Abstract:
The present invention refers to a wearer-friendly hook and eye closure for garments such as brassieres. In order to provide comfort, the eye closure component of the hook and eye closure includes, as part of its structure, a laminated foam or rubber-type padding. This foam or rubber could also be used without lamination. The foam or rubber-type base provides a cushion shielding the wearer from the feeling of the metal hardware. The foam edges also provide soft edges on the eye tape for extra comfort to the wearer. In addition, the backing material of this laminated foam eye tape is printable, so that label instructions can be printed on to it, and the brassiere can be designed tag-free for additional comfort. This hook and eye tape is also dyeable, so it can be offered in any desired color.

Description:
FIELD AND BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates to garments that are fastened with a number of book and eye pairs. In the present conventional eye tape that is used, the interlocked hooks and eyes often caused the wearer discomfort such as pain, chafing, and pressure because they could be felt through the thin folded fabric tape. 
         [0002]    The foam type padding, according to the present invention, replaces the conventional folded eye tape construction, and herewith grants protection and comfort to the wearer. 
         [0003]    Garments such as brassieres have used hook and eye fasteners for more than ninety years. The hooks and eyes are mounted on a stabilized fabric, usually a tape. The tape is then mounted on the garment. Typically, a series of vertical columns of eyes, usually between two and four eyes each, are aligned on a tape. Similarly there is a tape containing one corresponding vertical column of hooks such that the number of eyes for each column corresponds to the number of hooks. If there are three hooks in the hook column, there will be three eyes in each vertical column of eyes. 
         [0004]    The use of multiple columns of eyes allows for horizontal adjustments to the garment&#39;s fit. Typically, the eye columns are separated by approximately  16  millimeters. In such a case, if there were three columns of eyes mounted on the tape (usually the limit) the wearer would have an adjustment range of 16 millimeters to 32 millimeters. If the brassiere is of an incorrect size, discomfort and poor fit are experienced. Studies show that 30% of women buy brassiere of a size too small. Often the brassiere size requirements change over time or even during the day. Multiple columns of eyes provide for some relief. When the hook row gets inserted into an eye row, the back of the hook can be felt by the wearer due to the pressure of the closure that can be felt through the fabric. 
         [0005]    U.S. Pat. No. 1,421,002 of Brenner, patented Jun. 27, 1922 taught the use of fastening ends of brassiere band using a row of eyes and a line of hooks.  FIGS. 1   a  and  1   b  of the prior art illustrates a brassiere  10 , a line of hooks  11 , and a row of eyes  12 . 
         [0006]    U.S. Pat. No. 4,550,734 of Porco, granted Nov. 5, 1985 taught the use a brassiere which is useful for nursing, maternity, and holding prosthetic devices.  FIG. 2  of the prior art illustrates a brassiere  20 . Brassiere  20  includes fastening means which are hooks  21  and several sets of eyes  22  so that the brassiere can be easily adjusted to accommodate different sized girths. 
         [0007]    There is thus a widely recognized need for, and it would be highly advantageous to have a garment such as brassiere where the metal eyes and hooks are cushioned by a foam type barrier so that the wearer will not feel the metal closure. 
       SUMMARY OF THE INVENTION 
       [0008]    It is an object of the present invention to provide the wearer of a garment such as brassiere with a comfortable garment hook and eye closure, where the engaged metal eyes and hooks are cushioned by a foam type barrier so that the wearer will not feel the metal closure. 
         [0009]    According to the present invention there is provided a wearer friendly garment book and eye closure, including: (a) an eye closure component including: (i) at least one layer of padding material, having thickness value; and (ii) at least one eye disposed on the padding material layer. 
         [0010]    According to further features in preferred embodiments of the invention, the padding material layer&#39;s thickness value is at least one millimeter. 
         [0011]    According to further features in preferred embodiments of the invention, the eye closure component further including: (iii) at least two eye columns, wherein each of the eye columns has at least two eyes. 
         [0012]    According to further features in preferred embodiments of the invention, the eye closure component further including: (iv) at least one fabric sheet, disposed on the padding material layer. 
         [0013]    According to further features in preferred embodiments of the invention, the eye closure component further including: (v) sewing thread, wherein the sewing thread connects the at least one eye to the padding material layer. 
         [0014]    According to further features in preferred embodiments of the invention, the padding material layer is selected from a group consisting of a polyester foam, plastic foam, and rubber-based material. 
