Abstract:
A method is provided for molding a breast-receiving cup for a garment, comprising laminating a support fabric to a lofted material to form a lofted assembly, positioning the lofted assembly in a molding apparatus having a first mold with a projecting element and a second mold having a recessed element, and closing together the first mold and the second mold while maintaining a uniform preset gap between the projecting element and the recessed element to form a molded lofted assembly in the shape of a breast-receiving cup.

Description:
RELATED APPLICATION 
     This application is a divisional of U.S. patent application Ser. No. 11/150,985, filed on Jun. 13, 2005, now U.S. Pat. No. 7,666,059, which is a continuation-in-part of U.S. application Ser. No. 10/631,474, filed on Jul. 31, 2003, now abandoned, the contents of which are incorporated by reference herein in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a method for molding garments and the garments made. More particularly, the present invention relates to a method for molding a lofted material having a laminated support layer and the resultant garment. 
     2. Description of the Prior Art 
     Various methods and mechanisms for molding different types and assemblies of material have been developed and are known. For example, U.S. Pat. No. 3,464,418 provides an apparatus and method for making brassiere pads from bonded non-woven fibrous batting material, U.S. Pat. No. 4,025,597 provides a method of making a brassiere cup from a soft fibrous board material, U.S. Pat. No. 4,080,416 provides a method for making multi-layered seamless brassiere pads, and U.S. Pat. No. 4,250,137, provides a process for preparing breast pads or fronts such that the pads are centrally soft and peripherally firmer. 
     Notwithstanding that which is known, there remains a continuing need for improved methods for molding lofted material having a laminated support layer to provide a three dimensional shape thereto without compromising the loft characteristics associated with such material. Problems heretofore associated with various processes of molding a lofted material include at least the following: (1) thinning of material at points of increased pressure or applied heat, or both, such as for example, the apex of a bra cup or pad, (2) requiring relatively complicated or additional structural elements, or both to facilitate a desired result, for example, spacer devices or vacuum systems, and (3) requiring that heat, pressure or both be avoided at relatively substantial portions of the material being molded, which can complicate the molding process. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a method for molding lofted material having a nylon laminated support layer. 
     It is another object of the present invention to provide a garment that is made from a lofted material that has a nylon laminated support layer that is molded to maintain the loft characteristics of the lofted material. 
     It is yet another object of the present invention to provide a garment that is molded from a lofted material that has a laminated synthetic support layer. 
     It is still yet another object of the present invention to provide a brassiere that is molded from a lofted assembly having a lofted material and a laminated synthetic support layer that is deeply molded to provide support for a large sized brassiere. 
     These and other objects and advantages of the present invention are achieved by a molding apparatus with at least a first die or mold with a projecting element and a first level portion, and a second die or mold with a recessed element and a second level portion. The projecting element and the recessed element are formed such that when the first level portion of the first mold and the second level portion of the second mold are brought into relatively close relation, a uniform preset distance or gap is created between the projecting element and the recessed element. The gap is preferably adjustable to accommodate the loft of different materials. The first mold and second mold each are preferably selectively and/or independently heatable and configured as appropriate to facilitate the following material molding method. 
     The method for molding the lofted material essentially comprises the steps of first placing a pre-cut piece of nylon support fabric that is in a pre-determined position on a piece of lofted material, laminating the two materials together to form a lofted assembly, and positioning the lofted assembly in the molding apparatus. Thereafter, the first mold is closed in relation to the second mold, or vice-versa, sandwiching the lofted assembly therebetween such that the portion of the lofted assembly situated between the first and second level portions is compressed and the portion of the lofted assembly situated between the projecting element and recessed element is compressed only to the extent desired, or not at all. The extent of compression is adjustable. Following this closing step is a step of opening the first mold in relation to the second mold after a period of selectively providing pressure and/or heat as appropriate for the desired molding result. The resulting molded lofted assembly preferably provides a balance of comfort, support and durability. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other and further objects, advantages and features of the present invention will be understood by reference to the following specification in conjunction with the accompanying drawings, in which like reference characters denote like elements of structure. 
