Abstract:
A moulded brassiere having a core of a first molded foam and a laminated second foam layer. An intermediate bridge between the cups with a flexible non-stretch bridge between the cups. Outer fabric layers extend beyond the core and defining straps.

Description:
PRIORITY CLAIM  
       [0001]    This is a continuation-in-part of U.S. patent application Ser. No. 10/349,514, filed Jan. 21, 2003. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to brassieres and in particular to a brassiere which incorporates a seamless breast cup construction and wherein the entire brasierre includes a negligible amount of stitching joining various components of the brassiere together.  
         BACKGROUND TO THE INVENTION  
         [0003]    Construction details of brassieres (hereinafter referred to as “bras”) have been developed over many years. Construction details have evolved along with the introduction of new materials and new processes which can be utilised for the manufacturing of bras. As with most consumer products, manufacturers endeavour to reduce the cost of goods sold. A reduction in cost of goods sold can be brought about by the use of cheaper materials. For bra technology however, a significant saving in the cost of a bra can be achieved by eliminating the man-hours required to manufacture the bra. Many bras that are available on the market will include multiple panels of materials which need to be cut, and joined. Cutting can be automated, however when it comes to stitching the panels together, this will mostly be done by a person. The breast cup of a bra may consist of multiple panels which each need to be stitched together, the entire breast cup then needs to be stitched to the chest band and to the over the shoulder straps. Perimeter stitching or overlooking to ensure that the edges of the material of the bra do not fray also needs to be added to the bra. Such is also done by a person. It can hence be seen that in order to manufacture a bra, the labour component of the overall cost can be relatively high.  
           [0004]    Accordingly it is an object of the present invention to provide a bra which reduces the amount of stitching that is required compared to the majority of bras available on the market. It is also an object of the present invention to provide a seamless breast cup construction which will at least provide the public with a useful choice.  
           [0005]    It is also an object of the present invention to provide a method of manufacturing a seamless breast cup construction and related bra incorporating such construction to reduce the labour content of manufacturing of the bra or to at least provide the public with a useful choice.  
         BRIEF DESCRIPTION OF THE INVENTION  
         [0006]    In a first aspect the present invention consists in a moulded brassiere including,  
           [0007]    a core assembly of at least a first layer of moulded foam material and a second layer of foam material laminated with said first layer said core assembly defining two breast cup regions and an intermediate bridge region extending there between and wherein a layer of flexible material having non-stretch properties is provided intermediate of and laminated to said first and second layer of moulded foam material at said bridge region, said flexible material having non-stretch properties oriented so that across the bridge region parallel to the cup to cup direction said core assembly is non-stretchable, and  
           [0008]    a first and second exterior layer each of at least a fabric material layer disposed outward most and each laminated with said core assembly on a respective side of said core assembly to encase said core assembly, said first and second exterior layers extending beyond the perimeter of said core assembly to provide at least that part of the brassiere defining chest strap(s).  
           [0009]    Preferably said first layer and said second layer of foam are laminated directly to each other save for said flexible material having non-stretch properties.  
           [0010]    Preferably said flexible material having non stretch properties is provided extending at said bridge region only.  
           [0011]    Preferably said flexible material having non stretch properties is captured intermediate of said first and second layer of moulded foam material.  
           [0012]    Preferably said flexible material having non stretch properties is a woven fabric material.  
           [0013]    Preferably said flexible material having non stretch properties is a woven fabric material with bi directional non-stretch properties and is oriented such that the non stretch orientation extends across said bridge region parallel to the cup to cup direction of said core assembly.  
           [0014]    Preferably said first and second layers of foam are coextensive with each other.  
           [0015]    Preferably said core assembly is of a shape defining only the breast cups and said bridge but not said chest strap(s).  
           [0016]    Preferably said chest straps extending outwardly from each side of said core assembly provided region of said moulded brassiere.  
           [0017]    Preferably said first and second layers of foam are co extensive.  
           [0018]    Preferably said first and second layers of foam are laminated directly to each other save for where said flexible material having non stretch properties is provided said breast cup regions having been moulded therein simultaneous to the lamination of said core assembly.  
           [0019]    Preferably two underwire structures are provided intermediate of said first sheet and said second layers, one each adjacent the breast cup regions.  