         [0015]    According to further features in preferred embodiments of the invention, the padding material layer is laminated foam. 
         [0016]    According to further features in preferred embodiments of the invention, the wearer-friendly garment hook and eye closure further including: (b) a hook closure component, including: (i) at least one fabric sheet; and (ii) at least one hook disposed on the fabric sheet. 
         [0017]    According to further features in preferred embodiments of the invention, the hook closure component is attached to corresponding girth portions of a brassiere 
         [0018]    According to further features in preferred embodiments of the invention, the laminated foam layer&#39;s thickness value is at least one millimeter, wherein the eye closure component further including: (iii) at least two eyes column, wherein each of the eye columns has at least two eyes. 
         [0019]    According to further features in preferred embodiments of the invention, the wearer-friendly garment hook and eye closure further including: (c) at least one fabric sheet, disposed on said laminated foam layer, wherein the sewing thread intimately connects each of the eyes to the laminated foam layer and to the fabric sheet, wherein the sewing thread creates a lateral stitch and tacking along the eye closure component. 
         [0020]    According to further features in preferred embodiments of the invention, the padding material layer&#39;s thickness value is at least three millimeters. 
         [0021]    According to the present invention there is provided wearer-friendly garment hook and eye closure having edges, including: (a) an eye closure component, including: (i) at least one layer of laminated foam, having thickness value; (ii) at least one eye column disposed on the laminated foam, wherein each of the eye columns has at least two eyes; (iii) at least one fabric sheet, disposed on the laminated foam layer; (iv) a sewing thread, wherein the sewing thread intimately connects each of the eyes to the laminated foam layer and to the fabric sheet, wherein the sewing thread creates a lateral stitch along the eye closure component; and (v) a printed label on the back of said eye closure component; wherein said laminated foam is intimately connected to said fabric sheet along at least one line close to one of the edges of said eye closure component through sealing, and wherein said eye closure component has soft edges; (b) a hook closure component, including: (i) at least one fabric sheet; and (ii) at least one hook disposed on the fabric sheet. 
         [0022]    According to further features in preferred embodiments of the invention the layer of laminated foam is made of non-yellowing foam, having sewable, and resilient characteristics. 
         [0023]    According to further features in preferred embodiments of the invention the padding material layer&#39;s thickness value is at least three millimeters. 
         [0024]    According to the present invention there is provided a method for enabling a wearer to wear a garment including a wearer-friendly garment hook and eye closure comfortably without any sensation of discomfort such as pain, chafing, pressure, etc. that could be caused as a result of the pressure of interlocked metal hooks and eyes felt through merely folded fabric layers, the method including the steps of: (a) providing a wearer-friendly garment hook and eye closure, the wearer-friendly garment book and eye closure including: (i) a eye closure component, including: (A) at least one layer of laminated foam, having thickness value; and (B) at least one eye disposed on the laminated foam layer, wherein the laminated foam layer&#39;s thickness value is at least one millimeter; (ii) a hook closure component, including: (A) at least one fabric sheet; (B) at least two hooks disposed on the fabric sheet; and (C) a sewing thread, wherein the sewing thread intimately connects each of the eyes to the laminated foam layer and to the fabric sheet, wherein the sewing thread creates a lateral stitch along the eye closure component; wherein said laminated foam is intimately connected to said fabric sheet along at least one line close to one of the edges of said eye closure component and wherein said eye closure component has soft edges; (b) sewing the eye closure component to corresponding girth portions of a garment; (c) sewing the hook closure component to corresponding girth portions of a garment; (d) wearing the garment; and (e) closing the wearer-friendly garment hook and eye closure. 
         [0025]    According to further features in method the garment is a brassiere. 
         [0026]    According to the present invention there is provided a process for producing a eye closure component including the steps of: (a) providing a laminated foam; (b) providing metal eyes; (c) feeding the laminated foam into an eye sewing machine, that attaches the metal eyes onto the laminated foam with sewing thread and at the same time the tacking stitches are hidden with an additional thin layer of fabric that covers the top; (d) sealed the top layers of fabric to the laminated foam; (e) printing label information on the back of said eye closure component; and (f) cutting the laminated foam and the top layers of fabric by cold cut, exposing the laminated foam on the edge. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0027]    The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein: 
           [0028]      FIGS. 1   a  and  1   b  of the prior art illustrates a brassiere with a line of hooks and a row of eyes. 
