Bra construction

A breast cup construction of a cup shape to be incorporated as part of a brassiere, the breast cup construction comprising a molded to a cup shape laminated core assembly comprising a ply of foam material and a ply of fabric material disposed to the convex side of the foam material. An exterior ply is overlying and to the concave and convex sides of at least part of the laminated core assembly. The exterior ply is folded at and to define at least part of the neckline perimeter of the cup shape.

FIELD OF THE INVENTION

The present invention relates to an improved bra construction and in particular to a bra construction which includes a molded cup form utilizing moldable materials.

BACKGROUND

For some people it is important that a bra is of a kind which is as inconspicuous as possible. Modest and conservative people still treat a bra as a traditional form of undergarment, parts of which should not be visible when worn underneath overgarments. Accordingly in bra constructions and to meet such desires, bra assemblies and construction techniques need to be considered which achieve such needs. An inconspicuous bra cup construction may not just need to address the pattern of panels defining the cup construction but may also need to pay attention to the perimeter construction of element of the overall bra. The importance of the construction around the top or neckline region of the breast cups of a bra is important as it is this region of the bra which may on occasion become exposed to the exterior of the garment either through shadowing through the material of the overgarment or through a gap of the overgarment and the wearers body.

Molded breast cup constructions are becoming more prevalent and can eliminate the need for stitching across the breast cup which previously was required to define the three dimensional cup shape formed from at least two panels sewn together across the breast cup configuration. Molded breast cups have eliminated the need for stitching across the breast cup, however stitching may still be provided to provide a trim to the neckline and indeed to the entire perimeter of the breast cup construction as incorporated with the other components to define the bra.

Accordingly it is an object of the present invention to provide a bra with a breast cup construction which provides a reduced conspicuous neckline.

It is a further object of the present invention to provide a breast cup construction which has no stitching provided along at least a substantial part of the neckline of the breast cup.

BRIEF DESCRIPTION OF THE INVENTION

In a first aspect the present invention consists in a breast cup construction of a cup shape to be incorporated as part of a brassiere, said breast cup construction comprising:

a molded to a cup shape laminated core assembly comprising a ply of foam material and a ply of fabric material disposed to the convex side of said foam material

an exterior ply overlying and to the concave and convex sides of at least part of said laminated core assembly, said exterior ply folded at and to define at least part of the neckline perimeter of said cup shape.

Preferably said exterior ply is folded at and along to define the entire neckline perimeter of said cup shape.

Preferably said ply of foam material and said ply of fabric material are coextensive.

Preferably said ply of foam material and said ply of fabric material are coextensive, said ply of foam material being of a reduced thickness at the neckline perimeter disposed perimeter thereof.

Preferably said ply of foam material and said ply of fabric material are coextensive, said ply of foam material being of a reduced thickness at the neckline perimeter disposed perimeter thereof and wherein the transition towards said reduced thickness is gradual.

Preferably said transition is a taper and wherein the thinnest part of said foam ply is at said neck line perimeter of said cup shape.

Preferably said transition is at region of said foam ply extending from said neck line perimeter disposed perimeter thereof to less than one third the diametric width across said cup shape.

Preferably said ply of foam material and said ply of fabric material are coextensive save for at a region extending inwardly from the neckline perimeter disposed perimeter of said core laminate assembly where said core laminated assembly is absent of said ply of foam material.

Preferably said region extending inwardly is less than one third the diametrical width of said cup shape.

Preferably said exterior ply is laminated to the concave side of said core assembly.

Preferably said exterior ply is laminated to the convex side of said core assembly.

Preferably said exterior ply is laminated to the concave side and the convex side of said core assembly.

Preferably said exterior ply is not sewn to said core assembly at said neckline.

Preferably said exterior ply is folded only about said core assembly at said neckline.

Preferably said exterior ply is sewn to said core assembly at the base line perimeter of said cup shape.

Preferably said exterior ply is coextensive with said core assembly to said concave side thereof.

