Abstract:
A method of manufacturing a breast-covering garment pad having a thicker summit area, as well as the pad itself, includes holding a sheet of resilient and formable material of uniform thickness, such as thermoplastic foam, and forming the sheet to have a graduated thicker summit area corresponding to each breast summit of the pad or a garment including the pad, and a surrounding thinner area. Each pad thus has a thicker summit area for extending over the nipples the breasts.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This is a continuation-in-part of application Ser. No. 11/054,185 filed Feb. 9, 2005 entitled BRA PAD CONSTRUCTION and now U.S. Pat. No. 6,997,775, which was a continuation-in-part of application Ser. No. 10/804,403 filed Mar. 19, 2004 entitled A BRASSIERE AND RELATED BREAST CUP CONSTRUCTION and now U.S. Pat. No. 7,052,360, and application Ser. No. 10/911,269 filed Aug. 4, 2004 entitled PADS HAVING A CENTRAL SUMMIT FOR BRAS AND THE LIKE and now U.S. Pat. No. 6,986,696, all of which are incorporated here by reference. 

   FIELD AND BACKGROUND OF THE INVENTION 
   The present invention relates generally to the field of bras and related garments, and in particular to a new and useful method and pad product having a thicker central summit area for use in bras, camisoles, slips, swimsuits or any other breast covering garment where padding is desired. 
   It is known to provide resilient pads in bras to accentuate the figure. Padded bras are not always desirable, however. Bras without pads are also known but these have limited ability to enhance the figure. 
   Recently, materials for the manufacture of brassieres have been developed that allow for more convenient manufacture of a brassiere. Traditionally the cup forms of a brassiere have, in order to introduce a three dimensional cup shape therein, consisted of several panels which have been sewn or otherwise affixed together. With the advent of moldable synthetic materials such as foam and synthetic fabric materials, cup forms are now moldable into a single panel of material or assembly of panels of materials to define the three dimensional cup form. The ability to mold material to define a cup form of a desirable shape has allowed the manufacturing process to be simplified or accelerated. As well as providing support to a breast of a wearer, the cup forms are often also required for additional benefits to the wearer. 
   Some women prefer that a brassiere conceals some if not all of the regions of the breasts. For modesty, it is desirable that the nipples of a wearer at all times remain unnoticeable from the exterior of the brassiere and any over garment that may be worn by the wearer. Molded cup forms of brassieres that are currently available generally do not provide for any enhancement to the cup form for such purpose. Molded cup forms are normally of a substantially even thickness across the body of the cup and while it may be possible to increase the thickness of the cup in order to thereby reduce the visibility of the nipples of a wearer to the exterior of the brassiere, such increasing thickness may add to the cost of manufacture of the brassiere. Furthermore it is undesirable for increased thickness of the brassiere to exist at its perimeter if the presence of the brassier entirely, is to be as unobtrusive as possible. It is desirable for the perimeter of the bra to be relatively thin so that it has the appearance of feathering in with the skin of the wearer. 
   The patent prior art contains various relevant examples. 
   U.S. Pat. No. 4,013,750 discloses a method for making brasserie pad pre-forms which can produce a bra pad having a thicker central region than its outer regions. A mold apparatus is utilized which produces a substantially conical pad of polyester fibers with a summit which is thicker than the periphery of the conical pad. Also see U.S. Pat. No. 3,947,207. 
   Other patents of interest to the present invention are: 
   
     
       
             
             
           
         
             
                 
             
             
               U.S. Pat. No. 
               Inventor(s) 
             
             
                 
             
           
           
             
               2,507,543 
               Prager 
             
             
               2,565,400 
               Skeoch 
             
             
               2,616,093 
               Talalay 
             
             
               2,627,368 
               Jantzen 
             
             
               2,702,769 
               Alderfer 
             
             
               2,845,974 
               Ashton et al. 
             
             
               3,164,655 
               Howard et al. 
             
             
               3,186,271 
               Kaiser 
             
             
               3,311,007 
               McGee 
             
             
               3,417,755 
               Howard et al. 
             
