defining only the breast cups, said bridge
and preferably at least in part said shoulder straps, but not chest
strap(s).
8. A moulded brassiere according to claim 7, wherein said chest
straps extend outwardly from each side of said core assembly
provided region of said moulded brassiere.
9. A moulded brassiere according to claim 1, wherein two underwire
structures are provided intermediate of said first layer and said
second layers of foam, one each adjacent the breast cup
regions.
10. A moulded brassiere according to claim 1, wherein said first
layer and said second layer of foam are laminated directly to each
other save for said flexible material having non-stretch properties
and said two underwire structures.
11. A moulded brassiere according to claim 9, wherein said
underwire structure comprises a rigid elongate member and a
flexible material casing about at least part of said rigid elongate
member.
12. A moulded brassiere according to claim 11, wherein said casing
is a fabric material.
13. A moulded brassiere according to claim 11, wherein said casing
is adhered to one or each of the facing surfaces of said first and
second layers of foam by an adhesive material.
14. A moulded brassiere according to claim 1, wherein said casing
is a tubular sock within which said rigid elongate member is
located, the sock having closed distal ends.
15. A moulded brassiere according to claim 1, wherein said first
layer and said foam layer or the foam layers are coextensive each
other.
16. A moulded brassiere according to claim 1, wherein said second
layer and said foam layer or the foam layers are coextensive each
other.
17. A moulded brassiere including, a core assembly of at least a
first layer of moulded foam material said core assembly defining at
least one breast cup region and a first and second layer, each of
at least a fabric material, disposed outside of said core assembly
on the respective interior and exterior sides of said core
assembly, said first layer laminated to the interior side of said
core assembly, said second layer joined at the interior side of
core assembly at its lower edge at the lower perimeter of the core
assembly to said core assembly (and preferably to the first layer)
and folded over to wrap around said core assembly to the exterior
side of core assembly.
18. A method of manufacturing a moulded component assembly for a
brassiere comprising or including: affixing to a core of at least a
first layer of moulded foam material (and preferably a second layer
of foam material) and preferably with which and/or between which
there is sandwiched a layer of flexible material having non stretch
properties, a layer of fabric material at the inner side of the
core and adjacent the lower perimeter of the core, wrapping the
layer of fabric material around at least part of the lower
perimeter to the exterior of the core and affixing the layer to at
least part of other perimeter regions of the core.
19. A moulded brassiere, including a core assembly having a
proximal face and an opposed distal face, said core assembly
comprising a core layer defining two breast cup regions, and at
least one upper edge and at least one lower edge, and a bridge
region extending between the breast cup regions; a distal fabric
layer, defining an upper edge and a lower edge, said distal fabric
layer extending from the distal face of the core assembly around at
least part of the lower edge of the core assembly to the proximal
face of the core assembly, said distal fabric layer being folded
over distally along its lower edge to form a distal flap, said
distal flap being secured to the proximal face of the core
assembly.
20. A moulded brassiere according to claim 19, wherein distal
fabric layer is comprised of at least one layer of moulded foam and
at least one layer of fabric.
21. A moulded brassiere according to claim 19, wherein the core
layer is composed of at least one layer of moulded foam and at
least one layer of fabric.
22. A moulded brassiere according to claim 19, wherein the distal
fabric layer extends from the distal flap, around the lower edge of
the core assembly, across at least part of the distal face of the
core assembly, and around the upper edge of the core assembly, to
the proximal face of the core assembly.
23. A moulded brassiere according to claim 19, wherein the distal
fabric layer is secured along its upper edge towards the upper edge
of the proximal face of the core assembly.
24. A moulded brassiere according to claim 19, wherein the distal
flap is secured to the proximal face of the core assembly towards
the lower edge of the core assembly.
25. A moulded brassiere according to claim 24, wherein the distal
flap is secured to the proximal face of the core assembly towards
the lower edge of the core assembly by means of ultrasonic
welding.
26. A moulded brassiere according to claim 23, wherein the distal
fabric layer is secured to the proximal face of the core assembly
towards the upper edge of the core assembly by adhesive
bonding.
27. A moulded brassiere according to claim 23, wherein the distal
fabric layer is secured to the proximal face of the core assembly
towards the upper edge of the core assembly by ultrasonic
welding.
28. A moulded brassiere according to claim 19, wherein the core
assembly includes an underwire structure comprising at least one
resiliently rigid arcuate elongate member.
29. A moulded brassiere according to claim 28, wherein the
underwire structure is secured to the distal face of the core
layer.
30. A moulded brassiere according to claim 28, wherein the
underwire structure further comprises a sock surrounding the
elongate member.