Preferably said exterior ply is coextensive with said core assembly to said convex side thereof.

Preferably said exterior ply is coextensive with said core assembly to said concave side and said convex side thereof.

Preferably said exterior ply is a fabric material.

Preferably said neckline is curved when viewed in frontal direction.

Preferably said core assembly includes a ply of reinforcing material disposed to the concave side of said core assembly and is provided at the to be upwardly supportive region of said cup shape.

Preferably said reinforcing material is a panel of fabric material.

Preferably said panel of fabric material is laminated to the concave side of said foam ply.

Preferably said panel of fabric material is laminated to said foam material.

Preferably said exterior ply is creased defining the fold thereof.

In a second aspect the present invention consists in a breast cup of a cup shape to be incorporated as part of a brassiere, said breast cup comprising:

a molded to a cup shape laminated core assembly comprising a ply of foam material and a ply of fabric material disposed to the concave side of said foam material

an exterior ply overlying and to the concave and convex sides of at least part of said laminated core assembly, said exterior ply folded at and to define the neckline perimeter of said cup shape.

In a further aspect the present invention consists in a breast cup construction of a cup shape to be incorporated as part of a brassiere, said breast cup construction comprising:

a molded to a cup shape laminated core assembly comprising a ply of foam material and a ply of fabric material disposed to the convex side of said foam material

an exterior ply overlying and to the concave and convex sides of at least part of said laminated core assembly, said exterior ply enveloping the core assembly at at least those regions of said laminated core assembly disposed to the neckline side of said cup shape.

In a further aspect the present invention consists in a method of forming a breast cup construction comprising

(a) placing a molded to a cup shape laminated core assembly comprising a ply of foam material and a ply of fabric material disposed to the convex side of said foam material onto a ply of fabric material which has molded therein two cup shaped reliefs which are juxtaposed and abut each other along a junction line, in a manner to position said core assembly onto one of said cup shaped reliefs and wherein the neckline to be disposed perimeter of said core assembly is positioned adjacent said junction line,

(b) affixing said core assembly with said ply of fabric material,

(c) folding said ply of fabric material about said junction line to bring the other of said cup shape reliefs in overlying relation with said core assembly to the other side of said core assembly as affixed in step (b) and

(d) affixing the second cup shaped relief with one or both of said core assembly and said first cups shaped reliefs.

Preferably said neckline to be disposed perimeter of said core assembly is positioned adjacent said junction line,

Preferably said affixing the second cup shaped relief with one or both of said core assembly and said first cups shaped reliefs is by laminating.

Preferably said affixing said core assembly with said ply of fabric material a laminating affixing.

Preferably said cup shape laminated core assembly is formed from a perform panel laminated core assembly of a ply of foam material and a ply of fabric material.

Preferably said ply of foam material is tapered towards an edge of said panel.

Preferably said cup shape is molded into said perform by a molding press, the positioning of the region of taper of said panel being placed relative to said molding press such that said cups shape is generated therein with said taper disposed at the neckline to be disposed region of said cup shape.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth. For the purposes of illustrating the invention, there is shown in the drawings a form which is presently preferred. It is being understood however that this invention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION OF THE INVENTION

With reference toFIG. 1there is shown a bra1which incorporates a breast cup construction2which is supported by a lower perimeter support3, torso straps4, and optionally shoulder straps5. The breast cup construction defines a three dimensional cup form and may be of a particular size and/or shape as desired. The breast cup construction includes a neckline15a base region6a central region7and an outer perimeter region8. A breast cup2formed according to the present invention may be incorporated with the other components of the bra by the sewing of the lower perimeter support3to the breast cup2and the engagement of the shoulder straps5to upper portions of the breast cup2. The neckline15of the breast cup remains a free edge and preferably extends between the central region7of the breast cup2at where the breast cup construction2engages to the other of the breast cups of the bra and the shoulder strap attachment region where the shoulder straps5engage with the breast cup2or the perimeter3.