             
               3,464,418 
               Silverman 
             
             
               3,502,083 
               Howard et al. 
             
             
               3,800,650 
               Schroder 
             
             
               4,351,211 
               Azzolini 
             
             
               5,017,174 
               Gowrylow 
             
             
               5,299,483 
               Ber-Fong. 
             
             
                 
             
           
        
       
     
   
   U.S. Pat. No. 2,627,368 to Jantzen discloses a method of making curved pad filler in which a mold is provided with a concave part for receiving a part of a blank of material. A means are provided for pushing or pressing the blank into the concave part of the mold. A sharp moving knife is passed between the mold and the pressing element, resulting in a curved shoulder pad filler and uniformly tapered portions extending from the thick end to a feathered edge. 
   U.S. Pat. No. 3,186,271 to Kaiser discloses an apparatus and method for producing shaped articles consisting of foam such as sponges and cushions. 
   Neither the Jantzen nor the Kaiser patents teach or suggest a sheet of material having a pair of thicker areas positioned so that they correspond to the location where the central summit of the bra pad will be when it is completed. 
   U.S. Pat. Nos. 3,164,655, 3,417,755 and 3,502,083 to Howard et al. disclose molding of a blank to give it a desired shape and contour but fail to teach or suggest forming a foam sheet of material having a pair of thicker areas positioned so that their position corresponds to the location where the central summit of the bra pad will be when it is completed after thermoforming. 
   U.S. Pat. No. 2,616,093 to Talalay discloses an apparel pad such as a shoulder or breast pad, which as a concavo-complex shape with a thickness graduated from a relatively thick portion to a relatively thin portion using different pieces of material to build up the pad. 
   U.S. Pat. No. 3,311,007 to McGee discloses an apparatus for producing at least one contoured surface upon a foamed material pad but is very different from the present invention because it teaches the effects of cutting a foam member which is compressed by a male mold portion against an opposite flat mold portion, and thus, the contour of the shaved material is based on the shape of the male mold portion. McGee fails to teach contouring of an article based on a foam material being pressed to cover and penetrate a recess before the foam material is shaved. 
   U.S. Pat. No. 2,727,278 to Thompson discloses a method of making a molded composite bra, in which the thickness of filler material in each bra pad has a summit thickness greater than the thickness surrounding the summit. The process for making the molded bra is however very different from the present invention and does not teach shaving a material compressed into a recess. 
   The remaining patents disclose other pad-related technology which are distinguishable from the invention, and they are enclosed for general reference. 
   A need remains for an improved pad, as well as a method for producing such a bra pad, which adds some padding effect to the bra but in a very subtle manner so that the padding is barely perceptible. 
   SUMMARY OF THE INVENTION 
   It is an object of the present invention to provide a method of manufacturing a bra pad having a thicker central summit area, as well as the pad itself and the apparatus for manufacturing the pad, comprising holding a sheet of uniform thickness, resilient and formable material, such as thermoplastic foam, and forming the sheet to have one or two thicker summit areas corresponding to the summits of the bra or bra-like garment (here called a bra for any garment in which the pads are ultimately used). Each pad thus has a thicker summit area for extending over the summits of the breasts of a wearer of the bra. 
   A further object of the invention is to provide the bra pad made in accordance with the method of the invention. 
   A further object of the present invention is to provide a bra or brassiere which includes molded cup forms which address the abovementioned limitations of the prior art or which will at least provide the public with a useful choice. 
   It is a further object of the present invention to provide a molded cup form for a brassiere including a laminated structure of a first panel of a flexible foam material and a second panel material, the first and second panels being substantially coextensive to each other and define a breast cup perimeter shape, wherein the first panel of flexible foam material is of varying thickness, providing a zone of greater thickness at a region or regions away from the perimeter as compared to regions of lesser thickness more proximate to the perimeter. Preferably the zone of greater thickness is located where, in use, a nipple of the wearer of the bra incorporating the breast cup is normally located. 
