Abstract:
A method for making a garment having a lofted assembly having an outer support layer and garment so produced are provided. The method includes the steps of positioning a support fabric on a lofted material; sewing the support fabric to the lofted material to form a lofted assembly; positioning the lofted assembly in a molding apparatus having at least a first mold and a second mold, closing together the first mold and the second mold thereby sandwiching the lofted assembly therebetween and while maintaining a uniform preset gap between said first mold and the second mold so that the inherent loft characteristics of the lofted assembly are substantially preserved after pressure and/or heat are applied.

Description:
RELATED APPLICATION  
       [0001]     This application is a continuation-in-part of application Ser. No. 11/152,859 filed on Jun. 15, 2005; which is a continuation-in-part of application Ser. No. 11/150,985 filed on Jun. 13, 2005; which is a continuation-in-part of U.S. application Ser. No. 10/631,474, filed on Jul. 31, 2003. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to a method for molding garments and the garments made therefrom. More particularly, the present invention relates to a method for molding a lofted material having a sewn decorative support panel, and the resultant garment.  
         [0004]     2. Description of the Prior Art  
         [0005]     Various methods and mechanisms for molding different types and assemblies of material have been developed and are known. For example, U.S. Pat. No. 3,464,418 provides an apparatus and method for making brassiere pads from bonded non-woven fibrous batting material, U.S. Pat. No. 4,025,597 provides a method of making a brassiere cup from a soft fibrous board material, U.S. Pat. No. 4,080,416 provides a method for making multi-layered seamless brassiere pads, and U.S. Pat. No. 4,250,137 provides a process for preparing breast pads or fronts such that the pads are centrally soft and peripherally firmer.  
         [0006]     Notwithstanding that which is known, there remains a continuing need for improved methods for molding a lofted material having a laminated support layer to provide a three dimensional shape thereto without compromising the loft characteristics associated with such material. Problems heretofore associated with various processes of molding a lofted material include at least the following: (1) thinning of material at points of increased pressure or applied heat, or both, such as for example, the apex of a bra cup or pad, (2) requiring relatively complicated or additional structural elements, or both to facilitate a desired result, for example, spacer devices or vacuum systems, and (3) requiring that heat, pressure or both be avoided at relatively substantial portions of the material being molded, which can complicate the molding process.  
       SUMMARY OF THE INVENTION  
       [0007]     It is an object of the present invention to provide a method for molding a lofted assembly having an outer laminated support layer.  
         [0008]     It is another object of the present invention to provide a garment that is made from a lofted material that has a outer laminated support layer that is molded to maintain the loft characteristics of such lofted material and the support layer.  
         [0009]     It is yet another object of the present invention to provide a garment that is molded from a lofted material that has an outer laminated support layer that is a decorative outer layer that is sewn to the lofted material.  
         [0010]     It is still yet another object of the present invention to provide a brassiere having molded breast cups that are made from a lofted assembly having a lofted material and an outer laminated synthetic support layer that is a decorative panel sewn or attached to the lofted material to provide support for average to large sized brassieres.  
         [0011]     These and other objects and advantages of the present invention are achieved by a molding apparatus with at least a first die or mold with a projecting element and a first level portion, and a second die or mold with a recessed element and a second level portion. The projecting element and the recessed element are formed such that when the first level portion of the first mold and the second level portion of the second mold are brought into relatively close relation, a uniform preset distance or gap is created between the projecting element and the recessed element. The gap is preferably adjustable to accommodate the loft of different materials. The first mold and second mold each are preferably selectively and/or independently heatable, and are configured, as appropriate, to facilitate the following material molding method.  
         [0012]     The method for molding the lofted material essentially comprises the steps of first sewing a pre-cut support layer in a pre-determined position on a piece of lofted material to form a lofted assembly and positioning the lofted assembly in the molding apparatus. Then, closing the first mold in relation to the second mold, or vice-versa, sandwiching the lofted assembly therebetween such that the portion of the lofted assembly situated between the first and second level portions is compressed and the portion of the lofted assembly situated between the projecting element and recessed element is compressed only to the extent desired or not at all. The extent of compression being adjustable. Following this closing step pressure and/or heat as appropriate is applied for the desired molding result. The resulting molded lofted assembly preferably provides a balance of comfort, support, durability and aesthetic appeal. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     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.  