The breast cup2of the present invention is of a molded breast cup construction and as a consequence allows for the breast cup to be formed without the need or by reducing the need for stitching to finish. Accordingly a substantial part if not all of the parts of the breast cup2are made from moldable materials. With reference toFIG. 2, there is shown a sectional view of a breast cup2through for example section AA ofFIG. 1. At the neckline15of the breast cup2there is shown a free edge of the breast cup2and at the lower perimeter region6there is shown stitching9which may for example be the stitching provided to affix the breast cup to the lower perimeter support3.

The breast cup construction preferably includes a core assembly10which consists of at least a ply of foam material11such as for example stretched foam. This foam material may be of a thickness of approximately 6 mm. Affixed by lamination (e.g. by heat welding and/or adhesive affixing) to the foam ply11is a fabric ply12. This fabric ply may contain for example 90% polyster and 10% spandex. The fabric material is significantly thinner than the foam material and provides a supporting substrate to ensure the maintenance of the integrity of the foam layer prior to and during the forming steps and also to provide a separation between the foam layer and that portion of the molding machine (reference to which will be made hereinafter) to mold a cup form into the core assembly10of the breast cup2. The foam ply11is preferably directly laminated to the fabric ply12however in some configurations an intermediate ply may exist between the foam ply11and the fabric ply12. Furthermore additional plies may be provided to the preferred form of the core assembly10as just described and a second fabric layer (not shown) may be provided to the opposite side of the foam ply to which the fabric ply12is provided.

The breast cup2has a convex side13and a concave side14. Provided to both the concave and convex side and extending continuously about and at least in part along the neckline15extending between the central region7and the opposite end of the neckline15at or proximate to which the shoulder strap5is affixed, there is provided an exterior ply or assembly of plies of exterior covering ply16of preferably a fabric material (containing for example 72% nylon and 28% LYCRA spandex). In the most preferred form and when viewed in frontal direction, the exterior covering ply16extends along the entire neckline15of the assembly. The exterior covering ply16is folded at the neckline region15about and to define the neckline15of the breast cup2. In the most preferred form the exterior covering ply16envelopes the entire core assembly10of the breast cup2. Indeed in the most preferred form the exterior covering ply16is of a single sheet of fabric material however in alternative configurations, the exterior covering ply16is also engaged to another fabric material which provides an extension to the portion of the exterior covering ply16which does extend and fold about the neckline15of the breast cup2. As for example shown inFIG. 4, the exterior covering ply16terminates on the concave side14at a seam18at which it is engaged to a further ply such as a fabric ply19. Effectively the exterior covering ply16and the ply19do provide coverage to envelope the core assembly10. However and in yet further configurations, the core assembly10may not be entirely enveloped by a or the exterior covering ply16. However the exterior covering ply16does extend and fold about and to define the neckline15. The core assembly may include additional plies positioned intermediate of the foam ply11and the exterior covering ply16.

With the provision of a fold defining the neckline15of the breast cup2and provided by the exterior covering ply16, no stitching is necessary at the neckline of the breast cup2and hence of the bra assembly. By folding about the neckline disposed edge of the core assembly10, the covering ply16provides a trim without the need for stitching to be provided to the breast cup2. In order to enhance the degree of unobtrusiveness of the neckline of the breast cup construction a further enhancement may be provided by the provision of a taper or tapered region20of the breast cup core assembly10as shown inFIG. 20. The neckline disposed edge15Aof the core assembly10may consist solely of the fabric ply12. Extending from the neckline disposed edge15Aof the core assembly10is the foam ply11which tapers to a full thickness over a distance which allows for the taper to be gradual enough to not be noticeable to the exterior of the breast cup2. The tapered region20of the foam ply11tapers to a point at the neckline disposed edge15Aof the core assembly and with reference toFIG. 21, is positioned at the neckline15of the cup2when the covering fabric ply16is engaged and folded about the neckline15. In an alternative configuration the foam ply11may not extend all the way to the neckline15and the fold of the covering fabric ply16may be provided a distance away from the neckline disposed end15Aof the foam ply11. In the configuration ofFIG. 22, the core fabric ply12does extend to the neckline15however this may also be optional and the core fabric ply12may terminate at the same point as the foam ply11at its neckline disposed edge15Awhich is not at the neckline15.