   Preferably the first panel is of a uniform thickness save for the zone of greater thickness, the zone of greater thickness having a maximum thickness at the center of the zone and being of a gradually reducing thickness toward the perimeter of the zone. 
   The second panel is disposed to the first major side of the first panel, to form a coextensive planar assembly which is molded to define a cup shape into the planar assembly and then any excess non-cup shape defined regions are removed from the assembly. 
   This invention may also be said broadly to comprise in the parts, elements and features referred to or indicated in this specification, 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 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 being understood, however, that this invention is not limited to the precise arrangements shown. 
   The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings: 
       FIG. 1  is a side elevation view of an open shaving mold used to make the pads and to practice the method of the present invention with a sheet of polyurethane foam material therebetween; 
       FIG. 2  is a view similar to  FIG. 1  of the shaving mold in its closed position and with a shaving device in an initial position of use; 
       FIG. 3  is a view similar to  FIG. 2  with the shaving apparatus in a final position; 
       FIG. 4  is a side elevational view of a shaved or graduated sheet component of the bra pad in accordance with the present invention; 
       FIG. 5  is a view similar to  FIG. 4  of an assembled pre-form of the bra pad according to the present invention; 
       FIG. 6  is an exploded view of a forming mold with the pre-form bra pad between the mold halves thereof; 
       FIG. 7  is a sectional view of a formed component for creating two foam pads of the present invention; 
       FIG. 8  is a top plan view of the formed component of  FIG. 7 ; 
       FIG. 9  is a view of a pair of bra pads constructed in accordance with the present invention; 
       FIG. 10  is an exploded sectional view through an assembly of panels prior to being formed and laminated together for the purposes of providing the bra cup, according to another embodiment of the present invention; 
       FIG. 11  is a sectional view through an assembly of panels of  FIG. 10 , prior to being molded; 
       FIG. 12  illustrates two panel assemblies of the invention, prior to being laminated together and prior to being formed into a three dimensional cup form by molding elements; 
       FIG. 13  is a plan view of a cup form having been molded and trimmed to define a perimeter suitable for incorporation as part of a brassiere; 
       FIG. 14  is a sectional view through an alternative configuration of an assembly of panels to that of  FIG. 11 ; 
       FIG. 15  is an alternative to  FIG. 14 ; 
       FIG. 16  is a perspective view of a brassiere incorporating the cup forms of the invention; 
       FIG. 17  is a sectional view through section  17 - 17  of  FIG. 13  wherein the assembly of panels according to that shown in  FIG. 12  is provided; and 
       FIG. 18  is a sectional view through section  17 - 17  of  FIG. 13  wherein an assembly of panels as shown in  FIG. 14  is provided. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring now to the drawings, in which like reference numerals are used to refer to the same or functionally similar elements,  FIG. 1  shows a shaving mold generally designated  10  comprising a lower shaving mold portion  12  and an upper shaving mold portion  14  with a thickness of e.g. 7 mm polyurethane foam  16  therebetween. Although polyurethane foam is illustrated, any thermo plastic foam material can be used according to the present invention and in fact any formable material can be used which is resilient and is capable of being formed into a permanent yet resilient three-dimensional shape. The shaving mold halves or portions  12  and  14  can be made of wood, plastic, metal or other suitable rigid material. Lower mold half  12  contains a pair of recesses  18  in its upper surface which are positioned so that they are near the central summit of each bra pad to eventually be made in accordance with the present invention. 
     FIG. 2  illustrates the shaving mold in its closed position with the resilient formable sheet of material  16  pressed down onto the lower mold half so that some of the material of sheet  16  is pressed into each recess  18  but also a thickness of material, for example at  20 , remains along the shaving mold halves. 