           [0020]    Preferably said underwire structure comprises a rigid elongate member and a flexible material casing about at least part of said rigid elongate member.  
           [0021]    Preferably said casing is a fabric material.  
           [0022]    Preferably said casing is adhered to one or each of the facing surfaces of said first and second layers of foam by an adhesive material.  
           [0023]    Preferably said casing is a tubular sock within which said rigid elongate member is located, the sock having closed distal ends.  
           [0024]    Preferably said first exterior layer is an assembly of laminated plies of a fabric material ply provided outwardly of said assembly and a foam ply provided inward of said fabric material ply.  
           [0025]    Preferably said foam layer ply of said exterior layer is laminated to said core assembly.  
           [0026]    Preferably said fabric material ply and said foam ply of said exterior layer are coextensive.  
           [0027]    Preferably said second exterior layer is an assembly of laminated plies of a fabric material ply provided outwardly of said assembly and a foam ply provided inward of said fabric material ply.  
           [0028]    Preferably foam layer ply of said second exterior layer is laminated to said core assembly.  
           [0029]    Preferably said fabric material ply and said foam ply of said exterior layer are coextensive.  
           [0030]    In a second aspect the present invention consists in a method of manufacturing a moulded component assembly for a brassiere comprising:  
           [0031]    placing a core assembly of a first layer of foam material and a second layer of foam material between which there is sandwiched a layer of flexible material having non stretch properties intermediate of two mould portions of a moulding machine each portion defining a complementary shaped two cup defining moulding surface, and wherein said layer of flexible fabric material is located at a region intermediate of said two cup  
           [0032]    moulding said core assembly by bringing said mould portions towards each other  
           [0033]    wherein the bringing together thereby subjects said core assembly to a moulding force which with the combination of heat, will permanently impress two cup forms,  
           [0034]    trimming said core assembly to define a moulded core assembly perimeter form which includes said two cups forms and a bridge region extending there between  
           [0035]    sandwiching said moulded core assembly between two exterior layers of flexible material including an outer layer of a fabric material  
           [0036]    trimming said two exterior layers to define a perimeter which includes about the chest securing straps.  
           [0037]    Preferably said moulding of said second layer of foam material to said first layer of foam material is achieved by the placement of said second layer adjacent said first layer and applying a force pressing said second sheet and said first layer together and with the application of heat and an appropriate dwell time of pressing thereby adhering said first and second layer together.  
           [0038]    Preferably prior to moulding of said first and second layer of foam, an underwire structure is provided intermediate of said first and second layer.  
           [0039]    In a further aspect the present invention consists in a method of making a brassiere comprising  
           [0040]    taking a core assembly of at least a first layer of moulded foam material and a second layer of foam material laminated with said first layer said core assembly defining two breast cup regions and an intermediate bridge region extending there between and wherein a layer of flexible material having non-stretch properties is provided intermediate of and laminated to said first and second layer of moulded foam material at said bridge region, said flexible material having non-stretch properties oriented so that across the bridge region and parallel to the cup to cup direction said core assembly is non-stretchable and  
           [0041]    sandwiching the core assembly between a first and second exterior layer each comprising of at least a fabric material layer disposed outward most and each laminated with said core assembly on a respective side of said core assembly to encase said core assembly, said first and second exterior layers extending beyond the perimeter of said core assembly and  
           [0042]    perimeter trimming such to provide also, the brassiere chest strap(s).  
           [0043]    Preferably each of said two exterior layer are affixed to opposite sides of said core assembly by adhesive moulding.  
           [0044]    Preferably each of said two exterior layer are affixed to opposite sides of said core assembly by an adhesive.  
           [0045]    Preferably adhesion of said shoulder straps and said back clasp to said chest straps is achieved by ultrasonic welding. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0046]    A preferred embodiment of the present invention will now be described with reference to the accompanying figures.  