In the most preferred form and as a consequence of the manufacturing steps which will hereinafter be described, the fabric ply12of the core assembly10is disposed to the convex side of the core assembly10. The foam ply11is disposed to the concave side of the core assembly10. With reference toFIG. 3, an additional reinforcing panel30may be incorporated with the core assembly10. The reinforcing pad or panel30may be of a fabric or non-woven synthetic material and may for example contain 82% nylon and 18% LYCRA spandex. It is preferably disposed to the lower portions of the breast cup2as for example shown inFIG. 3. The reinforcing panel30is provided towards the lower portion of the breast cup2as this is where the greatest pressure as a result of the weight of the breast is supported by the breast cup2. Accordingly such additional reinforcing will ensure that the integrity of the shape of the breast cup2may be maintained or is encouraged to be maintained. The panel30is preferably laminated to the foam panel11. Such lamination may be by a heat welding or by an adhesive or in part by both. The reinforcing panel30may be of a single ply material or of a multi-ply assembly.

The exterior covering ply16preferably also lies over the reinforcing panel30thereby capturing the reinforcing panel30between the exterior covering ply16and the foam ply11.

In one form the foam ply11is not tapered as for example shown inFIGS. 2 and 3. The tapered configuration as for example shown inFIG. 4or in part shown inFIG. 21or22allows for the breast cup2to be of a thin walled construction at the neckline15. The provision of the thin walled construction of the breast cup2at the neckline15further reduces the obtrusiveness of the breast cup2at the neckline and virtually feathers the breast cup at the neckline with and against the skin of the wearer of the bra.

Accordingly the fold of the exterior covering ply16to define the edge of the neckline of the breast cup2can be provided without the need for stitching at that region. Whether or not the foam ply is tapered, the absence of stitching will allow for the neckline to remain very plain and uncomplicated and thereby reduce the obtrusiveness of the neckline of the breast cup2.

A preferred method of manufacture of the present invention will now be described with reference toFIGS. 5 to 19.FIG. 5shows a pre-form construction of the core assembly consisting of a planar foam ply11and the fabric ply12. The pre-form as shown inFIG. 5is of a rectangular or square shape and of a sufficient size to allow for the introduction by molding, of a cup form therein. For the configuration of the breast cup construction where the foam is tapered at the regions towards the neckline15, a region40of the foam adjacent one edge41of the pre-form may be removed. Such removal may be to provide a gradual taper of the foam from the major region42of the foam ply to a thin or pointed edge at the perimeter41of the ply. Whilst in the preferred form the taper is towards the perimeter41it may be that the taper is provided to terminate inward from such edge41of the pre-form of the core assembly10.

In the method where a molding device as shown inFIG. 8is provided which simultaneously molds two cup forms, the pre-form of the core assembly10may be affixed to a like pre-form by the sewing along the edge41of the respective core assemblies10as shown inFIG. 7.

With reference toFIG. 8, the core assembly10is moved to a molding device which includes an upper mold44and a lower mold45which include relief features46,47(preferably x2) which are of a three dimensional cup form of an approximate shape of the desired breast cup shape to be assumed by the breast cup2. The upper and lower molds44,45are able to move towards and away from each other. In a condition moved towards each other they will subject the pre-form of the core assembly10to a deformation. Preferably the upper and lower molds are heated sufficient to affect the resilience of the core assembly such that when the mold is released after the molding step, a three dimensional cup form remains in each of the pre-forms of the core assembly10. During this molding step the upper mold may be of a temperature of approximately 200 degrees Celsius and the lower mold may be of a temperature of approximately 195 degrees Celsius. The dwell time of the molding holding the molds in the closed condition would be in the order of 90 seconds.