   A shaving apparatus generally designated  22  is also illustrated in  FIG. 2  which comprises a movable carriage  24 , which carries a blade, knife or shaving member  26  that extends transversely the full width of material sheet  16  (perpendicular to the plane of FIG.  2 ). Blade  26  is also positioned intermediate to the upper and lower shaving mold halves  14 ,  12  respectively so that a portion of the layer  20  can be neatly shaved from the sheet  16 . For this purpose, member  26  may be heated (e.g., a cutting wire), may be mounted for movement like a band saw, may be reciprocally vibrated back and forth like an electric knife or oscillated in any other appropriate way for cutting the foam material of sheet  16 . 
   With the shaving apparatus  22  activated to vibrate, heat or otherwise activate member  26 , the carriage  24  is moved in the direction of arrow A and across the sheet  16  until it reaches its final position shown in  FIG. 3 . In this position a slice  30  has been made in sheet  16  thus achieving the shaving effect.  FIG. 4  shows the shaved component or graduated sheet  16   a  which is removed from the shaving mold after it is opened and which contains a pair of thicker material areas  17  at a summit e.g. of 5.5 mm thickness, surrounded by thinner material areas  19 , e.g. 1 mm thick.  FIG. 8  illustrates in dotted line the two summit areas  17  on the rectangular and graduated sheet  16   a  which, in  FIG. 8 , has already been attached to as second outer cup sheet  32 , e.g. 2 mm thick, shown in  FIG. 5  which is also made of polyurethane foam material. Shaved or graduated sheet  16   a  forms an inner cup sheet. 
   As shown in  FIG. 5 , each of the cup sheets  16   a  and  32  may also include a laminate or fabric covering  33  and  34 , respectively, made, for example, of nylon or nylon with spandex. This is a conventional covering for foam pads used in bras. It is important that in accordance with the present invention, the laminate  33  be on the outer inner surface of the inner cup sheet  16   a  so that it is not shaved away by the shaving apparatus  22  and that the outer cup sheet  32  have its laminate  34  on its outer surface. This leaves the inner surfaces of panels  16   a  and  32  free to receive sprayed on glue. After the glue is sprayed on the two surfaces are pressed against each other to produce the single composite pre-form illustrated in  FIG. 5 . 
   In  FIG. 6  a thermo-forming mold  40  is generally designated  40  and, as illustrated, includes a lower female mold portion or half  42  and an upper mold half or portion  44 . The pre-form  16   a,    32  is positioned between the mold halves  42 ,  44  with the summits  17  centered on a pair of recesses  46  formed in the lower female mold half  42  which also correspond with a pair of male projections  48  formed in the male mold half  44 . Each projection  48  may also include a slight recessed or flattened area  49  or an area which is shaped to keep from completely crushing the summit areas  17  of the inner cup sheet  16   a.    
   The mold halves are heated to the appropriate level for molding the pre-form into a finished molding illustrated in  FIGS. 7 and 8 . The finished molding has thicker summit areas  17 , e.g. 5-6 mm thick, surrounded by the thinner surrounding areas  19 , e.g. 1 mm thick, which completely encircle each summit area  17  and have an inner area of e.g. 2 mm thick, so that a bra manufactured with or containing the bra pads of the present invention will have a slightly thicker area  17 , for example 3 mm, over the summit of each breast summit, and thinner material, e.g. tapering down to 1 mm, in thinner areas  19 . 
     FIG. 9  illustrates the pair of pads  52 ,  54  which are cut from the molding of  FIGS. 7 and 8  and are ready for use in a bra, in a conventional manner. The pads  52 ,  54  may also be used in other garments for covering the torso of a woman and which contain bra or bra-like structures such as bathing suits, camisoles, and the like. 
   With reference to  FIG. 16  there is shown a bra or brassiere  101  including two breast cup constructions  102  which have been engaged to various other components of the brassiere  101  such as for example body straps  103  and over the shoulder straps  104 . 
   The breast cups  102  are engaged together at an intermediate connection  105 . The breast cups have a perimeter  106  and a body portion  107  inward of the perimeter  106 . The breast cup is of a form having been molded and to a large extent is of a single structure comprising or consisting of a plurality of overlying and preferably substantially coextensive panels defining the assembly of the cup form. It is however envisaged that the breast cup of the present invention may have disposed therefrom or engaged thereto by means of sewing or otherwise affixing additional panels which may extend from the perimeter  106  of the cup form or may be associated with the cup form  102  intermediate of the perimeter  106  and define part of the body portion  107  of the cup form. 
   The two breast cups  102  of the brassiere are substantial mirror image about the intermediate connection  105 . Reference has been and will now be made to a single breast cup formed or to be formed from precursor materials, however, it will be appreciated that such reference is also reflective of the provision of the same form of breast cup for the other cup to be incorporated into a brassiere. 