31. A moulded brassiere according to claim 19, wherein the core
assembly includes a chest strap member secured to the core layer
outwardly of each breast cup region.
32. A moulded brassiere according to claim 31, wherein the chest
strap member is secured to the core layer at a securing zone.
33. A moulded brassiere according to claim 31, wherein each of the
chest strap members is secured to the core layer by sewing.
34. A moulded brassiere according to claim 31, wherein each of the
chest strap members is secured to the core layer by ultrasonic
bonding.
35. A moulded brassiere according to claim 31, wherein each chest
strap comprises at least a pair of ultrasonically bonded fabric
layers each having an upper and lower edge.
36. A moulded brassiere according to claim 35, wherein the fabric
layers of the chest strap are coextensive of each other and are
bonded to each other towards their lower edges.
37. A moulded brassiere according to claim 36, wherein the lower
edge of each of the pair of fabric layers of the chest strap are
folded in towards each other and bonded at their adjacent
faces.
38. A moulded brassiere according to claim 31, wherein each chest
strap includes a resilient elongate strap.
39. A moulded brassiere according to claim 38, wherein the
resilient elongate strap is composed of natural or synthetic
rubber.
40. A moulded brassiere according to claim 19, wherein the core
assembly includes a shoulder strap secured to the core layer
towards its upper edge above each breast cup region.
41. A moulded brassiere according to claim 19, wherein the distal
fabric layer overlaps at least one of the securing zones where it
extends from the proximal face of the core layer to the distal face
of the core layer.
Description
[0001] The present invention relates to a brassiere that has
improved comfort and in particular has reduced evident
stitching.
[0002] A bra normally is manufactured from a number of pieces.
These pieces are shaped into three dimensional forms, either by
cutting and re-sewing or heat and pressure forming. The resultant
pieces are then assembled into a bra by sewing.
[0003] Any raw edge of a garment such as a bra that is in contact
with the skin of the wearer can become irritating after a long
period of wearing the garment. The removal of such raw edges and
seams is complicated when the three dimensional nature of the
garment is taken into account.
[0004] It is therefore an object of the present invention to
provide an improved brassiere that at least partly does not include
sewn edges that present against the skin of the wearer and/or that
will at least provide the public with a useful choice.
[0005] In a first aspect the present invention consists in a
moulded brassiere including,
[0006] a core assembly of at least a first layer of moulded foam
material preferably laminated with a second layer of moulded foam
material, said core assembly defining two breast cup regions and an
intermediate bridge region extending there between and wherein at
least one layer of flexible material having non-stretch properties
is provided adjacent one of or intermediate of and laminated with
said first and second layer of moulded foam material 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, and a first
and second layer, each of at least a fabric material, is disposed
on opposed sides of and each laminated with said core assembly on a
respective interior and exterior side of said core assembly to
preferably encase said core assembly, and a third layer joined at
least to said first layer at or near the lower most perimeter of
said core assembly, said third layer wrapped over the lower most
perimeter and extending to or towards the remaining perimeter of
said core assembly.
[0007] In a second aspect the present invention consists in a
moulded brassiere including,
[0008] a core assembly of at least a first layer of moulded foam
material preferably laminated with a second layer of moulded foam
material, said core assembly defining two breast cup regions and an
intermediate bridge region extending there between and wherein at
least one layer of flexible material having non-stretch properties
is provided adjacent one of or intermediate of and laminated with
said first and second layer of moulded foam material 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, and
[0009] a first and second layer, each of at least a fabric
material, disposed on opposed sides of said core assembly on the
respective interior and exterior sides of said core assembly, said
first layer laminated to the interior side of said core
assembly,
[0010] said second layer joined at its lower edge at the lower
perimeter of the core, to said first layer and folded over to wrap
around said core assembly to the exterior side of said core
assembly,
[0011] the join between said third and second exterior layers
located toward the bottom periphery of said moulded brassiere,
having no raw edges or sewing presenting exteriorly.
[0012] Preferably there is an intermediate fabric layer between
said core and at least one of said first and second layers of
fabric that is/are laminated with said core.
[0013] Preferably said flexible material having non stretch
properties is a woven fabric material with bidirectional
non-stretch properties and is oriented such that the non stretch
orientation extends across said bridge region parallel to the cup
to cup direction of said core assembly.
[0014] Preferably said layer of flexible material having non
stretch properties is captured intermediate of said first and
second layer of moulded foam material.
[0015] Preferably said first and second layers of foam are
coextensive with each other and both define the perimeter of the
said core assembly.
[0016] Preferably said core assembly is of a shape defining only
the breast cups, said bridge and preferably at least in part said
shoulder straps, but not chest strap(s).
[0017] Preferably said chest straps extend outwardly from each side
of said core assembly provided region of said moulded
brassiere.