         FIG. 1  is a top view of the lofted material that is to be molded in accordance with an illustrative embodiment of the present invention; 
         FIG. 2  is a top view of the pre-cut piece of synthetic support fabric that is to be laminated to the lofted material in accordance with the present invention; 
         FIG. 3  is top view of the laminated assembly of lofted material and the synthetic support fabric in accordance with the present invention; 
         FIG. 4  is a cross-sectional side view of an apparatus for molding a lofted assembly in accordance with an illustrative embodiment of the present invention with the apparatus shown in an open position; 
         FIG. 5  is a cross-sectional side view of the apparatus of  FIG. 4  with the apparatus shown in a closed position; 
         FIG. 6  is a side sectional view of the apparatus of  FIG. 4 , reflecting a forming step in accordance with an illustrative embodiment of the present invention; 
         FIG. 7  is a side sectional view of an alternative apparatus for molding a lofted assembly; 
         FIG. 8  is a side sectional view of another alternative apparatus for molding a lofted assembly; 
         FIG. 9  is a plan view of yet another alternative apparatus for molding a lofted assembly; 
         FIG. 10  is a plan view of still another alternative apparatus for molding a lofted assembly; 
         FIG. 11  is a side sectional view of yet still another alternative apparatus for molding a lofted assembly; and 
         FIG. 12  is a perspective view of the lofted assembly molded in the form of a breast-receiving cup. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the drawings in general, and in particular to  FIG. 1 , there is shown an illustrative embodiment of the lofted material generally represented by reference numeral  30 . As used herein, as used herein, the term “lofted material” includes foam and circularly knitted and/or warp knitted single ply materials that may be a variety or combination of materials, such as batting, spacer fabric, etc. Spacer fabric may be a polyester and/or nylon fabric. Lofted material  30  is sized to form a deep breast-receiving cup for a brassiere upon being molded. 
     Referring to  FIG. 2 , support fabric  32  is shown. Support fabric  32  is cut in the shape of a crescent to ensure a comfortable and close fit at the lower lateral portion of the finished breast-receiving cup. Although the shape of support fabric  32  is shown as a crescent, other shapes capable of offering comfort and support to the wearer could also be used. Support fabric  32  may be any synthetic material. Preferably, the support fabric  32  is a warp knit material, such as nylon Jacquard, lace, etc. In all instances, support fabric  32  provides the level of comfort and support to the breasts of the wearer that would otherwise not be available without the enhanced support. Support fabric  32  may include a design such as, for example, a floral design; however, any design, such as a geometric pattern, also may be used. 
     In  FIG. 3 , support fabric  32  is pre-positioned on lofted material  30  before the two pieces of fabric are laminated together. A layer of adhesive is placed on support fabric  32  before it is placed on lofted material  30 . The adhesive is a glue that is heat activated and may comprise a film, a web, or polyester. The temperature required to laminate support fabric and lofted material  30  is between approximately 320° F. to 360° F. The lamination process is of a temperature that will preserve the loft and the aesthetic appeal of the lofted material  30  and the support fabric. After the lamination process, lofted material  30  and the support fabric  32  together form lofted assembly  36 . 
     Referring to the drawings and, in particular to  FIG. 4 , there is shown an illustrative embodiment of an apparatus for molding lofted assembly  36 . The apparatus  1  preferably has at least two mold elements, a first mold  10  and a second mold  20 . Preferably, the first mold  10  and the second mold  20  are complementary to one another. 
     First mold  10  and second mold  20  cooperate to mold or form a lofted assembly  36  positioned therebetween into a three-dimensional shape, such as, for example, that required by molded brassiere pads. Lofted assembly  36  may be any of a variety of materials or combination of materials and may be fashioned into a variety of forms, such as, for example, a garment. 
     First mold  10  preferably has at least one first contact surface  40  with at least one projecting element  50  in the form of a dome. First contact surface  40  also has a first level portion  42  about projecting element  50 . First contact surface  40  may also have any of a variety of other surface elements  43  associated therewith, such as, for example, one or more nodes, dimples, and/or teeth as shown in  FIGS. 9 through 11 . First contact surface  40  may be interchangeably associated with first mold  10 . First mold  10  may be interchangeably associated with apparatus  1 . The interchangeability of first contact surface  40  and/or first mold  10  provides apparatus  1  with further diversity in application or use. 
     First mold  10 , first contact surface  40 , projecting element  50 , and/or first level portion  42  may be heatable. This heating may be accomplished in any of a variety of ways, such as, for example, via electric heating wires or rods associated with first mold  10 . These heating wires or rods may conduct or transmit heat, via first mold  10 , as appropriate, to provide any and/or all of the aforementioned elements thereof with sufficient heat for effective molding under a variety of different molding parameters. First mold  10  may have any shape, size, and/or configuration suitable for accomplishing one or more different molding operations. See, for example,  FIGS. 7 and 8 , which show alternative embodiments of first mold  10 . It is noted that the present invention is not limited to those configurations discussed and/or shown and that other configurations are also within the scope of the present invention. 
     The surface elements  43  are suitable for achieving a variety of different molding effects. For example, surface elements  43  may be on either or both projecting element  50  and first level portion  42  to interact with lofted assembly  36  during the molding process. Surface elements  43  may be, for example, one or more piercing elements, heating or cooling elements, cushioning or insulating elements, or any combination thereof. Other similar types of elements also may be used and are within the scope of the present invention. 