   With reference to  FIG. 13 , there is shown a breast cup  102 . The breast cup is molded to a three dimensional form, such as a cup form appropriate for the purpose of supporting and covering at least part of the breast of the wearer. The breast cup  102  has been molded from materials which, with reference to  FIG. 10 , may include a first panel of flexible foam material  108 , preferably a second panel of flexible foam material  109 , a covering panel of flexible fabric material  110  and a second panel of covering flexible fabric material  111 . In an alternative form however as for example shown in  FIG. 14 , the breast cup may be defined by a first panel of flexible foam material  108 , the covering flexible fabric material  110  and the second panel of covering flexible material without there being a provision of a second panel of flexible foam material  109 . 
   While reference herein is made to such panels being directly affixed to each other preferably by laminating such as by heat and/or adhesive laminating, it will be appreciated that panels or panel assemblies consisting of plies of sheet material may be provided intermediate of those panels. 
   With reference to  FIG. 10 , there is shown a sectional view of the panels of the breast cup of the present invention consisting of a first panel of a flexible foam material  108  and a second panel of a flexible foam material  109 . Disposed and preferably substantially coextensive with the first panel of foam material  108  there is provided a panel of flexible fabric material  110 . The laminated assembly of the panel  108  and  110  may be provided from roll stock material to be used in the method of the present invention. The fabric material  110  may for example be nylon and the foam material may for example be polyurethane. The foam panel  109  includes a first major surface  113  which is exposed and a second major surface  114  against which the fabric panel  110  is laminated. In this precursor form of the assembly of panel  108  and  110 , such an assembly is in an unmolded condition and in a natural state assumes a flat or planar condition. 
   A second panel of flexible foam material  109  in assembly for example with a second panel of flexible fabric material  111  is also provided. The second panel of foam material  109  includes an exposed major surface  115  and a covered major surface  116  against which the second flexible fabric panel is laminated. Like the assembly of panels  108  and  110 , the panels  109  and  111  may be provided in a precursor form from a feed of roll stock and in a natural state assume a substantially planar or flat condition. 
   The size of the resulting rectangular cut precursor panel assemblies is such that when subjected to molding in a molding machine to define the three dimensional cup form thereof, it is of a sufficiently large size to define the entire desired cup form. The first panel of foam material  108  is preferably of a greater thickness X than the thickness Y of the second panel of foam material  109 . 
   With reference to  FIG. 11 , the first panel of foam material  108  is formed to define a zone of increased thickness  116 . This zone of increased thickness  116  is provided intermediate of the perimeter  117  of the assembly of panels  108 ,  110 . The zone of increased thickness  116  is also provided inward (inward of the perimeter) of that region of the panel assembly  108 ,  110  into which a molded cup form to ultimately define a breast cup of the present invention will be defined. 
   Accordingly when formed to a cup form with the other panels to define the breast cup of the present invention as shown in  FIG. 13 , the zone of increased thickness  116  is provided inward from the perimeter  106  of the breast cup. In the preferred form the first panel of flexible foam material prior to being molded is formed to be of a substantially constant thickness Z save for the zone of increased thickness  116 . In the most preferred form such contouring is by the shaving of the panel to define the contoured shape on the first major side  113  of the precursor panel of flexible foam material  108  as disclosed in greater detail above. 
   After having been formed/shaped the then contoured first major surface  113 A of the first panel of flexible foam material  108  will include the zone of increased thickness  116  extending from regions of reduced thickness at or towards the perimeter of the panel assembly  108 ,  110 . The zone of increased thickness may for example be a dome shape as for example shown in  FIG. 11  and of a constant diameter D. 
