Abstract:
A method for forming a molded garment is provided. The method includes positioning an assembly of material between a first heated mold element and a second heated mold element, moving the first and second heated mold elements in relation to one another to laminate the assembly of material into a laminated assembly; moving a third heated mold element through the first heated mold element into contact with the laminated assembly so that the third heated mold element shapes a portion of the laminated assembly; and causing the first and second heated mold elements to trim fabric from the laminated to define the molded garment.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to an apparatus and method for forming garments. More particularly, the present invention relates to an apparatus and method for forming laminated and molded garments.  
         [0003]     2. Description of the Related Art  
         [0004]     Various methods and/or mechanisms for making garments have been developed and are known. For example, U.S. Pat. No. 3,058,154 is directed to an apparatus and method for making breast fronts without the use of any sewing or seams. However, notwithstanding that which is known, there remains a constant need for improved methods and/or devices for providing simple, efficient, and economical garment manufacturing.  
       BRIEF DESCRIPTION OF THE INVENTION  
       [0005]     It is an object of the present invention to provide an apparatus and method for forming a laminated and molded garment.  
         [0006]     It is another object of the present invention to provide an apparatus and method for simultaneously laminating and molding a garment simply, efficiently, and economically.  
         [0007]     It is still another object of the present invention to provide an apparatus and method that employs at least one first element, at least one second element, and at least one third element that interact to facilitate the simultaneous laminating and molding of garments.  
         [0008]     It is yet another object of the present invention to provide an apparatus and method for forming a garment that offers improved durability and longevity.  
         [0009]     These and other objects and advantages of the present invention are achieved by a method for forming a molded garment. The method includes positioning an assembly of material between a first heated mold element and a second heated mold element, moving the first and second heated mold elements in relation to one another to laminate the assembly of material into a laminated assembly; moving a third heated mold element through the first heated mold element into contact with the laminated assembly so that the third heated mold element shapes a portion of the laminated assembly; and causing the first and second heated mold elements to trim fabric from the laminated to define the molded garment.  
         [0010]     These and other objects and advantages of the present invention are achieved by a method including positioning an assembly of material between a first heated mold element and a second heated mold element; holding the assembly of material in a desired location on the second heated mold element; moving the first and second heated mold elements in relation to one another to laminate the assembly of material into a laminated assembly while the second heated mold element shapes a portion of the laminated assembly; and causing the first and second heated mold elements to trim fabric from the laminated to define the molded garment.  
         [0011]     Still further objects and advantages of the present invention are achieved by an apparatus having three heatable mold portions. The first heatable mold portion has a pair of breast cup cavities defined therein. The second heatable mold portion has a pair of openings defined therein. The openings correspond in position to the cavities. The third heatable mold portion has a pair of breast cup molds defined thereon. The breast cup molds are reciprocatively positioned in the openings so that the breast cup molds are moveable into and out of the breast cup cavities. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0012]     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.  
         [0013]      FIG. 1  is a front perspective view of an apparatus for forming a laminated and molded garment in accordance with an illustrative embodiment of the present invention;  
         [0014]      FIG. 2  is an exploded perspective view of an assembly of material in accordance with an illustrative embodiment of the present invention;  
         [0015]      FIG. 3  is an exploded perspective view of an assembly of material in accordance with another illustrative embodiment of the present invention;  
         [0016]      FIG. 4  is a side sectional view of the apparatus of  FIG. 1 , reflecting a forming step in accordance with an illustrative embodiment of the present invention;  
         [0017]      FIG. 5  is a side sectional view of the apparatus of  FIG. 1 , reflecting another forming step in accordance with an illustrative embodiment of the present invention;  
         [0018]      FIG. 6  is a side sectional view of the apparatus of  FIG. 1 , reflecting still another forming step in accordance with an illustrative embodiment of the present invention;  
         [0019]      FIG. 7  is a front perspective view of an apparatus for forming a laminated and molded garment in accordance with another illustrative embodiment of the present invention;  
         [0020]      FIG. 8  is a side sectional view of the apparatus of  FIG. 7 , reflecting a forming step in accordance with an illustrative embodiment of the present invention;  
         [0021]      FIG. 9  is a side sectional view of the apparatus of  FIG. 7 , reflecting another forming step in accordance with an illustrative embodiment of the present invention;  
         [0022]      FIG. 10  is a plan view of a laminated and molded garment in accordance with an illustrative embodiment of the present invention; and  
         [0023]      FIG. 11  is a perspective view of the integral laminated and molded garment of  FIG. 10 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]     Referring to the drawings and, in particular to  FIG. 1 , there is shown an illustrative embodiment of an apparatus for forming a laminated and molded garment, generally represented by reference numeral  10 . The apparatus  10  essentially has at least one first element  20 , at least one second element  30 , and at least one third element  40  that cooperate to form the integral laminated and molded garment from an assembly of material  50  shown in  FIG. 2 .  