         [0047]    [0047]FIG. 1 is a front view of a brassiere (hereinafter referred to as a “bra”) made in accordance to the methods of the invention hereinafter described,  
         [0048]    [0048]FIG. 2 is a plan view of two layers of precursor material, the upper being a foam material and the lower being a fabric material to be laminated together,  
         [0049]    [0049]FIG. 3 is a plan view of precursor layers of material, the upper being a foam material and the lower being a fabric material,  
         [0050]    [0050]FIG. 4 illustrates the layers of FIG. 2 having been laminated together to define a precursor outer assembly by the use of, for example, an adhesive and/or heat lamination,  
         [0051]    [0051]FIG. 5 is a perspective view of the layers of FIG. 3 having been laminated together to define a precursor outer assembly wherein the lamination has been achieved by an adhesive and/or heat lamination,  
         [0052]    [0052]FIG. 6 is a perspective view of an underwire assembly to be incorporated in the bra of the present invention,  
         [0053]    [0053]FIG. 7 is a sectional view through Section AA of FIG. 6,  
         [0054]    [0054]FIG. 8 is a sectional view through Section BB of FIG. 6,  
         [0055]    [0055]FIG. 9 is a plan view of a precursor layer of material of foam,  
         [0056]    [0056]FIG. 10 is a plan view of a precursor layer of another foam material,  
         [0057]    [0057]FIG. 11 is a plan view of a precursor fabric layer,  
         [0058]    [0058]FIG. 12 is a sectional view through a moulding device consisting of an upper and lower mould intermediate of which an assembly of core assemblies of the layers of FIG. 9, 10 and  11  and the underwire assembly are placed for the simultaneous moulding and lamination thereof to define a moulded core assembly capturing within the assembly the underwire assemblies underneath or adjacent of each of the cups mould formed in the layers,  
         [0059]    [0059]FIG. 13 is a sectional view through the two cup forms of the assembly of layers shown in FIG. 12 after the mould forming and lamination thereof,  
         [0060]    [0060]FIG. 14 is a plan view of the flexible core assembly of FIG. 13 and wherein perimeter trimming has occurred to define a core assembly of layers,  
         [0061]    [0061]FIG. 15 is a sectional view through a moulding device providing upper and lower mould portions intermediate of which the flexible core assembly of FIG. 14 is placed and relative to which the core precursor panel assembly of FIGS. 4 and 5 are positioned for the subsequent mould forming and lamination of the plies together,  
         [0062]    [0062]FIG. 16 is a plan view of the assembly of panels moulded according to the moulding process of FIG. 15 and wherein excess perimeter material has been trimmed, and  
         [0063]    [0063]FIG. 17 is a sectional view through Section CC of FIG. 16. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0064]    With reference to FIG. 1 there is shown a front view of a bra which has been manufactured according to the method as herein described.  
         [0065]    The bra  1  consists of an assembly of panels which have been laminated together to define a single structure incorporating the chest band  2  and two breast cup forms  3 . The chest band  2  may at their free ends  4 ,  5  be provided with mutually interactable catches or locking elements to allow for the free ends  4  and  5  to be engaged together. Also provided may be shoulder straps  6 ,  7  which are fixed to an appropriate region of the unitary chest strap and cup assembly of panels to allow for such to have over the shoulder support from the wearer of a bra.  
         [0066]    Such over the shoulder straps may however be optional as it is envisaged that the bra may be of a strapless version. Indeed whilst reference is herein made to the most preferred form of the present invention acting as a bra, it is envisaged that the assembly of panels to define such may alternatively be incorporated into other garments such as, for example, evening dresses or bathing suits or similar.  
         [0067]    Reference will now be made to a preferred method of construction which will explain the particular assembly of panels which may be provided to create the bra of FIG. 1.  
         [0068]    With reference to FIG. 2 there is shown two precursor layers, panels or sheets, or plies of material (hereinafter “layer”), the first layer  8  being of a foam material, preferably of a thickness of 3.1 mm.  
         [0069]    The second layer  9  is a fabric material such as the product known by model number CMF-7440MU of Friendly Foundate Ltd. This is a fabric and is made of 80% Tactel and 20% lycra.  
         [0070]    The foam is preferably a polyurethane foam of a density of, for example, 30-40d.  