           [0029]      FIG. 2  of the prior art illustrates a brassiere includes fastening means which are hooks and several sets of eyes. 
           [0030]      FIG. 3   a  is a schematic illustration of a perspective view of a hook. 
           [0031]      FIG. 3   b  is a schematic illustration of a side view of a hook. 
           [0032]      FIG. 3   c  is a schematic illustration of a top view of a hook. 
           [0033]      FIG. 3   d  is a schematic illustration of a perspective view of an eye. 
           [0034]      FIG. 3   e  is a schematic illustration of a perspective view of a hook and an eye in engaged position. 
           [0035]      FIG. 4   a  is a schematic illustration of a side view of a longitudinal section of the present invention eye tape. 
           [0036]      FIG. 4   b  is a schematic illustration of a top view of eye tape of the present invention. 
           [0037]      FIG. 4   c  is a schematic illustration of a side view of a longitudinal section of hook tape of the present invention. 
           [0038]      FIG. 4   d  is a schematic illustration of a top view of hook tape of the present invention. 
           [0039]      FIG. 5   a  is a schematic illustration of a perspective view of several eye closure components connected together in the production process prior to their separation according to the present invention. 
           [0040]      FIG. 5   b  is a schematic illustration of a perspective view of a garment hook and eye closure of the present invention. 
           [0041]      FIG. 5   c  is a schematic illustration of a side view of a section of the present invention garment hook and eye closure, in connected state, in which hook is interlocked in eye. 
           [0042]      FIG. 5   d  is a schematic illustration of a top view of the present invention garment hook and eye closure, in connected state, in which hook is interlocked in eye. 
           [0043]      FIG. 5   e  is a schematic illustration of a side view of a section of the present invention garment hook and eye closure, in connected state, in which hook is interlocked in eye, fitted snugly against the wearer&#39;s back. 
           [0044]      FIG. 6   a  is a schematic illustration of a top view of an eye closure component showing the sewing lines according to the present invention. 
           [0045]      FIG. 6   b  is a schematic illustration of a side view of a local longitudinal section of an eye closure component showing the sewing line in a local section of an early production stage according to the present invention. 
           [0046]      FIG. 6   c  is a schematic illustration of a side view of a local longitudinal section of an eye closure component showing the sewing line in a local section of a later production stage according to the present invention. 
           [0047]      FIG. 7   a  is a schematic illustration of a bottom view of the present invention eye closure component. 
           [0048]      FIG. 7   b  is another schematic illustration of a bottom view of the present invention eye closure component. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0049]    The present invention is an apparatus and a method for adding malleability in the third dimension of a garment hook and eye closure. 
         [0050]    The principles and operation of the added malleability in the third dimension of a garment hook and eye closure according to the present invention may be better understood with reference to the drawings and the accompanying description. 
         [0051]    Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. 
         [0052]    Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, dimensions, methods, and examples provided herein are illustrative only and are not intended to be limiting. 
         [0053]    Although the addition of foam to eye tape such as used in a brassiere may seem simple at first glance a workable solution for use in brassiere is by no means trivial. 
         [0054]    Proper operation of hook and eye tape closure for a brassiere has traditionally depended on suitable stability of the hook and eye tape used so as to assure proper alignment of the fastener and acceptable durability of the garment. Mere substitution of adding a protective material would result in unacceptable misalignment twisting and bulkiness. 
         [0055]    To solve the problems the present invention selected a material that provides cushioning while maintaining stability for proper alignment of the book and eye. By using foam-type material between 1 to 5 millimeters thick, this eye tape has been transformed from being a functional closure to becoming a comfortable closure providing padding not as an additionally added padding, that might get stuck or entwined to the eye tape, but this invention makes padding an integral part of its base construction. Furthermore this new eye tape provides soft edges. 
