Abstract:
A decoratively patterned, laminated brassiere, including an outer fabric layer, a foam core and an inner fabric layer. The outer fabric layer having embossing therein to define the decorative pattern of the brassiere, the core having a corresponding embossed pattern in the surfaces thereof underlying the fabric layer and which is impressed through the latter into the core so that the material of the core impregnates the fabric layer to permanently retain the decorative pattern therein.

Description:
FIELD OF INVENTION  
         [0001]    This invention relates generally to brassieres, slips or other articles of feminine wearing apparel, and/or methods of manufacturing same.  
         BACKGROUND  
         [0002]    It is often desirable in the manufacture of brassieres to include embossed decorative or ornamental designs to enhance the appearance thereof, and which may be correlated with the patterns of lace or other decorative fabrics included in the associated garments or wearing apparel.  
           [0003]    Prior art attempts at permanent decorative embossing may not be capable of withstanding the repeated launderings to which wearing apparel are usually subjected.  
           [0004]    It would also be desirable to include decorative embossing but which would only appear on the outer or exposed surface of the cups while the inner surface, which is in contact with the wearer&#39;s body, remains smooth for optimum comfort to the wearer.  
         SUMMARY OF INVENTION  
         [0005]    It is an object of the present invention to provide a brassiere and/or method of manufacturing same that goes some way to overcoming the abovementioned disadvantages in the prior art, achieving some of the abovementioned desideratum or which will at least provide the public with a useful choice.  
           [0006]    In a first aspect, the present invention consists in a decoratively patterned, laminated cup for a brassiere, comprising  
           [0007]    at least one outer fabric layer, and  
           [0008]    a foam core;  
           [0009]    wherein said outer fabric layer having a portion including embossing therein to define the decorative pattern of the cup, the core having a corresponding embossed pattern in a portion of the surfaces thereof underlying said outer fabric layer and which is impressed or impregnated through, or adhered to said outer fabric layer to permanently retain the decorative pattern therein.  
           [0010]    Preferably said cup further comprises an inner fabric layer on the opposite side of said core to said outer fabric layer.  
           [0011]    Preferably said cup further comprises a further foam core and an inner fabric layer on the opposite side of said core to said outer fabric layer.  
           [0012]    In a second aspect the present invention consists in a method of manufacturing a cup for brassiere comprising the steps  
           [0013]    providing a laminate comprising at least an elastic foam layer and an elastic fabric layer,  
           [0014]    heating said laminate until said foam layer becomes at least plastic, and  
           [0015]    compressing said laminate with an engraved or embossed mold on at least the fabric layer side.  
           [0016]    In a third aspect the present invention consists in a brassiere including two cups, the improvement comprising that at least one said cups comprising:  
           [0017]    at least one outer fabric layer, and  
           [0018]    a foam core;  
           [0019]    wherein said outer fabric layer having a portion including embossing therein to define the decorative pattern of the cup, the core having a corresponding embossed pattern in a portion of the surfaces thereof underlying said outer fabric layer and which is impressed or impregnated through said outer fabric layer to permanently retain the decorative pattern therein.  
           [0020]    Preferably the improvement further comprises  
           [0021]    an inner fabric layer on the opposite side of said core to said outer fabric layer.  
           [0022]    Preferably the improvement further comprises  
           [0023]    a further foam core and an inner fabric layer on the opposite side of said core to said outer fabric layer.  
           [0024]    In a fourth aspect the present invention consists in a method of forming a brassiere including two cups the improvement comprising that at least one of said cups is formed according to at least the steps of:  
           [0025]    providing a laminate comprising at least an elastic foam layer and an elastic fabric layer,  
           [0026]    heating said laminate until said foam layer becomes at least plastic, and  
           [0027]    compressing said laminate with an engraved or embossed mold on at least the fabric layer side.  
           [0028]    In a fifth aspect the present invention consists in a computer aided method of forming a cup for a brassiere comprising the steps of receiving input relating to the design and/or dimensions of said cup and storing said input;  
           [0029]    determining the design and/or dimensions of two mold halves based on said input for molding said cup; and  
           [0030]    molding a laminate between said mold halves to form said cup.  
           [0031]    Preferably the method further comprises the step of forming said mold halves based on said determined design and/or dimensions.  
           [0032]    To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.  
           [0033]    The invention consists in the foregoing and also envisages constructions of which the following gives examples. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0034]    The preferred forms of the present invention will now be described with reference to the accompanying drawings in which:  
         [0035]    [0035]FIG. 1 is a sectional view illustrating the manner in which fabric either side of a core of foam material is laminated during the production of an embossed cup in accordance with a preferred embodiment of the invention,  
         [0036]    [0036]FIG. 2 is a sectional view of an embossed cup produced from foam core and fabric of FIG. 1 along the line AA of FIG. 6,  
         [0037]    [0037]FIG. 3 is a cross section of the moulding process, of the lay up FIG. 1,  
         [0038]    [0038]FIG. 4 is a cross section of the 4 layer laminate,  
         [0039]    [0039]FIG. 5 is a cross section of the 4 layer molding process, and  
         [0040]    [0040]FIG. 6 is a perspective view of the completed embossed cup. 