         [0071]    The fabric layer  9  may have a make-up of approximately 80% Tactel 40d/34f and 20% lycra 40d and of a weight of, for example, 190 g/m 2 . With reference to FIG. 4, the foam panel  8  and the fabric panel  9  to provide an exterior assembly of panels, have been laminated together. The first exterior panel assembly  10  comprises of the layer of foam  8  laminated to the layer of fabric  9 . The layers are preferably substantially co-extensive with each other and have been laminated together using an adhesive such as glue HM-1 of Forbo Swift Adhesives SA. This glue will stick the fabric and foam together when dry without heating. It is sprayed onto at least one of the facing surfaces of the foam or fabric panels  8 ,  9 . The surface of foam panel  8  that is not facing fabric panel  9  is also sprayed with a glue such as RM-30 of Ultra Energy Adhesive Trading Co., Ltd. This glue will dry without sticking but will stick when heated in the mould during the moulding process shown in FIG. 15 and described hereinbelow.  
         [0072]    With reference to FIG. 3 there are shown a foam panel  11  and a fabric panel  12  which similar to the foam panel  8  and fabric panel  9  are laminated together to define a second exterior panel assembly  13  as shown in FIG. 5. The foam panel  11  is of a foam such as EWA35 of Inoac Corporation which is a polyurethane and is of a thickness of 1.7 mm.  
         [0073]    The fabric panel  12  is preferably the same as that of the fabric panel  9 . The second exterior panel assembly  13  is to be provided (once fully manufactured) to the interior side of the bra and the first exterior assembly  10  is to be provided to the exterior side of the bra. The fabric panels  9 ,  12  will be provided as the exterior most panels to the bra. Again, the surface of foam panel  11  that is not facing fabric panel  12  is also sprayed with a glue such as RM-30 of Ultra Energy Adhesive Trading Co., Ltd.  
         [0074]    As part of the bra of the present invention an underwire may be provided incorporated with the bra. The underwire structure consists of a substantially rigid but to a certain extent flexible wire  20  which may be of a diameter of, for example, 2 mm as shown in FIG. 7. The wire may be made from a material such as stainless steel. The wire is captured within a sock  21 . The sock has been closed at each end  22 ,  23  as, for example, shown in FIG. 8. The sock may be made from a material such as TRICOT. The closure at the end of the sock  22 ,  23  may be achieved by using the ultrasonic machine to bond. The underwire assembly  25  is then ready for subsequent use. The bra however may not incorporate the underwire in its final form.  
         [0075]    With reference to FIG. 9 there is shown a plan view of a layer of foam material  29  which is to form the convex side disposed layer of material for the core assembly layers for the bra. The foam layer  29  is preferably of a polyurethane foam/memory foam such as, for example, EL58-4S of Inoac Corporation which is a polyurethane/memory foam and is of a thickness of, for example, 6 mm.  
         [0076]    [0076]FIG. 10 is a plan view of a layer of foam  30  which is to form a layer to the concave side of a core assembly of layers to be used in the bra of the present invention. The foam layer  30  is made of a polyurethane foam/memory foam such as, for example, EL58-4S of Inoac Corporation. It is preferably also of a thickness of approximately 6 mm. In FIG. 11 there is shown a plan view of a layer of fabric material  31  which is to be incorporated as part of the core assembly of layers including layers  29  and  30 .  
         [0077]    The fabric layer  31  is of fabric  7118  of Goldspring Co. Ltd. It is preferably a piece of gauze which is 100% nylon. This layer is included in the assembly to define the core assembly of layers to be provided intermediate of the two foam panels  29  and  30  of the core assembly. The fabric material layer  31  is provided to be engaged intermediate of the foam layers  29  and  30  at a region which is to define the location intermediate of the two cup forms  39  and  40  to be moulded into the core assembly  33 . The fabric layer  31  accordingly becomes located intermediate of the two cup forms. It provides resistance against the elasticity which may otherwise be resultant in the region intermediate of the cups were there only the foam layers  29  and  30  provided at such an intermediate region. It is important to ensure that the cups remain at a constant disposition relative to each other. Accordingly in order to reduce the elasticity of the core assembly at the region intermediate of the cups, such a fabric layer is provided. In the most preferred form such a centre fabric layer  31  does not extend to be provided in a region below the breast cups. It merely extends at the region which bridges between the breast cup forms to be moulded therein and preferably no further. However at such bridging region the foam panels are also still provided. Each of the to be laminated sides of the layers  31 ,  29  and  30  and also the sock  21  of the underwire assembly  25  are sprayed with an adhesive whereupon they are then assembled but yet remain in a planar form. Two underwire assemblies  25  if used, are positioned intermediate of the foam layers  29  and  30  at appropriate locations at where a cup form is to be moulded into the core assembly  33  comprising of the layers  29 ,  30 ,  31  and optionally any additional layers engaged exteriorly from or intermediate thereof. Moulding of the assembly of layers  33  then occurs by the mould portions  34 ,  35 . The mould portions  34 ,  35  have surface relief provided thereto for the purposes of moulding and introducing into the core assembly  33  two cup forms. The upper mould  34  is preferably of a temperature of 180° C. to 200° C. and the lower mould is preferably of 180° C. to 200° C. The fabric material  31  is preferably applied with an adhesive to both sides. The dwell time holding the mould portions together is for example 120 seconds.  