         [0056]    The following list is a legend of the numbering of the application illustrations: 
         [0057]      3  eye 
         [0058]      4  hook 
         [0059]      5  fabric 
         [0060]      5   a  lip 
         [0061]      5   b  strips 
         [0062]      5   c  eye flange 
         [0063]      6  padding layer (such as foam or rubber) 
         [0064]      6   a  padding/foam top fabric lamination 
         [0065]      6   b  padding/foam bottom fabric lamination 
         [0066]      6   c  printed label information 
         [0067]      6   d  compression zone of padding layer 
         [0068]      7  sewing thread 
         [0069]      7   y  sewing line (invisible or visible, optional) 
         [0070]      8  soft edge 
         [0071]      9   a  marking line for sealing (for example by ultrasonic sealing) 
         [0072]      9   b  imprint of the ultrasonic sealing and the adjoining cutting to expose soft edge 
         [0073]      10  brassiere (according to Brenner) 
         [0074]      11  line of hooks (according to Brenner) 
         [0075]      12  row of eyes (according to Brenner) 
         [0076]      20  brassiere (according to Porco) 
         [0077]      21  hooks (according to Porco) 
         [0078]      22  eyes (according to Porco) 
         [0079]      30  wearer&#39;s back 
         [0080]      31  wearer&#39;s spine 
         [0081]      32  brassiere back 
         [0082]      100  eye closure component 
         [0083]      200  hook closure component 
         [0084]      300  garment hook and eye closure 
         [0085]    Referring now to the drawings,  FIG. 3   a  is a schematic illustration of a perspective view of a hook  3 . 
         [0086]      FIG. 3   b  is a schematic illustration of a side view of a hook  3 . 
         [0087]      FIG. 3   c  is a schematic illustration of a top view of a hook  3 . 
         [0088]      FIG. 3   d  is a schematic illustration of a perspective view of an eye  4 . 
         [0089]      FIG. 3   e  is a schematic illustration of a perspective view of a hook  3  and an eye  4  combined. 
         [0090]      FIGS. 3   a,    3   c,    3   d,  and  3   e  show loops that assist in connecting eye  3  and hook  4  to layers of flexible material, such as fabric, by means of sewing thread  7 . 
         [0091]      FIG. 4   a  is a schematic illustration of a side view of longitudinal section a-a of the present invention eye closure component  100 . The illustration shows a laminated foam type padding layer composed of three auxiliary layers: foam top fabric lamination  6   a;  foam  6 ; and foam bottom fabric lamination  6   b.    
         [0092]    This padding layer serves as an eye flange  5   c,  and can include additional layers of fabric that can be attached to top fabric lamination  6   a,  and to foam bottom fabric lamination  6   b,  and which are not shown in this illustration. These layers are optional, but not necessary. 
         [0093]    All eyes  3  are sewn by sewing line  7   y  shown in side view, to top fabric lamination  6   a,  this thread also connects an additional layer of fabric  5 , or any other suitable material, to the aforementioned structure, by sewing through all layers of materials and marrying all components, which is the top layer of eye closure component  100 . The illustration shows that on the left end of eye closure component  100  the uppermost layer of fabric shown creates an open lip  5   a  in order to enable good connection of eye closure component  100  to a garment, for example the end of a brassiere back. 
         [0094]    Foam  6  layer is sufficiently thick, approximately 1 to 5 millimeters along Z axis, to ensure that when it is used in a garment combined with an eye closure component  100  including metal eyes  3 , the wearer does not feel the eyes or pressure from the engaged hooks. 
         [0095]    The section in the illustration shows the main improvement achieved in eye closure component  100  in comparison with the standard eye tape commonly used nowadays. 
         [0096]    Eye closure component  100  can be manufactured at present thanks to recent technological developments, enabling the incorporation of padding foam  6  in applications that were not available until recently such as in a garment hook and eye closure. The new use of the padding foam  6  grants the material new properties such as: softness, padding, soft edges, a new level of comfort, etc. 
         [0097]    The padding material  6  can also be a material such as a plastic-type or rubber-type material, the laminated fabric is added for looks, comfort and color matching. 
         [0098]    Even though the illustration shows a laminating fabric on the top and bottom surfaces of the padding layer  6 , this description is in no way limiting the present invention to this formation, and the eye closure component  100  according to the present invention can be used with laminating fabric on the top and bottom surfaces of the padding layer  6 , or without laminating fabric to the padding layer  6 . The desired qualities can be achieved thanks to the pliability of the foam material. 
         [0099]      FIG. 4   b  is a schematic illustration of a top view of eye closure component  100  of the present invention Eye closure component  100 , when deployed on a surface, has a Cartesian axis system as shown in  FIGS. 4   a  and  4   b,  in which the length dimension of eye closure component  100  is along X axis, the width dimension is along Y axis, and the thickness dimension is along Z axis. 