In an alternative form of a molding device as for example shown inFIG. 9, the molding device may only include a single cup form relief feature in each of the upper and lower molds44,45. As can be seen with reference toFIGS. 8 and 9, the tapered region40is provided to be positioned between the two mold portions such that the taper initiates within the relief portion and extends beyond the relief portion to the parallel planar surfaces49exterior of the cup form relief of the mold.

As a consequence the cup form molded in the pre-form core assembly has the tapered region positioned extending inwardly from the neckline of the cup form which is defined by the region50of the upper mold44and likewise for a corresponding region of the lower mold45.

With reference toFIG. 10, there is shown an alternative of the method of the present invention and wherein no removal of foam to provide a tapered or reducing thickness region is provided in the foam ply of the core assembly10. In this alternative configuration and which would generate for example a breast cup construction shown in cross-section inFIGS. 2 and 3, the step of removing the foam to define a pre-form as shown inFIG. 6is absent.

With reference toFIG. 11there is shown a plan view of the sewn together pre-form core assemblies10of the present invention having been subjected to forming by the molding device ofFIG. 8. As can be seen the relief of the upper and lower molds provide the neckline15of the cup forms molded in the pre-form at the region of reduced thickness of the foam of the core assembly.

The appropriate alignment of the pre-form with the mold can allow for such alignment to be achieved. Whilst in the most preferred form it is the entire neckline edge of the molded cup form which is of a reduced thickness, it may only be the upper or most prominent regions of the neckline15at where the region of reduced thickness of the foam ply is provided. With reference toFIGS. 6 and 11, it can be seen that the region of reduced thickness40is initiated from the main panel region42along a straight line. The straight line provision of the initiation of the reduction in thickness of the foam is convenient to achieve by machine or tool assistance. However it may be that a profiled line of initiation of reduced thickness of the foam may be provided which may be proximate to and to be parallel with the to be neckline of the breast cup2. Such is for example shown inFIG. 11A. InFIG. 11Athe line of initiation51runs parallel with at least a substantial part of the neckline15. However the molding apparatus may be reversed through 180 degrees and the concave defining side of the mold portion may instead be the upper mold portion.

The molds may be of 200° C. and 195° C. and a dwell time of approximately 90 seconds may be utilized to the apply the molding force and heat to the core assembly. Once the cup form has been molded into the pre-form of the core assembly the cup form may be cut from the perimeter of the pre-form to thereby define a cup shape as for example shown inFIG. 12. With reference toFIG. 12, there is shown the perimeter of the cup form. This configuration is of a kind where the foam panel is tapered and the line of initiation of taper is also shown. Prior to removal of the cup forms from the molded pre-form or subsequent thereto, the concave sides of the cups are sprayed with an adhesive. The adhesive is sprayed on at this point in time and allowed to dry for, say, 5 to 6 hours to avoid affixing when the cups are being placed onto the exterior covering ply16as hereinafter described, before heat is being applied by way of the molding devices at which time the adhesive will be melted to enable affixing. The application of the adhesive to the concave side of the cup form is to allow for this to be engaged to the exterior covering ply16to which reference will hereinafter be made.

Where a configuration as, for example, shown inFIG. 3is desired, and where a reinforcing panel30is to be included, such a reinforcing panel as, for example, shown inFIG. 13can be affixed to the concave side of the core assembly10. Such an assembled configuration is for example, shown inFIG. 14.

In the preferred form both sides of the reinforcing panel30are sprayed with an adhesive such as that which has been applied to the core assembly cup form and allowed to dry for between 5 to 6 hours. With the application of an adhesive to the various components of the assembly as herein described, and with the suitable application of heat which preferably comes by way of the molding devices during the lamination steps of the invention, the activation of the adhesive occurs for the purposes of achieving the laminated affixing of the components.