         [0078]    With reference to FIG. 13 there is shown a cross sectional view of the core assembly  33 . FIG. 14 illustrates the core assembly  33  after having its perimeter trimmed to define a core cup assembly wherein two cup forms  39 - 40  are provided and remain interconnected through the transition region  41  to provide as a unit assembly, the core cup assembly  33 . It can accordingly be seen that the core cup assembly  33  is of a unitary assembly of layers. All of the layers of the cup assembly, save for the fabric layer  31  are substantially coextensive with each other. Where an underwire assembly is provided underneath each cup form, it remains that the foam panels  29  and  30  remain substantially coextensive with each other.  
         [0079]    The unit assembly  33  is then adhesively laminated with the exterior assembly of panels  10  and  13  again by a moulding device consisting of two mould portions  45 ,  46  which each have surface relief features defining two cup forms. The panel assemblies  10  and  13  are of a size which are sufficiently large so that the assemblies  10  and  13  can also provide the straps  2  extending from the cup regions  3 . The top mould in the moulding process of the core assembly  33  with the exterior panel assemblies  10  and  13  is provided where the top mould is at a temperature of approximately 180° and the bottom mould is approximately 170°. The dwell time is for example 120 seconds. As well as heat being used to ensure a lamination between the core assembly  33  and the exterior panel  10  and  13  occurs, the core assembly may be sprayed with an adhesive such as glue RM-30 of Ultra Energy Adhesive Trading Co. on both faces of the core assembly.  
         [0080]    The assembled exterior panel assemblies  10  and  13  with the core assembly  33  moulded to the appropriate form can then be trimmed to assume a form as for example, shown in FIG. 16. Such trimming may occur manually or may be done ultrasonically by an ultrasonic machine such as device EGR-053 of Ever Green Ultrasonic Co., Ltd. and a trimming roller  28 . The ultrasonic trimming device cuts and bonds the edge together at the same time.  
         [0081]    As can be seen the core assembly  33  is of a perimeter which is smaller than the trimmed perimeter of the exterior panel assemblies  10 ,  13 . Accordingly the core assembly  33  is captured within the exterior panel assemblies  10 ,  13 .  
         [0082]    [0082]FIG. 17 shows the perimeter region  50  of the bra through Section CC wherein the exterior panel assemblies  10  and  13  are engaged to each other at the perimeter and capture there within the core assembly  33 .  
         [0083]    Subsequent to the trimming, the peripheral components such as the catches  4 ,  5  and the over the shoulder straps may be fastened to the breast cup assembly as shown in FIG. 16. The shoulder straps may be length adjustable and the catches may allow for the adjustment of the size of the around the chest perimeter of the bra. Such peripheral components are preferably engaged to the assembly of FIG. 16 by the use of ultrasonic welding.  
         [0084]    Whilst reference has herein been made to the provision of the exterior assemblies  10  and  13  consisting of a layer of foam  8 ,  11  and a layer of fabric  9 ,  12 , it may well be that either or both of the exterior assemblies  10 ,  13  only provide the fabric layer  9 ,  12 .  
         [0085]    The construction of the present invention is simplified by the fact that the core assembly is a single piece assembly of layers. In this manner this invention does not require for the orientation of two independent cup forms in respect of the sandwiching or exterior layers of fabric and foam but merely requires the handling of the single core assembly for such purposes. The bra can also be manufactured substantially without or with no significant stitching.