         [0014]      FIG. 1  is a perspective view of the lofted material that is to be molded in accordance with an illustrative embodiment of the present invention;  
         [0015]      FIG. 2  is a top view of the pre-cut decorative support layer that is to be laminated to the lofted material in accordance with the present invention;  
         [0016]      FIG. 3  is top view of the laminated assembly of lofted material sewn to the decorative support layer in accordance with the present invention;  
         [0017]      FIG. 4  is a cross-sectional side view of an apparatus for molding a lofted assembly in accordance with an illustrative embodiment of the present invention with the apparatus shown in open position;  
         [0018]      FIG. 5  is a cross-sectional side view of the apparatus of  FIG. 4  with the apparatus shown in a closed position;  
         [0019]      FIG. 6  is a side sectional view of the apparatus of  FIG. 4 , reflecting a forming step in accordance with an illustrative embodiment of the present invention;  
         [0020]      FIG. 7  is a side sectional view of a second embodiment of an apparatus for molding a lofted assembly according to the present invention;  
         [0021]      FIG. 8  is a side sectional view of third embodiment of an apparatus for molding a lofted assembly according to the present invention;  
         [0022]      FIG. 9  is a plan view of a fourth embodiment of an apparatus for molding a lofted assembly according to the present invention;  
         [0023]      FIG. 10  is a plan view of a fifth embodiment of an apparatus for molding a lofted assembly according to the present invention;  
         [0024]      FIG. 11  is a side sectional view a sixth embodiment of an apparatus for molding a lofted assembly according to the present invention; and  
         [0025]      FIG. 12  is a front view of the lofted assembly molded in the form of the breast-receiving cup with the decorative support panel. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0026]     Referring to the drawings and, in particular to  FIG. 1 , there is shown an illustrative embodiment of the lofted material generally represented by reference numeral  30 . In this disclosure, the term lofted material  30  includes foam and circularly knitted and/or warp knitted single ply materials that can be a variety of materials or combination of materials (batting, spacer fabric, etc.). Spacer fabric could be a polyester and/or nylon fabric. Lofted material  30  has a inner side or first side  31   a  that contacts the skin of the wearer and an outer side or second side  31   b  that faces in an outward direction opposite inner side  31 . Lofted material  30  is sized to form an average or deep breast-receiving cup for a brassiere after being molded. Lofted material  30  has a loft  33  associated therewith.  
         [0027]     Referring to  FIG. 2 , support layer  35  is shown. Support layer  35  is cut in the shape of a crescent to ensure a comfortable and close fit at the lower lateral inner surface portion of the finished breast-receiving cup. Although the shape of support layer  35  is shown as a crescent with a curved edge, other shapes capable of offering comfort and support to the wearer could also be used. Support layer  35  can be any synthetic material or a natural material. Preferably, the support layer  35  is made of a warp knit material. In all instances, support layer  35  provides the level of comfort and support to the breasts of the wearer that would otherwise not be available without the enhanced support. Support layer  35  has a decorative pattern  32  thereon.  
         [0028]     In  FIG. 3 , support layer  35  that has an inner side is pre-positioned on lofted material  30  on outer side  33 , and the support layer and lofted material are secured, and preferably, sewn together using a multifilar yarn to form a curvilinear seam  36 . By securing, and preferably, sewing the lofted material  30  and the support layer  35 , their relative position is fixed prior to the molding and lamination step to prevent any slipping. Further, seam  36  provides aesthetic appeal by providing a contour across the breast-receiving cup.  