     Referring again to  FIG. 4 , second mold  20  has at least one second contact surface  60  with at least one recessed element  70  in the form of a dish. Recessed element  70  is complementary to and cooperative with projecting element  50  of first mold  10 . Second contact surface  60  also has a second level portion  62  about recessed element  70 . Second contact surface  60  also may have surface elements  43  associated therewith. Second contact surface  60  may be interchangeably associated with second mold  20 , and the second mold may be interchangeably associated with apparatus  1 . The interchangeability of second contact surface  60  and/or second mold  20  provides apparatus  1  with further diversity in application or use. 
     Second mold  20 , second contact surface  60 , recessed element  70 , and/or second level portion  62  may be heatable. Such heating may be accomplished in any of a variety of ways, such as, for example, by electric heating wires or rods associated with second mold  20 . These heating wires or rods could conduct or transmit heat, via second mold  20 , as appropriate to provide any and/or all of the aforementioned elements thereof with sufficient heat for effective molding under a variety of different molding parameters. Second mold  20  may be any shape, size, and/or configuration suitable for accomplishing one or more different molding operations in cooperation with mold  10 . See, for example,  FIGS. 7 and 8 , which show alternative embodiments of second mold  20 . It is noted that the present invention is not limited to those configurations discussed and/or shown and that other configurations also are within the scope of the present invention. 
     As with the first mold  10 , surface elements  43  for providing a variety of different molding effects that may be on either or both recessed element  70  and second level portion  62  to interact with lofted assembly  36  during the molding process. 
     Referring to  FIGS. 5 and 6 , having described some of the elements of an illustrative embodiment of the present invention, first and second molds  10 ,  20 , respectively, may be configured to engage one another such that when first level portion  42  of first mold  10  and second level portion  62  of second mold  20  are brought into relatively close relation, a uniform preset distance or gap  80  is created between projecting element  50  and recessed element  70 . In one embodiment, gap  80  has an extent of about 0.1 inches. However, gap  80  also may have any extent appropriate for accomplishing a desired molding operation. Hence, gap  80  may be adjusted to accommodate the loft characteristics associated with a variety of different materials. This adjusting feature may be accomplished in different ways, such as, for example, via the preferred interchangeability of first and second molds  10 ,  20  and/or first and second contacting surfaces  42 ,  62 . Gap  80  also may be adjusted to influence the degree of loft associated with a material. That is, gap  80  may be reduced to provide a desired finish or effect to a lofted assembly  36 . Thus, it is apparent that the preservation of the inherent loft characteristics associated with a lofted assembly is independent of the heat, pressure and/or time associated with a particular molding process. The present invention efficiently and effectively preserves the inherent loft characteristics associated with a lofted assembly during the molding process. 
     The process of molding lofted assembly  36  includes at least the following steps. Referring to  FIG. 1 , lofted assembly  36  is first positioned in apparatus  1  between first mold  10  and second mold  20 . On lofted assembly  36 , support fabric  32  is positioned so that after the molding process, support fabric  32  will be positioned at the lower side edge of the lofted assembly. Referring to  FIG. 2 , first mold  10  is then closed in relation to second mold  20 , or vice-versa, to sandwich lofted assembly  36  therebetween. At least a portion of lofted material  30  is situated in gap  80  so that the inherent loft characteristics thereof are substantially preserved while at least another portion of lofted assembly  36  is substantially compressed between first and second level portions  42 ,  62  of first and second contact surfaces  40 ,  60 , respectfully. Next, first mold  10  is opened in relation to second mold  20 , or vice-versa, after an appropriate amount of heat and/or pressure has been applied for an appropriate period of time. Then, the molded lofted assembly is removed from apparatus  1  to perform any additional operations required for obtaining a desired effect, such as for example, eliminating any excess or unwanted material as appropriate to leave lofted assembly  36  with a three dimensional shape. 
     Referring to  FIGS. 1 through 3  and  12 , the molding process is capable of producing a three-dimensional lofted assembly  36 , in the form of a breast-receiving cup  90  having at the lower lateral position, the support fabric  32 . An advantage of the molding process is that cup  90  may be very deeply molded to accommodate wearers having larger breasts. The material of support fabric  32  is of such stitch pattern and material that it limits the elasticity of the lofted material  30  from which cup  90  is made. By limiting the elasticity of the lofted material  30 , wearers who require substantial breast support may wear cup  90  with comfort and confidence. 
     The present invention having been thus described with particular reference to the exemplary embodiments, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined herein.