   Alternatively the shape may be of a gradually undulation as for example shown in  FIG. 14 . So that the existence of this zone of increased thickness in the final version of the brassiere is to a large extent disguised, it is preferred that the zone of increased thickness  116  has a maximum thickness or summit substantially centrally within the zone and provides a reduction in thickness towards the perimeter  119  of the zone. Such reduction in thickness may be by a linear tapering, for example, shown in  FIG. 14 . In the most preferred form the second panel of flexible foam material  109  is not subjected to any contouring. The first panel of flexible foam material  108  is subjected to contouring but only on the non-fabric side of the first panel, opposite to panel  110 . 
   The assembly of panels  108 ,  110  is then laminated with the assembly of panels  109 ,  111  in a molding device as for example shown in  FIG. 12 . The molding device consists of two mold portions  120  and  121  each having formed therein a profile or contour of a kind to introduce into the precursor assemblies of panels the three dimensional or cup form of the breast cup. The upper mold portion  120  for example includes a concave relief and the lower portion  121  provides a convex upstand of a substantially complimentary shape to the concave recess of the upper mold portion  120 . 
   The assemblies of panels  108 ,  110  and  109 ,  111  are positioned intermediate of the mold portions in a manner so that they overly each other in an appropriate condition (preferably coextensively) whereupon the two mold portions are then brought together. The two mold portions are preferably heated. Additional adhesive may be placed intermediate of the assemblies so that both pressure adhesive and heat will ensure that a good laminated bond can be established between the two subassemblies. Upon the formation of the cup form into the precursor panel or panel assemblies, the cup form can be trimmed from the molded precursor panels to define a perimeter shape such as for example shown in  FIG. 13 . Part of the perimeter of the cup form  106  may include an additional compression zone  123  where the overlying panels of material have been subjected to more enhanced compression than that of the main body portion  107 . Such additional compression zones may serve the purpose of allowing for the cup to define a flange useful for the purposes of securing the cup to other components of the brassiere. 
   With reference to  FIG. 13 , it can be seen that upon the forming of a three dimensional form or cup form in the precursor materials as well as laminating the precursor materials together, will locate the zone of increased thickness  116  inward from the perimeter  106  of the breast cup  102 . The zone of increased thickness  116  is provided within the body portion  107  of the breast cup  102 . This zone of increased thickness is positioned to correspond with the usual location of the nipple of the breast of a wearer of a brassiere incorporating the breast cup  102 . 
   With reference to  FIG. 17  there is shown a cross sectional view through section  17 - 17  of  FIG. 13  wherein the zone of increased thickness  116  is shown to be provided to enhance the overall thickness of the breast cup in such zone. Thickness B is greater than thickness C. While the thickness is perhaps only marginally greater at B than at C, a further enhancement to reduce the visibility of a nipple of a wearer through the breast cup is as a consequence of the higher density of material at the zone of increased thickness  116 . Once the breast cup has been formed, the zone of increased thickness  116  will compress slightly such compression enhancing the material density at this zone thereby reducing the likelihood of observing the presence of the nipple through the breast cup. In the preferred form the thickness E is substantially the same as the thickness X and accordingly at the region of maximum thickness of the zone of increased thickness  116 , little or no shaving or removal of the foam from the precursor precontoured panel of flexible foam material  8  has occurred. 
   With reference to  FIG. 15 , there is shown an alternative to the formation of the zone of increased thickness  116  wherein a first ply of foam material has engaged to its exposed major surface  113  a second ply of material  124  such as a like foam material which has been contoured to provide the same desired profile to the assembly of the first ply and the second ply  124  as that shown for example in  FIG. 11  or  14 . 
   While in the most preferred form, the second assembly consisting of the second panel of flexible foam material  109  and panel of fabric material  111  laminated by adhesion to the first panel of foam material, with reference to  FIG. 18  there is an alternative where the first panel  108  receive the flexible panel of fabric material  111 , directly engage without the presence of a second panel of foam material  109  being present. An assembly of such a configuration formed to a cup form is shown in  FIG. 18 . 
   While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.