     
    
     DETAILED DESCRIPTION  
       [0041]    The present invention allows a permanent pattern to be embossed on the cups of a molded brassiere.  
         [0042]    Referring to the drawing in detail, and initially to FIG. 1 thereof, it will be noted that a composite material embodying the present invention and generally identified by the reference numeral  10 , is of the laminated type and includes a relatively thin liner or core  11  of elastic foam, such as, for example, polyurethane or the like, and an elastic textile fabric  12  of cotton, or other suitable fibre, natural or synthetic, around the core  11  so as to envelop the latter. The core is preferably of a sufficient density to retain the embossing over normal life of the garment. In case of polyurethane foam a density of at least 25 kg/m 3  is preferred.  
         [0043]    The woven textile fabric  12  forms an inner or bottom layer  12   a  and an upper or outer layer  12   b  about the core  11 .  
         [0044]    The inner and outer layers  12   a  and  12   b  of fabric are bonded together by pressing together such layers while the material of core  11  is in a semi plastic or molten condition such that the material of core  11  impregnates at least in part the fibres of the fabric layers and, upon setting thereof, forms a secure bond therewith. Suitable adhesive as known in the art can be applied to the surfaces to be bonded in order to improve the bonding.  
         [0045]    Making the Mold  
         [0046]    A pattern (such as a flower pattern) is first hand drawn with (for example) a black marker on a plastic cup of the intended shape and size for the bra to be produced. The pattern can be on any side or both sides of the cup. Then a 3-D scanner is used to scan the shape of and the pattern on the plastic cup to form a 3-D scanned image. The scanned image consists of pixels and may need to be “smoothed” to form the lines of the pattern. The design of the shape of the cup and the pattern thereon will then be finalized and stored in a computer. Alternatively the design may be completely generated within the computer using known 3D graphic or CAD software tools. The computer then controls and drives a milling machine to mill the pattern on and the shape of the cup onto the molds. The molds will then be used in the molding machine for making the bra cup.  
         [0047]    Making the Breast Cup  
         [0048]    The foam core  11  and the fabric  12   a  and  12   b  are laminated together as shown in FIGS. 3 and 5. The foam core  11  is cut to the size and shape needed. The cut foam core  11  is loaded into the molding machine  22  shown in FIG. 3 in between the upper mold half  24  and lower mold half  20 . The top mold half  24  is pressed down onto the laminate  10  for, for example, 120 seconds. The temperature of the upper mold half  24  is for example 198° C. and the temperature of the lower mold half  20  is for example 202° C. The temperature of the lower mold half  20  would in general be higher than that of the upper mold half  24 , due to heat dissipation as a result of the repeated opening and closing action of the upper mold half  24 . The foam and the fabric will then form a cup shape with the pattern formed thereon as seen in FIG. 6.  
         [0049]    It has been found that, where the core  11  underlies the upper or outer layer  12   b  of textile fabric, the embossing of the latter is transmitted to the core, that is, the raised portions of the design in the upper fabric layer  12   b  are filled or supported by correspondingly raised portions of the core, as is clearly apparent in FIG. 2. Further, the core impregnates the fabric  12  so that, when the core has set, the pattern or design embossed in the upper fabric layer  12   b  tends to be permanently retained by the foam core  11  even after repeated launderings of the laminate  10 .  
         [0050]    In the absence of the core  11 , embossing of the material is not permanently retained and further results in the transmission of the embossed pattern to the lower or inner surface of the material, and in weakening of the textile fabric. Thus, in the material  10  embodying the present invention, the core  11  performs the multiple functions of retaining the embossed design or pattern in the upper or outer surface of the material, of permitting the restriction of the embossed design or pattern merely to the outer layer or surface of the material so that a smooth lower or inner surface can be maintained, and further of retaining the material in the desired shape, that is, preventing deformation during use.  
         [0051]    With certain breast cup designs the outer fabric  12   b  (the fabric further away from the skin) will be subject to much greater tensile force than the inner fabric  12   a  and may thus be overly stretched resulting in less desirable “hand” feel. This problem can be reduced (assuming the same cup thickness) if two foam panels are molded, each with only single sided fabric. Referring to FIGS. 4 and 5 it is seen the inner foam  13  and outer foam  11  can be molded separately or integrated in one step to a 4 ply laminate  14 .  
         [0052]    Making the Bra  
         [0053]    The completed breast cup may be sewn together with the straps, underwire, elastic and any decorative additions to form the brassiere. Alternatively a one piece brassiere could be formed completely with the laminate molded to the required shape. The brassiere may include over shoulder straps, strapless or other configuration as are known of the art. The embossed patterns need not be on the cup but on any part of the article made from the laminate for example the straps. Also the brassiere or the embossed cups may form part of a larger garment.  
         [0054]    It will be appreciated that other forms of manufacture are possible without departing from the scope of the invention. For example the outer fabric layers could be adhered to the core. The adhesive may be surface applied or sprayed to the core. The layers are then hot pressed to form the cup.