[0018] Preferably two underwire structures are provided
intermediate of said first layer and said second layers of foam,
one each adjacent the breast cup regions.
[0019] Preferably said first layer and said second layer of foam
are laminated directly to each other save for said flexible
material having non-stretch properties and said two underwire
structures.
[0020] Preferably said underwire structure comprises a rigid
elongate member and a flexible material casing about at least part
of said rigid elongate member.
[0021] Preferably said casing is a fabric material.
[0022] 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.
[0023] Preferably said casing is a tubular sock within which said
rigid elongate member is located, the sock having closed distal
ends.
[0024] Preferably said first layer and said foam layer or the foam
layers are coextensive each other.
[0025] Preferably said second layer and said foam layer or the foam
layers are coextensive each other.
[0026] In a further aspect the present invention consists in a
moulded brassiere including,
[0027] a core assembly of at least a first layer of moulded foam
material said core assembly defining two breast cup regions and an
intermediate bridge region extending there between
[0028] and a first and second layer, each of at least a fabric
material, disposed outside of said core assembly on the respective
interior and exterior sides of said core assembly, said first layer
laminated to the interior side of said core assembly,
[0029] said second layer joined at the interior side of core
assembly at its lower edge at the lower perimeter of the core
assembly to said core assembly (and preferably to the first layer)
and folded over to wrap around said core assembly to the exterior
side of core assembly.
[0030] In a second aspect the present invention consists in a
method of manufacturing a moulded component assembly for a
brassiere comprising or including:
[0031] affixing to a core of at least a first layer of moulded foam
material (and preferably and a second layer of foam material) and
preferably with which and/or between which there is sandwiched
layer of flexible material having non stretch properties, a layer
of fabric material at the inner side of the core and adjacent the
lower perimeter of the core,
[0032] wrapping the layer of fabric material around at least part
of the lower perimeter to the exterior of the core and affixing the
layer to at least part of other perimeter regions of the core.
[0033] In a third aspect the present invention consists in a
moulded brassiere, including
[0034] a core assembly comprising
[0035] a core layer defining two breast cup regions and having a
proximal face and an opposed distal face and at least one upper
edge and at least one lower edge, and a
[0036] a bridge region extending between the breast cup
regions;
[0037] a distal layer, defining an upper edge and a lower edge,
said distal layer extending from the distal face of the core
assembly around at least part of the lower edge of the core
assembly to the proximal face of the core assembly, said third
fabric layer being folded over distally along its lower edge to
form a distal flap, said distal flap being secured to the proximal
face of the core assembly.
[0038] Preferably, the distal fabric layer may be comprised of at
least one layer of moulded foam and at least one layer of
fabric.
[0039] Preferably, the core layer may be composed of at least one
layer of moulded foam and at least one layer of fabric.
[0040] Preferably, the distal fabric layer may extend from the
distal flap, around the lower edge of the core assembly, across at
least part of the distal face of the core assembly, and around the
upper edge of the core assembly, to the proximal face of the core
assembly.
[0041] Preferably, the distal fabric layer may be secured towards
its upper edge to the proximal face of the core assembly towards
its upper edge.
[0042] Preferably, the distal flap may be secured to the proximal
face of the core assembly towards the lower edge of the core
assembly.
[0043] Preferably, the distal flap may be secured to the proximal
face of the core assembly towards the lower edge of the core
assembly by means of ultrasonic welding.
[0044] Preferably, the distal fabric layer may be secured to the
proximal face of the core assembly towards the upper edge of the
core assembly by adhesive bonding.
[0045] Preferably, the distal fabric layer may be secured to the
proximal face of the core assembly towards the upper edge of the
core assembly by ultrasonic welding.
[0046] Preferably the core assembly may include an underwire
assembly comprising at least one resiliently flexible curved
elongate member.
[0047] The underwire assembly may be secured to the distal face of
the core layer.
[0048] Preferably the underwire assembly may further comprise a
sleeve disposed around the elongate member.
[0049] Preferably, the core assembly may include a chest strap
member secured to the core layer outwardly of each breast cup
region.
[0050] Preferably, the chest strap member may be secured to the
core layer at a securing zone.
[0051] Preferably, the of the backs trap members may be secured to
the core layer by sewing.
[0052] Preferably, the of the backs trap members may be secured to
the core layer by ultrasonic bonding.
[0053] Preferably, each chest strap comprises at least a pair of
ultrasonically bonded fabric layers each having an upper and lower
edge.
[0054] Preferably, the fabric layers may be bonded to each other
towards their lower edges.
[0055] Preferably, the lower edge of each of the pair of fabric
layers of the chest strap may be folded in towards each other and
bonded at their adjacent faces.