         [0025]     First element  20  is preferably a surface heated retention plate that cooperates with second element  30  and/or third element  40  to form a garment  70 , such as that shown in  FIGS. 1 and 11 , from an assembly of material  50  such as that shown in  FIGS. 2 and 3 . First element  20  is preferably heated via any suitable method sufficient to accomplish the intended purposes thereof. For example, first element  20  can be heated via electric heating wires or rods (not shown), which transmit heat to a contacting surface  22  of the first element. First element  20  preferably has one or more through holes  24 . Preferably one or more through holes  24  are sized, shaped and/or configured to accommodate third element  40  such that the third element can cooperate with first element  20  and second element  30 , and can interact with the assembly of material  50  preferably during the garment forming process to provide a three dimensional shape to the assembly of material. Preferably, first element  20  can facilitate the controlled placement and/or lamination or bonding of material  50 . First element  20  can move relative to second element  30  and/or third element  40 . First element  20  can also be rigid and relatively stationary with respect to second element  30  and/or third element  40 . Further, the contacting surface  22  of first element  20  can have any of a variety of textures, patterns and/or configurations sufficient to provide any of a variety of different effects on the assembly of material  50 .  
         [0026]     Second element  30  is preferably a surface heated support plate. As discussed above, second element  30  cooperates with first element  20  and/or third element  40  to form a garment  70 , such as that shown in  FIG. 11 , from the assembly of material  50 . Second element  30  is preferably heated via any suitable method sufficient to accomplish the intended purposes thereof. For example, second element  30  can be heated via electric heating wires or rods (not shown), which transmit heat to a contacting surface  32  the second element. Second element  30  preferably has one or more cavities or female mold sections  34 . Preferably, one or more female mold sections  34  are sized, shaped and/or configured to accommodate third element(s)  40  such that third element(s)  40  can interact with material  50  preferably during the garment forming process to provide a three dimensional shape to the assembly of the material. Second element  30  can move relative to first element  20  and/or third element  40 . Second element  30  can also be rigid and relatively stationary with respect to first element  20  and/or third element  40 . The contacting surface  32  of second element  30  can have any of a variety of textures, patterns and/or configurations sufficient to provide any of a variety of different effects on the assembly of material  50 . For example, contacting surface  32  of second element  30  can have a plurality of nodes, dimples or grooves  36 , such as is shown in  FIG. 1 , for cooperating with a plurality of complementary nodes, dimples or grooves provided on first element  20  and/or third element  40 .  
         [0027]     Third element  40  is preferably one or more surface heatable male molds. As discussed above, third element  50  cooperates with first element  20  and/or second element  30  to form a garment  70  from the assembly of material  50 . Third element  40  is preferably heated via any suitable method sufficient to accomplish the intended purposes of the third element. For example, the third element can be heated via electric heating wires or rods (not shown), which transmit heat to a contacting surface  42  thereof. Preferably, one or more male molds  40  are sized, shaped and/or configured to interact with first element  20  and to engage second element  30  such that the third element(s) can interact with material  50  preferably during the garment forming process to provide a three dimensional shape to the assembly of the material. Third element  40  can move relative to first element  20  and/or second element  30 . Third element  40  can also be configured to be rigid and relatively stationary with respect to first element  20  and/or second element  30 . It is noted that the contacting surface  42  of third element  40  can have any of a variety of textures, patterns and/or configurations sufficient to provide any of a variety of different effects on the assembly of material  50 . For example, contacting surface  42  of third element  40  can have a plurality of nodes, dimples or grooves  36 , such as is shown in  FIG. 1 , for cooperating with a plurality of complementary nodes, dimples or grooves provided on first element  20  and/or second element  30 .  
         [0028]     Referring to  FIGS. 2 and 3 , the assembly of material  50  preferably has at least an outer layer  52 , an intermediate layer  54 , and an inner layer  58 . Preferably outer layer  52  is decorative and appealing to the eye, intermediate layer  54  is preferably a supportive type layer. Intermediate layer  54  preferably provides durability as appropriate for the type of garment being formed. Inner layer  58  is preferably soft to provide comfort during wear of the garment. Preferably, the various layers of material assembly  50  can be formed from natural and/or man-made fiber. Additional layers may also be incorporated as part of the assembly of material  50 . For example, a separate adhesive or bonding layer can be used to facilitate fusing or bonding the various layers of the assembly together. The adhesive layer can have elastic properties sufficient to compliment those properties associated with the fibers or materials used in the various layers of the assembly of material  50 . Adhesive layer may be suitable for use with a variety of fibers and fabric forming techniques, including microfibers and specialized nonwovens. Foam type materials may also be used or incorporated as part of material assembly  50 . Preferably, apparatus  10  is suitable to accommodate the loft material characteristics of various types of foam such that the loft characteristics remain relatively unchanged after having been formed and/or molded in accordance with any of the illustrative embodiments of present invention.  