         [0100]    The illustration shows three columns separated from each other along X axis with two eyes sewn in position in each column, separated from each other along Y axis. This six-eye arrangement is one of the most common arrangements; however other arrangements are also in use. The illustration shows the a-a section line. 
         [0101]    The illustration shows the imprint of the ultrasonic seal  9   b  and the soft edge  8 , which are created when ultrasonic seal and cut technology is used for cutting. This technology also includes a process in which a machine first ultrasonically puts double seal down into the fabric, and then all of the layers are cut together between the two seal lines. 
         [0102]      FIG. 4   c  is a schematic illustration of a side view of section b-b of hook closure component  200  of the present invention. The illustration shows hook  4 , and lip  5   d,  which is made of fabric or any other suitable material, and one additional layer of fabric or any other suitable material  5 . 
         [0103]      FIG. 4   d  is a schematic illustration of a top view of hook closure component  200  of the present invention, when hook closure component  200  is in an inverse position to that which enables hooking it into eye closure component  100 . Hook closure component  200 , when inversely deployed on a surface, has the same Cartesian axis system as eye closure component  100  as shown in  FIGS. 4   c  and  4   d.  The length dimension of hook closure component  200  is along X axis, the width dimension is along Y axis, and the thickness dimension is along Z axis. The illustration shows the b-b section line. 
         [0104]    The illustration shows one column with two hooks  4 , sewn in position, separated from each other by a gap along Y axis that conforms to the gap between the eyes  3 . Padding layer  6  protects and isolates the user from the hooks  4  both when being hooked into the eyes  3  and when opening the hook and eye closure. 
         [0105]    The illustration also shows imprint of the ultrasonic seal  9   b.    
         [0106]      FIG. 5   a  is a schematic illustration of a perspective view of several eye closure components  100  connected together in a production stage prior to their separation according to the present invention The production process also includes connection of all parts of the eye closure components  100  in large strips from which the individual eye closure components  100  are cut into suitable sizes. 
         [0107]    The illustration also shows a side view of sewing lines  7   y  connecting top fabric  5 , metal eyes  3 , and the padding layer  6  (such as flex foam or rubber), and lines  9  marking the suitable place for cutting, that can be done using ultrasonic seal and cut technology, which creates soft edges. Ultrasonic sealing technology can be used to cut all four sides of several eye closure components  100 . The illustration also shows open lip  5   a.    
         [0108]    The product is comfortable, dyeable, and printable on the back, enabling a tag free bra. 
         [0109]      FIG. 5   b  is a schematic illustration of a “transparent” perspective view of a garment hook and eye closure  300  of the present invention. The illustration shows the eye closure component  100  and the hook closure component  200  hooked together, in closed position. 
         [0110]      FIG. 5   c  is a schematic illustration of a side view of the present invention garment hook and eye closure  300 , in connected state, in which hook  4  and eye  3  are interlocked. This interlocking causes local compression of the foam  6 , shown in the illustration as the compression zone of padding layer  6   d,  which absorbs the pressure from the eye, thus canceling the pressure that each eye  3  might apply to the wearer&#39;s body. 
         [0111]      FIG. 5   d  is a schematic illustration of a top view of the present invention garment hook and eye closure  300 , connected state, in which hook  4  and eye  3  are interlocked. Garment hook and eye closure  300  is composed of eye closure component  100 , and hook closure component  200 . 
         [0112]      FIG. 5   e  is a schematic illustration of a side view of a section of the present invention garment hook and eye closure  300 , in connected state, in which hook  4  is interlocked in eye  3 , fitted snugly against the wearer&#39;s back  30 . Eye closure component  100  and hook closure component  200  are each separately connected to either end of brassiere back  32 . The illustration shows two compression zones of padding layer  6   d,  which are created as a result of pressure on both sides of padding layer  6 , on one side pressure is applied by garment hook and eye closure  300  and on the other side by the wearer&#39;s spine  31 . 
         [0113]      FIG. 6   a  is a schematic illustration of a top view of eye closure component  100 , showing sewing lines according to the present invention. The illustration shows lateral sewing lines  7   y  parallel to Y axis. This sewing is such that the sewing thread connects all the layers composing the eye closure component  100 , intimately and positively to each eye  3  perpendicular to the layer such that the required length of sewing thread is minimal Furthermore, the illustration shows two longitudinal imprints of the ultrasonic seal  9   b  parallel to Y axis, each of which is close to the edge of eye closure component  100 . If cutting is performed as described in the description of  FIG. 5   a,  eye closure component  100  has soft edges  8 . 