The introduction of the exterior covering ply16with the core assembly10firstly requires the pre-forming of the ply16. The covering ply16may be framed by a holding frame56which holds the fabric ply16at or towards its perimeter in a taught condition (FIG. 15). The fabric material held in such a condition is then able to be placed within a molding device ofFIG. 16analogous to the molding device ofFIG. 8. The molding device ofFIG. 16includes an upper mold57and a lower mold58. The molding device ofFIG. 16provides a molded profile to the covering ply16of two cup shapes separated by a gully58. With reference toFIGS. 17 and 17A, it can be seen that this gully58extends across the molded form60molded in the covering ply16by the molding device ofFIG. 16. During the molding of the ply16by the molding device ofFIG. 16, the upper mold is subjected to a temperature of approximately 185° C. and the lower mold to a temperature of approximately 185° C. and the dwell time for holding the mold in the closed condition thereby introducing the form to the exterior covering ply16is approximately 120 seconds. The path defined by the gully is substantially the same path as defined by the neckline disposed edge15A of the cup form core assembly shown inFIG. 12. The profile of the gully58is of a three dimensional profile which follows a three dimensional profile substantially similar to the neck line disposed edge15A of the cup form core assembly10. That portion61of the cup molded in the exterior covering ply16disposed to one side of the gully58is substantially of the same shape as the cup form of the core assembly10. Towards the other side of the gully58there is defined the other portion62of the shape molded in the exterior covering ply16.

With reference toFIG. 18, the core assembly10with or without the provision of the reinforcing panel30is placed onto the region61of the molded form of the exterior covering ply16such that the neck line disposed edge15A of the core assembly10is positioned along or at least parallel with the gully58. Since both are of a matching profile, the edge15A of the core assembly10can follow the gully58. However in some configurations of the present invention and as for example shown inFIG. 22, the neck line disposed edge15A of the core assembly10may not be positioned abutting the gully58and may be removed some distance therefrom. In any event, the gully58provides a fold line for the molded exterior covering ply16to be created, the fold line defining the neck line15of the finished form of the cup2. With reference toFIG. 18it can be seen how the other portion62of the molded ply16can be maneuvered to be folded about the fold line at the neck line15to thereby overlay the convex side of the core assembly10to a configuration as shown, for example, inFIG. 19.

During the affixing of the molded cup form core assembly10with the molded exterior covering ply16, heat and pressure are reapplied to encourage the adhesive affixing of the core assembly with the molded exterior covering ply16. In this step the molding temperature of both molds can be in the order of 185° C. and a dwell time pressure time of 30 seconds is used. The application of heat and pressure and with the use of adhesive would ensure a good laminated bond is established between the core assembly and the molded exterior covering ply.

In an alternative configuration, however not shown in the accompanying drawings, the core assembly10may be disposed to the concave side of the region61of the exterior covering ply16. The shape of the molding regions of the molding device ofFIG. 16may in such a situation be slightly different in order to provide a crease at the region of the exterior covering ply16intermediate of regions61and62to define a crease in the exterior covering ply16for defining the fold of that material to provide the neckline to the cup assembly. In such an application of the core assembly10, it may be that the fabric material12of the core assembly may be disposed to the concave side of the cup shaped core assembly10and the foam panel is disposed to the convex side in order to thereby have the foam ply11of the core assembly10engage against the convex side of the region61of the exterior covering ply16. However such a positioning of the plies of the core assembly may not be essential as the fabric ply12disposed to the convex side of the cup form core assembly may lend itself to being adhesively and laminatingly affixed to the exterior covering ply16which is preferably also of a fabric material. However since the foam panel lends itself more readily for laminated attachment to a fabric panel, it is the preferred form of the invention that during the step of attaching the core assembly10to the exterior covering ply16, that the interface of such engagement is between foam and fabric (foam ply11to fabric16).