         [0029]     Support layer  35  preferably has a layer of adhesive  37  applied to the inner side  34  to secure it against lofted material  30 . Adhesive layer  37  is applied to support layer in a heating process before layer  35  is laminated to lofted material  30 . Adhesive  37  is a heat-activated glue that can be a film, a web or polyester. The temperature that is required to activate adhesive  37  and laminate support layer  30  to mold lofted assembly  38  is approximately 320° F. to 360° F. The lamination process is of a temperature that will preserve the loft of lofted material  30 , as well as the aesthetic appeal of the lofted material  30  and support layer  35 .  
         [0030]      FIG. 4  shows an illustrative embodiment of an apparatus  1  for molding lofted assembly  38 . The apparatus  1  preferably has at least two mold elements, a first mold  10  and a second mold  20 . Preferably, the first mold  10  and the second mold  20  are complementary to one another.  
         [0031]     Preferably, first mold  10  and second mold  20  cooperate to mold or form lofted assembly  38  positioned therebetween into a three-dimensional shape, such as, for example, that required by molded brassiere pads or cups. Preferably, lofted assembly  38  can be any of a variety of materials or combination of materials and can be fashioned into a variety of forms, such as for example, a garment.  
         [0032]     First mold  10  preferably has at least one first contact surface  40  with at least one projecting element  50  in the form of a dome. First contact surface  40  preferably also has a first level portion  42  about projecting element  50 . First contact surface  40  may also have any of a variety of other surface elements  43  associated therewith, such as for example, one or more nodes, dimples, and/or teeth as shown in  FIGS. 9 through 11 .  
         [0033]     First contact surface  40  can be interchangeably associated with first mold  10 . First mold  10  can be interchangeably associated with apparatus  1 . The interchangeability of first contact surface  40  and/or first mold  10  preferably provides apparatus  1  with further diversity in application or use.  
         [0034]     Preferably, first mold  10 , first contact surface  40 , projecting element  50 , and/or first level portion  42  can be heatable. This heating can be accomplished in any of a variety of ways, such as for example, via electric heating wires or rods associated with first mold  10 . These heating wires or rods could preferably conduct or transmit heat, via first mold  10 , as appropriate, to provide any and/or all of the aforementioned elements thereof with sufficient heat for effective molding under a variety of different molding parameters. First mold  10  can preferably have any shape, size, and/or configuration suitable for accomplishing one or more different molding operations. See, for example,  FIGS. 7 and 8 , which show alternative embodiments of first mold  10 . It is noted that the present invention is not limited to those configurations discussed and/or shown and that other configurations are also within the scope of the present invention.  
         [0035]     It is also noted, with regard to surface elements  43  discussed above, that surface elements  43  are preferably suitable for achieving a variety of different molding effects. For example, surface elements  43  can be on either and/or both projecting element  50  and first level portion  42  to interact with lofted assembly  38  during a molding process. Surface elements  43  can be, for example, one or more piercing elements, heating or cooling elements, cushioning or insulating elements, or any combination of the same. Other similar types of elements may also be used and are within the scope of the present invention.  
         [0036]     Referring again to  FIG. 4 , second mold  20  has at least one second contact surface  60  with at least one recessed element  70  in the form of a dish. Preferably, recessed element  70  is complementary to and cooperative with projecting element  50  of first mold  10 . Second contact surface  60  preferably also has a second level portion  62  about recessed element  70 . Second contact surface  60  may also have surface elements  43  associated therewith. Second contact surface  60  can be interchangeably associated with second mold  20 , and, the second mold can be interchangeably associated with apparatus  1 . The interchangeability of second contact surface  60  and/or second mold  20  preferably provides apparatus  1  with further diversity in application or use.  
         [0037]     Preferably, second mold  20 , second contact surface  60 , recessed element  70 , and/or second level portion  62  can be heatable. Such heating can be accomplished in any of a variety of ways, such as, for example, by electric heating wires or rods associated with second mold  20 . These heating wires or rods could preferably conduct or transmit heat, via second mold  20 , as appropriate to provide any and/or all of the aforementioned elements thereof with sufficient heat for effective molding under a variety of different molding parameters. Second mold  20  can preferably have any shape, size, and/or configuration suitable for accomplishing one or more different molding operations in cooperation with mold  10 . See, for example,  FIGS. 7 and 8 , which show different embodiments of second mold  20 . It is noted that the present invention is not limited to those configurations discussed and/or shown and that other configurations are also within the scope of the present invention.  