         [0029]     Outer layer  52  preferably has an inner surface  51  and outer surface  53 . Preferably, inner surface  51  has an adhesive or bonding substance integrated therein and/or dispersed thereon for facilitating the fusing or laminating of outer layer  52  with intermediate layer  54  and/or inner layer  58 . Outer layer  52  can preferably be shaped, sized and/or configured to provide any of a variety of aesthetic impressions as appropriate or intended for a garment type. Intermediate layer  54  can preferably be secured or positioned only where essential for support.  
         [0030]     Intermediate layer  54  is preferably at least somewhat less flexible than either outer layer  52  or inner layer  58 . Like outer layer  52 , intermediate layer  54  preferably has an inner surface  55  and an outer surface  56 . Both inner and outer surfaces  55 ,  56 , respectively, of intermediate layer  54  can have an adhesive or bonding substance integrated therein and/or dispersed thereon for facilitating the fusing or laminating of the intermediate layer with outer layer  52  and/or inner layer  58 . Intermediate layer  54  can be shaped, sized and/or configured to comfortably conform against the body of a wearer of the garment to provide support and/or augmentation as appropriate or intended for a garment type. Intermediate layer  54  can preferably be secured or positioned only where essential for support. For example, intermediate layer  54  can be one or more stays or wires  54  positioned as shown in  FIG. 2 , which stays or wires  54  can preferably be made from any of a variety of different materials and/or combination of materials.  
         [0031]     Inner layer  58  can preferably be formed from any material suitable for improving the comfort to the wearer. Also, preferably, inner layer  58  has an inner surface  57  and an outer surface  59 . Preferably, outer surface  59  of inner layer  58  has an adhesive or bonding substance integrated therein and/or dispersed thereon for facilitating the fusing or laminating of outer layer  52  with intermediate layer  54  and/or outer layer  52 . Preferably, inner layer  58  can be shaped, sized and/or configured to comfortably conform against the body of a wearer of the garment to provide comfort and/or reduce irritation as appropriate or intended for a particular garment type. Inner layer  58  can, if desirable, be secured or positioned only where essential for providing comfort and/or reducing irritation.  
         [0032]     Having described some of the preferred characteristics of the illustrative embodiment, the process or method for forming a garment  70 , preferably includes at least the following steps. Referring to  FIG. 4 , an assembly of material  50  is first positioned in a heat molding apparatus having at least one first element  20 , at least one second element  30 , and at least one third element  40 . Then, as shown in  FIG. 5 , first element  20  is moved into a closed relation with second element  30 , or vice-versa, sandwiching the assembly of material  50  therebetween. Thereafter, third element  40  is engaged to cooperate with first element  20  and second element  30  such that the third element interacts with the assembly of material  50 . Now, referring to  FIG. 6 , third element  40  is disengaged, then, first element  20  is opened in relation to second element  30 , or vice-versa, to provide the integral laminated and molded assembly of material  50 , such as that shown in  FIG. 10 . Thereafter, as shown in  FIG. 11 , any excess material is eliminated as appropriate, leaving the integral laminated and molded garment. For example, first and second elements  20 ,  30  can trim excess material during the molding process such that when the elements are opened, garment  70  is completed.  
         [0033]     It is noted that the step of engaging third element  40  can be accomplished simultaneously with the step of closing first element  20  in relation to second element  30 . Further, the step of disengaging third element  40  is preferably performed after a period of about 10 seconds to about 60 seconds and more preferably about 35 seconds, from the time third element  40  is engaged. Still further, the step of opening first element  20  in relation to second element  30  is preferably performed after an additional period of about 5 seconds to about 30 seconds and more preferably about 15 seconds from the time that third element  40  is disengaged.  
         [0034]     Referring to  FIG. 7 , there is shown another illustrative embodiment of an apparatus for forming a laminated and molded garment, generally represented by reference numeral  100 . Apparatus  100  preferably has at least one first element  120 , a second element  130 , and alternatively a third element  140 , all of which cooperate to form the integral laminated and molded garment from an assembly of material  50 .  
         [0035]     First element  120  preferably has a surface heated retention plate  120  that can cooperate with second element  130  and/or third element  140  to form a garment  70 , such as that shown in  FIG. 11 , from an assembly of material  50  such as that shown in  FIGS. 2 and 3 . First element  120  is preferably heated via any suitable method sufficient to accomplish the intended purposes thereof. For example, first element  120  can be heated via electric heating wires or rods (not shown), which transmit heat to a contacting surface  122  thereof.  