[0056] Preferably, each chest strap may include a resilient
elongate strap.
[0057] The resilient elongate strap may be composed of natural or
synthetic rubber.
[0058] Preferably, the core assembly may include a shoulder strap
secured to the core layer towards its upper edge above each breast
cup region.
[0059] Preferably, the distal fabric layer may overlap at least one
of the securing zones where it extends from the proximal face of
the core layer to the distal face of the core layer.
[0060] 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.
[0061] Where reference herein is made to interior and exterior or
similar terminology, 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".
[0062] Any reference to the term "inner" or "interior" and "outer"
or "exterior" as used in this specification is to be construed in
accordance with the general definitions of the terms "proximal" and
"distal" respectively.
[0063] 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.
[0064] The term `comprising` as used in this specification means
`consisting at least in part of`, that is to say 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.
[0065] Preferred embodiments of the present invention will now be
described with reference to the accompanying drawings, in
which:
[0066] FIG. 1 shows a lamination of fabric layer with foam layer to
form an assembly of laminated plies, one rectangular piece is cut
from the assembly of laminated plies to form the exterior
layer,
[0067] FIG. 2 shows that the foam layer of the exterior layer has
been shaved so that an apex is formed at around the middle of each
bra cup region,
[0068] FIG. 3 shows in cut away the underwire structure formed by
wrapping a metallic underwire within a sock of fabric material
closed at both ends by bar-tacking,
[0069] FIG. 4 shows the shaved exterior layer located between the
upper and lower platens of a moulding machine, prior to moulding to
impart three dimensional shape,
[0070] FIG. 5 shows the foam side of the moulded exterior layer
being sprayed with adhesive by a spraying machine,
[0071] FIG. 6 shows from the inside, or what will be-come the
inside surface of the moulded exterior layer, an underwire
structure being positioned (e.g. by gluing) close to the lower
perimeter of each bra cup region on the foam layer of the moulded
exterior layer,
[0072] FIG. 7 shows a layer of flexible fabric material having
non-stretch properties being positioned (e.g. by gluing) at the
bridge region (i.e. between two bra cup regions) on the foam layer
of the exterior layer,
[0073] FIG. 8 shows another layer of flexible fabric material
(which is only slightly stretchable) having a general "W" shape
being positioned (e.g. by gluing) along and over the underwire
structures and across the bridge region,
[0074] FIG. 9 shows a piece of foam layer having a "U" shape being
positioned (e.g. by gluing) above the W-shaped fabric material and
along and over each underwire structure,
[0075] FIG. 10 shows the interior layer cut out from the assembly
of laminated plies shown in FIG. 1 and shaved, located in between
platens of a moulding machine, prior to being formed,
[0076] FIG. 11 shows lamination of the exterior layer with the
interior layer by a moulding machine to form a core assembly, prior
to the application of pressure and/or heat to form the lamination
of the two layers, the underwire structures and layers of fabric
material/foam pieces along the lower edge of each bra cup
portion/at the bridge region becoming sandwiched between the
exterior layer and the interior layer,
[0077] FIG. 12 shows the edges of the core assembly being
trimmed,
[0078] FIG. 13 (A) shows shoulder straps (made from an assembly of
pre-laminated plies having a foam layer sandwiched between two
fabric layers) being attached to the core assembly by two small
pieces of fabric tape having adhesive on one side, one end of the
shoulder strap is attached to the core assembly by wrapping the
small piece of fabric tape over the joint, the adhesive of which
will then melt and provide bonding upon being heated up, e.g. by
ironing, (B) shows the bra exterior side and bra interior side of
the core assembly when seen from side on,
[0079] FIG. 14 shows moulding of the exterior most fabric ply by
bullet moulds,
[0080] FIG. 15 shows the exterior most fabric ply after being
moulded,
[0081] FIG. 16 shows the exterior most fabric ply positioned onto
the exterior of the core assembly using needles, or pins,
[0082] FIG. 17 shows at (A) the exterior most fabric ply of each
wing region of the bra cut out from a piece of cloth along the
edges of a pre-shaped plastic ruler, and (B) the interior most
fabric ply of each wing region of the bra cut out from a piece of
fabric material which has adhesive on one side covered by
protective paper, a pre-shaped plastic ruler is used to guide the
cutting,
[0083] FIG. 18 shows the exterior most fabric ply of the wing
portion being attached to the interior most fabric ply of the wing
portion by sewing along the longest edge of each of these two
plies,
[0084] FIG. 19 shows cutting along the joined edge of the two plies
in FIG. 18 so that no stitching remains and at the same time
sealing of the two plies together along a new edge using ultrasonic
methods,
[0085] FIG. 20 shows fixing of adhesive tape onto rubber band,
[0086] FIG. 21 shows how the rubber band (having adhesive tape on
one side of it) is then fixed on the exterior most fabric ply of
the wing region along the edge joined with the interior most fabric
ply,
[0087] FIG. 22 shows the exterior most fabric ply of the wing
region and the interior most fabric ply of the wing portion located
between two platens, prior to being laminated together with
application of heat and/or pressure,
[0088] FIG. 23 shows each of the resultant laminated plies of the
wing regions after being trimmed along the edge of the interior
most fabric ply,
[0089] FIG. 24 shows in plan view the interior of the core
assembly, the exterior most fabric ply edge is moved away so as not
to be sewn at this point, each of the laminated plies of the wing
region is located with its edge to be sewn pointing outward (i.e.