         [0038]     As with the first mold  10 , surface elements  43  provide a variety of different molding effects that can be on either and/or both recessed element  70  and second level portion  62  to interact with lofted assembly  38  during the molding process.  
         [0039]     Referring to  FIGS. 5 and 6 , having described some of the preferred elements of an illustrative embodiment of the present invention, first and second molds  10 ,  20 , respectively, are preferably configured to engage one another such that when first level portion  42  of first mold  10  and second level portion  62  of second mold  20  are brought into relatively close relation, a uniform preset distance or gap  80  is created between projecting element  50  and recessed element  70 . Gap  80  preferably has an extent of about 0.1 inches. However, gap  80  can also have any extent appropriate for accomplishing a desired molding operation. Hence, gap  80  can preferably be adjusted to accommodate the loft characteristics associated with a variety of different materials. This adjusting feature can be accomplished in different ways, such as, for example, via the preferred interchangeability of first and second molds  10 ,  20  and/or first and second contacting surfaces  42 ,  62 . Gap  80  may also be adjusted to influence the degree of loft associated with a material. That is, gap  80  can be reduced to provide a desired finish or effect to lofted assembly  38 . Thus, it is apparent the preservation of the inherent loft characteristics associated with a lofted assembly is preferably independent of the heat, pressure and/or time associated with a particular molding process. The present invention efficiently and effectively preserves the inherent loft characteristics associated with a lofted assembly during the molding process.  
         [0040]     The process of molding lofted assembly  38  preferably includes at least the following steps. Referring to  FIGS. 1 and 4  through  6 , lofted assembly  38  is first positioned in apparatus  1  between first mold  10  and second mold  20 . Lofted assembly  38  is positioned in apparatus  1  such that inner side faces projecting element  50 , shown in  FIG. 4 . On lofted assembly  38 , support layer  35  is sewn so that after the molding process, support layer  35  will be positioned at the lower lateral inner side edge of lofted assembly  38 . Referring to  FIGS. 5 and 6 , first mold  10  is then closed in relation to second mold  20 , or vice-versa, or the molds are each moved towards each other to sandwich lofted assembly  36  therebetween. Preferably, at least a portion of lofted material  30  is situated in gap  80  so that the inherent loft characteristics thereof are substantially preserved while at least another portion of lofted assembly  38  is substantially compressed between first and second level portions  42 ,  62  of first and second contact surfaces  40 ,  60 , respectfully. Next, first mold  10  is opened in relation to second mold  20 , or vice-versa, or the molds are each moved towards each other after an appropriate amount of heat and/or pressure has been applied for an appropriate period of time.  
         [0041]     Referring to  FIG. 12 , finished cup  95  is shown. Cup  95  has a has decorative support layer  39  connected at a lower lateral edge. Layer  39  is preferably crescent shaped. Layer  39  is preferably lace although, other materials such as Jacquard, woven or knitted materials could also be used. Layer  39  is preferably decorative and can have any design such as, for example, a floral design or a geometric pattern, although any pattern could be used.  
         [0042]     The molding process of cup  95  results in a molded cup for a brassiere that accommodates wearers needing from average to large sized brassieres. Such a brassiere may include such conventional elements as side panels connected to one of a pair of breast receiving cups and shoulder straps connected to a separate one of a pair of breast receiving cups. The material of support layer  35  is of such stitch pattern and material that it limits the elasticity of the lofted material  30  from which cup  95  is made. The material is preferably a non-elasticized material that is knitted using a short stitch pattern. By limiting the elasticity in the material and using a shorter stitch pattern, the material of support layer will be less likely to stretch than an elasticized material of a longer stitch pattern. The material of support layer  35  will thus provide more rigid support and firm support. For wearers that require substantial breast support and for those that desire more support, breast cup  95  with comfort and confidence.  
         [0043]     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.