         [0036]     First element  120  preferably has one or more male molds  124  and one or more elongated relatively planar portions  126  about the one or more male molds. Preferably one or more male molds  124  and one or more planar portions  126  are sized, shaped and/or configured to cooperate with one or more complementary female molds  134  and one or more planar portions  136  of second element  130 .  
         [0037]     Preferably, third element  140  can cooperate with first element  120  and second element  130  such that third element  140  can interact with the assembly of material  50  preferably during the garment forming process to retain or secure the assembly of material  50  during the garment forming process and/or to provide a texture, pattern or other type of shape or configuration to the assembly of material  50 .  
         [0038]     First element  120  can move relative to second element  130  and/or third element  140 . First element  120  can be rigid and relatively stationary with respect to second element  130  and/or third element  140 . Further, the contacting surface  122  of first element  120  can have any of a variety of textures, patterns and/or configurations sufficient to provide any of a variety of different effects on the assembly of material  50 .  
         [0039]     Second element  130  is preferably a surface heated support plate  130  fashioned to cooperate with first element  120  and/or third element  140 . Second element  130  is preferably heated via any suitable method sufficient to accomplish the intended purposes thereof. For example, second element  130  can be heated via electric heating wires or rods (not shown), which transmit heat to a contacting surface  132  thereof. Preferably, one or more female molds  134  and one or more planar portions  136  of second element  130  are sized, shaped and/or configured to accommodate the one or more male molds  124  and one or more planar portions  126  of first element  120 . Accordingly, first element  120  can interact with the assembly of material  50  during the garment forming process to provide a three dimensional shape to the assembly of material  50 . Second element  130  can be rigid and/or move relative to first element  120  and/or third element  140 . Contacting surface  132  of second element  130  can have any of a variety of textures, patterns and/or configurations sufficient to provide any of a variety of different effects on the assembly of material  50 . For example, contacting surface  132  of second element  130  can have one or more holes, nodes, dimples or grooves  138  for cooperating with one or more complementary holes, nodes, dimples or grooves  128 ,  148  provided on first element  120  and/or third element  140 , respectively.  
         [0040]     Third element  140  is preferably a retention plate that can cooperate with first element  120  and/or second element  130  to form integral garment  70 . Third element  140  can be heated, for example, by electric heating wires or rods (not shown), which transmit heat to a contacting surface  142  thereof. Third element  140  is preferably positioned between first element  120  and second element  130 . Third element  140  can be sized, shaped and/or configured to facilitate or enable first element  120  to directly interact with second element  130  and/or the assembly of material  50  during the garment forming process. Preferably, third element  140  facilitates the controlled placement and/or lamination or bonding of the various layers of material assembly  50 . Third element  140  can be rigid and/or move relative to first element  120  and/or second element  130 . Contacting surface  142  of third element  140  can, as with the first and second elements  120 ,  130 , have any of a variety of textures, patterns and/or configurations sufficient to provide any of a variety of different effects on the assembly of material  50 . For example, contacting surface  142  can have one or more holes, nodes, dimples or grooves  148  for cooperating with one or more complementary holes, nodes, dimples or grooves  128 ,  138  provided on first element  120  and/or second element  130 , respectively.  
         [0041]     Having described some of the preferred characteristics of another illustrative embodiment, the process or method for forming a garment  70  using apparatus  100 , preferably includes at least the following steps. First, referring to  FIG. 8 , assembly of material  50  is positioned between first element  120  and second element  130  of apparatus  100 . Referring to  FIG. 9 , first element  120  is then closed in relation to second element  130 , or vice-versa, thereby sandwiching the assembly of material  50  therebetween. Then, first element  120  is opened in relation to second element  130 , or vice-versa, after a period of about 20 seconds to about 80 seconds and more preferably about 50 seconds, to leave a laminated and molded assembly  60  like that shown in  FIG. 10 , and then, eliminating any excess material as appropriate, leaving a laminated and molded garment  70  like that shown in  FIG. 11 .  
         [0042]     It is noted that third element  140 , if used, may be engaged in relation to second element  130  either before, after or simultaneously with the step of closing first element  120  in relation to second element  130 . Further, the step of disengaging third element  140  is preferably performed after the step of opening first element  120  in relation to second element  130 .  
         [0043]     It is also noted that various other steps and/or features well known in the art may also be incorporated into the present invention as appropriate for forming a desired garment type. Thus, for example, various alternative techniques for connecting fabrics/materials can used, various different cutting and/or finishing techniques can be used, or various material types may also be used as appropriate.  
         [0044]     The present invention having been thus described with particular reference to the preferred forms thereof, 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.