toward the perimeter of the cup of the core assembly) the wing
regions are then sewn on, (and the exterior most fabric ply, though
not shown as it is on the other side of the core assembly)
[0090] FIG. 25 shows a similar view to that of FIG. 24, but from
the other side (exterior side) of the core assembly, the exterior
most fabric ply has been un-pinned and flipped over to the interior
side of the core assembly, it is then oriented so that the moulded
in bullet shapes from FIG. 15 are pointing inward into the interior
surface of the core assembly, the wing regions then receive a
further sewing from the exterior side of the core assembly to the
core assembly,
[0091] FIG. 26 shows a local cross-section through the edge of the
core assembly, showing the sewing through the core and wing
assembly and exterior most fabric ply, the wing region edge is
directed toward the cup edge of the core assembly, the body of the
wing, directed toward the interior of the cup of the core assembly,
the exterior most fabric ply is shown with the bullet shape
pointing inward into the interior of the core assembly,
[0092] FIG. 27 shows in plan view the sewn assembly of the core
assembly, wing regions and exterior most fabric ply, the exterior
most fabric ply of the core assembly is then sewed onto the core
assembly along the lower perimeter of the core assembly, a further
line of stitching is added to attach the exterior most fabric ply
to the sewn assembly,
[0093] FIG. 28 shows the resultant assembly, formed after the
sewing shown in FIG. 27, after being trimmed and sealed at the same
time using ultrasonic method, the trimming width covers the
stitches so that no stitching remains along the lower perimeter of
the assembly, the exterior most fabric ply is still flipped to the
interior of the core assembly,
[0094] FIG. 29 shows the exterior most fabric ply of the core
assembly has been flipped over so that it covers the exterior
surface of the core assembly, each of the wing regions is also
flipped over so that its free end points away from the core
assembly, a small piece of fabric adhesive tape (the same type as
that used in FIG. 13A for joining the shoulder strap to the core
assembly) is then ironed over the interior side of the core
assembly and the wing region at their highest joining point (for
reinforcing the attachment of this relatively weak point),
[0095] FIG. 30(A) shows the exterior most fabric ply of the core
assembly having been re-positioned on the exterior of the core
assembly using needles or pins, (B) shows a detailed cross section
through the lower perimeter, showing the blind seamless join that
is formed,
[0096] FIG. 31(A) shows the exterior most fabric ply having been
trimmed so that a hem is formed for edge wrapping along the upper
perimeter of the bra cup regions of the core assembly and the
shoulder straps, adhesive tape is applied to the hem of the
exterior most fabric ply, (B) shows a cross-sectional detail
showing the exterior most fabric ply, the tape attached there to,
and the underlying core assembly,
[0097] FIG. 32(A) shows folding of the hem of the exterior most
fabric ply about the upper perimeter of the bra cup regions and the
shoulder straps, (B) shows a cross-sectional detail showing the
exterior most fabric ply, the tape attached there to, and the
underlying core assembly, the exterior most ply and tape having
been folded onto the interior side of the core assembly and sealed
thereto,
[0098] FIG. 33 shows the unfinished product after the step
described in FIG. 32,
[0099] FIG. 34 shows back strap fasteners (i.e. catches and hooks)
being positioned onto the free ends of the wing regions by adhesive
tape (a single column of two hooks on the left hand wing as looking
at the Figure and three columns of two "eyes" each on the right
hand wing, the hooks being attached from the interior side by
adhesive taping and ironing, the eyes being attached by a similar
method from the interior side of the wing and show through cuts in
the wing to the exterior surface, a small elongated foam piece is
positioned above the hook piece by adhesive tape, the free end of
each exterior most fabric ply which extends beyond the back strap
fastener is then folded so that it covers the back strap fastener,
the hooks being shown through cuts in the folded free end of the
exterior most fabric ply to the interior surface, and
[0100] FIG. 35 shows finished product in plan view looking at the
exterior side.