         [0114]    The incorporation of all of the sewing lines gives eye closure component  100  the necessary qualities to compose a single integral unit with the necessary mechanical qualities. 
         [0115]    The illustration shows local section line c-c. 
         [0116]      FIG. 6   b  is a schematic illustration of a side view of a local longitudinal section c-c, of eye closure component  100 , in an earlier production stage according to the present invention. The illustration shows a side view of eye  3  disposed above a laminated foam layer composed of a padding layer  6 , foam laminated with top fabric  6   a  and with bottom fabric  6   b.    
         [0117]    The illustration also shows two fabric strips  5   b,  one between the laminated foam layer and eye  3  and the other above eye  3 . The sewing thread shown in the illustration in side view, which creates lateral sewing line  7   y  (the tacking stitches) has been sewn to connect eye  3 , the two fabric strips  5   b,  and the laminated foam layer. 
         [0118]      FIG. 6   c  is a schematic illustration of a side view of a local longitudinal section c-c, of eye closure component  100 , in an advanced production stage according to the present invention. After sewing as described in  FIG. 6   b,  top fabric strip  5   b  is folded to the left so that a part of eye  3  is exposed to enable latching it into hook  4 , while lateral sewing line  7   y  is concealed from top view by top fabric strip  5   b  (concealment of sewing line optional). Bottom fabric strip  5   b  is the continuation of the top fabric strip  5   b  of eye  3 , which is not shown in the illustration and is disposed to the right on X axis with regard to eye  3  that is shown in the illustration. 
         [0119]    Proper selection of the materials of the padding layer  6 , can determine the quality of the eye closure component  100 . An example of this is selecting foam of the following characteristics: A non-yellowing foam product, laminated on both sides with fabric, sewable, resilient, and between one millimeter to five millimeters thick. 
         [0120]    An additional example is selecting a rubber based product, used without lamination. 
         [0121]      FIG. 7   a  is a schematic illustration of a bottom view of the present invention eye closure component  100 , showing the back of foam bottom fabric lamination  6   b  and showing sewing lines  7   y.    
         [0122]      FIG. 7   b  is a schematic illustration of a bottom view of the present invention eye closure component  100 , showing printed label information. The ability to print the label onto eye closure component  100  gives the advantage that there is no need to sew a label, sparing the wearer the itching that is often caused by the stitches of the label or the label itself. 
         [0123]    As used herein the specification and in the claims section that follows, the term “eye closure component” and the like refer to a component of a garment hook and eye closure substantially including an eye. 
         [0124]    As used herein the specification and in the claims section that follows, the term “hook closure component” and the like refer to a component of a garment hook and eye closure substantially including a hook. 
         [0125]    As used herein the specification and in the claims section that follows, the term “foam” and the like refer to a plastic, or other material substantially filled with many small bubbles of air to make it soft or light which has semi-rigid, spongy, and pliable characteristics. 
         [0126]    As used herein the specification and in the claims section that follows, the term “laminated foam” and the like refer to foam laminated, top and bottom with fabric. 
         [0127]    The production process of the eye closure component according to the present invention can be done according to the following steps:
   Providing laminated foam for use as a padding layer, and as the base material of the eye tape in the eye attaching machines. This base material is fed into the eye sewing machines, that attach the metal eyes onto the base with sewing thread and at the same time the tacking stitches are covered with an additional thin layer of fabric sewn on with a hidden stitch.   
 
         [0129]    This sewing process marries the hardware to the foam flex-base Using traditional sewing technology ensures increasing the strength of eye attachment to the base; however the hardware could be attached by applying ultrasonic stitching. After the metal eyes are sewn on to the foam flex base, the top layers of fabric are sealed to the foam base, and then cold cut, this way exposing the foam on the edge. One could alternately cut this with an ultrasonic edge, but this would create a sharper edge. One could also laminate the top fabric covering the tacking, to the base, instead of sewing technique. 
         [0130]    There are various cutting procedures one could use, such as to seal and cold cut in order to achieve soft edges. This product is comfortable, dyeable, and printable on the back, resulting in a tag free bra. 
         [0131]    Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.