One part of the molded form of the exterior covering ply16as molded by the apparatus ofFIG. 16is of a larger size than that portion to other side of the gully58. As can be seen with reference toFIG. 17, that portion62of the molded form of the molded exterior covering ply16is of a size larger than that portion61. The smaller portion61is that portion to which the core assembly10is adhesively affixed to be laminated as a first step to the exterior covering ply16. Since that portion62of the exterior covering ply16is to lie to the convex side of the core assembly it needs to be a larger size than that of the portion61disposed to the concave side of the core assembly. Furthermore, that portion disposed to the convex side, since it is more prone to shrinkage after washing requires for its size to be larger. Furthermore and in the preferred process during the application of the core assembly to the portion61of the molded exterior covering ply16as for example shown inFIG. 18, the core assembly10is to be held in situ and supported on a cooling mold during the adhesion process of the core assembly10with portion61of the molded exterior covering ply16cooling prior to the folding of portion62to the convex side of the core assembly, (for about 24 hours) will result in the shrinkage (due to the cooling of the material) of the portion62of the molded exterior covering ply16.

The profile of the molding device ofFIG. 16may be generated by computer aided design in order to achieve a profile of the gully58of the covering ply16to match the profile of the neckline disposed edge15A of the core assembly10.

Once the covering fabric16has been folded, it can be sewn at the base of the cup2by a line of sewing63extending about the lower edge of the cup2so as to ensure that the free edges of the exterior covering ply16are captured with the core assembly and are presented so as not to fray. Any trimming may also occur once the sewing step has occurred or before trimming has occurred wherein the sewing step is for example of an overlooking kind to provide an appropriate finish to that portion of the perimeter of the cup assembly finished by such sewing. By such methods, the cup form as disclosed in any of the configurations as herein described or appreciated by those skilled in the art to fall within the scope of this invention can be formed.

The portion62of the exterior covering ply when folded need not necessarily become adhered to the exterior or convex side of the core assembly10. Adhesion may occur but such is not essential and a slightly loose fitting or at least moveable to the core assembly convex side of the exterior covering ply may be provided.

With reference toFIG. 23, there is shown in a sectional view a support structure90and a pressing board91intermediate of which there is positioned the foam pre-form core assembly10. The support90includes a rebate92into which part of the pre-form core assembly10is located and supported. The rebate is of a shape so that at least a substantial part of the foam ply can be retracted within the support90below its upper surface93. That portion of the core assembly10protruding beyond the upper surface93of the support90is at least in a substantial part if not all parts thereof removed to define the tapered finish to the ply of foam prior to it being subjected to the molding. Accordingly the shaded portion of the core assembly10is removed to thereby define the tapered region. The core assembly10is placed on the support90with the fabric ply facing the rebate side of the support90.

With reference toFIG. 25there is shown a cutting station94. The cutting station94includes a support platform95to provide support to the support means90of the configuration ofFIG. 23. The lower surface96of the support means90ofFIG. 23is placed onto the support platform95. A cutter97which may for example be a saw is driven about a locus which includes the presentation of the cutter97for cutting the foam ply above the surface93of the support means90passing relative thereto. The cutter97is of an endless configuration and moves about a locus defined by idler wheels98or driven wheels98in for example direction X. The movement of the support means97and hence the foam ply of the core assembly10is in a direction and with reference toFIG. 25, either in or out of the page. The distance A between the support platform95and the cutter97presented for cutting the foam, is of a distance approximately the same as the distance B between the lower surface96and the upper surface93of the support means90. Distance A may be slightly larger but not less than distance B.

With reference toFIG. 24, there is shown a semi-automated arrangement wherein a conveyor belt99is provided supporting a plurality of units100ofFIG. 23. The conveyor99delivers the units100to the cutting station94for the presentation thereof to the cutter97for removing the foam. The panel91placed on top of the foam ply of the core assembly10provides a weighted member to press on top of the foam ply to provide some structure of rigidity to the foam during the cutting thereof. The weighted panel91ensures that the core assembly remains located in the appropriate position within the rebate92of the support means90during cutting.