[0101] With reference to FIG. 35 there is shown a bra 54 that may
generally be defined by a breast or bra cup region 17, wing regions
30A and 30B as chest bands and shoulder straps 55A and 55B. The
shoulder straps 55A and 55B extend between the breast cup regions
17 and each of the wing regions 30A and 30B respectively.
[0102] Such over the 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 similar.
[0103] The construction of the brassiere will now be described.
[0104] A core layer or lamination is formed consisting of a fabric
layer 1 with foam layer 2 to form an assembly of laminated plies 3.
Such assembly may be created in a continuous process to create a
long sheet. Alternatively the assembly may be formed as discrete
sheets. The lamination is formed by application of heat and
pressure to the fabric layer 1 and foam layer 2 by known methods.
From the assembly of laminated plies two rectangular pieces 4 are
cut. One of these is used to form an exterior layer 5; another is
used to form an interior layer. A further piece is cut from the
assembly 3, or from another lamination of foam and fabric to form
the shoulder strap parts 24. The shoulder strap parts 24 differ in
their construction to the interior and exterior layers in that they
have, in the preferred embodiment another fabric layer on the other
side of the foam, i.e. the layup is fabric, foam, fabric.
[0105] The rectangular piece 4 for the exterior layer 5 is then
shaped by shaving the foam. The shaping process forms a basic bra
shape including a pair of breast cup regions and a bridge region
extending between the two bra cup regions. In the preferred
embodiment this shaping is to form an apex 6 at around the middle
of each bra cup region 17. However in other embodiments there may
be no shaping at all, shaping just to reduce the overall thickness
of the foam layer, or other forms of shaping in other areas to
change the shape and/-or density of that area. In some embodiments
the exterior layer 5 may not have a fabric layer at all, the
exterior layer of the bra being formed by an exterior most fabric
ply 27 (see later).
[0106] An underwire structure 7 is formed by wrapping an arcuate
metallic underwire 8 within a sock of fabric material 9 closed at
both ends by bar-tacking 11. The fabric may also be closed by
folding and sewing, heat sealing or similar.
[0107] The shaved exterior layer 5 is then located between the
upper 12A and lower 12B platens of a moulding machine 12, prior to
moulding to impart a three dimensional shape to the exterior layer
5. The platens 12A and 12B are then brought together to apply
pressure and in the preferred embodiment, heat, to impart the three
dimensional shape to the exterior layer. The resulting layer has
the bra cup region 17 now clearly formed.
[0108] The foam side of the now moulded exterior layer 19 is then
sprayed with adhesive 13 by a spraying machine 15. The adhesive 13
may be any form of adhesive for example heat or chemical (two pot)
activated, contact adhesive, self setting or similar. The foam
layer 2 side of the exterior layer 19 has an underwire structure 7
positioned (in the preferred embodiment by gluing via the applied
adhesive) close to the lower perimeter 16 of each bra cup region 17
on the foam layer 2 of the moulded exterior layer 19. A first
bridge layer 18 of flexible fabric material having non-stretch
properties is then positioned (in the preferred embodiment by
gluing) at the bridge region 56 (i.e. between two bra cup regions
17) on the foam layer 2 of the exterior layer 19. A further or
second bridge layer 57 of flexible fabric material (which is only
slightly stretchable) has a general "W" shape and is positioned (in
the preferred embodiment by gluing) along and over the underwire
structures 7, across the bridge region 56 and over first bridging
layer 18. Finally a piece of foam layer having a "U" shape 21 is
positioned (e.g. by gluing) above the second bridge layer 57 and
along and over each underwire structure 7. In alternative
embodiments the underwire structures 7 may be coated them selves in
adhesive, or may be located to the foam layer 2 of the exterior
layer 5 by fusion, for example by ultrasonic techniques, or heat
and/or pressure. Additionally this is the preferred lay-up order;
in other embodiments the lay-up order may be different.
[0109] The interior layer 20 cut out from the assembly of laminated
plies 3 shown in FIG. 1, this is then shaved and moulded. The
moulding process for the interior layer 20 is the same as that for
the exterior layer with the exception that the orientation of the
interior layer is reversed. In the interior layer 20 moulding
operation the male mould platen 12A locates against the fabric
layer 1, the female mould platen 12B locates against the foam layer
2 of the interior layer 20. The interior layer 20 may be shaved and
moulded at any time in the process leading up to this point. In the
preferred embodiment whilst the moulding machine may be the same as
for forming the exterior layer 19, the platens of the machine are
different.
[0110] The moulded exterior layer 19 and the now moulded interior
layer 22 are then located in a moulding machine 12 (whether the
same machine as earlier, and in the preferred embodiment this has
different platens to those that moulded the interior and exterior
layers) to form a core assembly 23 having a proximal face and an
opposed distal face and an upper edge or perimeter 48 and a lower
edge or perimeter 16. The layer 19 and 22 located so that the foam
layer 2 of each respective layer are located against each
other.
[0111] Pressure and/or heat is then applied to form the lamination
of [0112] the two layers 19 and 22, [0113] the underwire structures
7, [0114] the layers of fabric material 18 and 57, and [0115] the
foam pieces 21 along the lower perimeter 16 of each bra cup region
17 and the bridge region becoming sandwiched between the moulded
exterior layer 19 and the moulded interior layer 22. The resultant
core assembly is then cut from the above sandwich lay-up. This
cutting may be part of the moulding process, either by knives
located in the mould as part of the primary or secondary motion of
the platens. It may also be achieved by a secondary motion of the
platens to shear the unwanted sandwich away. Alternatively it may
be done in an operation away from the mould, e.g. by hand cutting,
or other machining. The core assembly 23 has a bra exterior 65
(exterior most to the wearer) and a bra interior 64 (interior most
to the wearer).
[0116] Shoulder strap parts 24 (made from an assembly of
pre-laminated plies having a foam layer sandwiched between two
fabric layers) are attached to the core assembly 23 by two small
pieces of fabric tape 25 having adhesive on one side, one end of
the shoulder strap part 24 is attached to the core assembly 23 by
wrapping the small piece of fabric tape 25 over the butt or lap
joint of the strap end and core assembly. The adhesive of the tape
25 will then melt and provide bonding upon being heated up, e.g. by
ironing, or other fusion techniques depending on the adhesive
used.
[0117] A distal fabric layer or exterior most fabric ply 27 is then
preshaped by bullet 28 moulds via a pressure heat forming
operation. The shaped exterior most fabric ply 27 is then
positioned onto the bra exterior 65 of the core assembly 23 using
needles, or pins, 29.
[0118] Next will be described the formation of the wing regions 30
that form the chest straps of the brassiere 54.
[0119] The exterior most fabric ply 30A of each wing region 30 of
the brassiere 54 is cut out from a piece of cloth along the edges
of a pre-shaped plastic ruler 35. The interior most fabric ply 30B
of each wing region 30 is also cut out from a piece of fabric
material. The interior most fabric ply 30B has adhesive 33 (whether
activated or to be activated) on one side covered by protective
paper 34, a pre-shaped plastic ruler 35 (different to that used for
the exterior layer) is used to guide the cutting. The exterior most
fabric ply 30A is longer than the interior to provide overlaps to
be used later. The exterior most fabric ply 30A is then attached to
the interior most fabric ply 30B of the wing portion 30 by sewing
along the longest edge of each of these two plies. The adhesive
(once exposed) will be between the two plies.
[0120] The sewn wing region 30 assembly is then cut along the
joined edge of the two plies, so that no stitching remains, and at
the same time the two plies are sealed together along a new edge
using ultrasonic methods, producing a joined edge 59.
[0121] A strip 58 is also prepared (not necessarily at this point
of the process, but may be earlier prepared), by fixing of adhesive
tape 39 onto a rubber band 40. The strip (having adhesive tape on
one side of it) is then fixed, by the adhesive 39 located on it, to
the exterior most fabric ply 30A of the wing region 30 along the
joined edge 59; the purpose being to reinforce and/or provide
elasticity along the joined edge 59.
[0122] The exterior most fabric ply 30A and the interior most
fabric ply of the wing portion 30B of the wing region 30 are then
located between two platens 62A and 62B, and then are laminated
together with application of heat and/or pressure, to form the
chest strap 60. The resultant laminated plies of the chest straps
60 are then trimmed along the edge of the interior most fabric
ply.
[0123] The attachment of the exterior most fabric ply 27 and the
chest straps 60 to the core assembly 23 will now be described.
[0124] Each of the chest straps 60 is located with its edge 63 to
be sewn pointing outward (i.e. toward the perimeter 61 of the cup
of the core assembly 23). The exterior most fabric ply 27 edge is
moved away so as not to be sewn at this point (the exterior most
fabric ply, though not shown, is on the other side (the exterior
side) of the core assembly 23). The chest straps 60 are then sewn
36 on at a securing zone. This is easiest done with the core
assembly's bra interior 64 facing upward, though other ways are
also possible.
[0125] The assembly (chest strap 60, core assembly 23 and exterior
most fabric ply 27) is then turned over to have the bra exterior 65
showing. The exterior most fabric ply 27 is un-pinned and flipped
over to the interior side of the core assembly 23, it is then
oriented so that the moulded-in bullet shapes from FIG. 15 are
pointing into the bra interior 64 of the core assembly 23. The wing
regions then receive a further sewing from the exterior side of the
core assembly to the core assembly The exterior most fabric ply 27
of the core assembly 23 is then further sewn onto the core assembly
23 along the lower perimeter 16 of the core assembly 23, by a
further line of stitching added to attach the exterior most fabric
ply.
[0126] The result is sewing through the core assembly 23 and chest
strap 60 and exterior most fabric ply 27. The chest strap edge 63
is directed toward the perimeter 61 of the core assembly 23. The
body of the chest strap 60 is directed toward the bra interior 64.
The exterior most fabric ply 27 is shown with the bullet shape
pointing into the bra interior 64 of the core assembly 23.
[0127] The resultant assembly is then trimmed and sealed at the
same time using the ultrasonic method. The trimming width covers
the sewing 36 so that no stitching remains along the lower
perimeter 16 of the assembly. The exterior most fabric ply 27 is
still flipped to the bra interior 64 of the core assembly 23.
[0128] Each of the chest straps 60 is then flipped outward so that
its free end points away from the core assembly 23, a small piece
of fabric adhesive tape 25 is then ironed over the interior side of
the core assembly 23 and the chest strap at their highest joining
point. This reinforces the attachment at this relatively weak
point. The tape 25 can be the same as that used for attaching the
strap parts 24 and may be adhered using similar methods.
[0129] The exterior most fabric ply 27 is then re-positioned on the
bra exterior 65 of the core assembly using needles or pins. This is
achieved by folding it over the lower perimeter 16 so that covers
the raw edge of the sealed and trimmed lower edge and is relocated
back onto the bra exterior 65 surface. The folding of the exterior
most fabric ply 27 over the lower perimeter will create a distal
flap where the edge of the exterior most fabric ply 27 is sewn onto
the core assembly 23. The resulting seamless blind join 67 is then
formed on the bra interior 64. In the preferred embodiment this
seamless blind join 67 is located just "up" from the lower
perimeter 16. However in other embodiments it may be on the lower
perimeter 16 itself, or further up the "height" of the bra interior
64. In one embodiment, the exterior most fabric ply 27 will cover
the securing zone where the wings are sewn onto the core assembly
23, thereby increasing comfort levels of a person wearing the
brassiere.
[0130] The exterior most fabric ply 27 is then trimmed so that a
hem 66 is formed. The hem 66 is for edge wrapping along the upper
remaining perimeter 48 of the bra cup regions 17 of the core
assembly 23 and the shoulder straps 55 (or at least part thereof.
Adhesive tape 39 is applied to the hem 66 of the exterior most
fabric ply 27.
[0131] The hem of the exterior most fabric ply 27 is then folded
about the upper perimeter 48 of the bra cup regions 17 and the
shoulder straps--, FIG. 32(B) shows a cross-sectional detail
showing the exterior most fabric ply, and the tape is sealed to the
fabric layer 1 of the moulded interior layer 22 of the core
assembly 23.
[0132] Thereafter back strap fasteners (i.e. eyes 52 and hooks 51)
are positioned onto the free ends of the chest straps 60 by
adhesive tape 39. A single column of two hooks 51 on the left chest
strap 60 as looking at FIG. 34 and three columns of two "eyes" 52
each on the right chest strap 60. The hooks 51 are attached from
the interior side of the chest strap 60 by adhesive taping and
ironing. The eyes 52 are attached by a similar method from the
interior side of the chest strap and show through cuts 53 in the
chest strap to the exterior surface. A small elongated foam piece
is positioned above the hook piece by adhesive tape. The free end
of each exterior most fabric ply 27 which extends beyond the back
strap fastener is then folded so that it covers the back strap
fastener. The hooks are shown through cuts in the folded free end
of the exterior most fabric ply to the interior surface. Each
shoulder strap is then extended by connecting an extra piece
thereto by an ultrasonic method such as ultrasonic welding. The
finished product is shown in plan view looking at the exterior side
in FIG. 35.
[0133] At the ends of each of the chest bands 60 the hooks 51 and
eyes 52 for the hooks that are mutually cooperative to allow for
the bra to be fastened about the chest of a wearer.
[0134] The bra may be seamless and made from materials at least
some of which are moulded or mouldable and that are engaged to each
other preferably at least in part by lamination. In other
embodiments the brassiere 54 may have no shoulder straps, or the
seamless edge may be incorporated into garments other than a bra,
but nevertheless perform a similar function.
[0135] The foregoing description of the invention includes
preferred forms thereof. Modifications may be made thereto without
departing from the scope of the invention.
* * * * *