Abstract:
An injection molded component for incorporation with other components to form a padded brassiere. The component comprises an injection molded material unitarily defining two breast cups and a bridge connecting the two breast cups. At each breast cup the molded material varies in thickness to define a pad-like formation for the brassiere.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a brassiere and injection molded components therefor. 
       BACKGROUND TO THE INVENTION 
       [0002]    Various types of brassieres (hereinafter referred to as “bras”) are known. Bras are typically made from multiple components and may be made from moldable precursor fabric and foam plies. These multiple components may be laminated, with or without adhesives, heat molded and trimmed to form the appropriate and desired shape. Further stitching may at times be needed to connect different portions of the bra. Foam pads may be provided for extra support and rigidity. Besides offering extra padding, foam pads in the cup regions also offer improved modesty. 
         [0003]    Manufacturing methods associated with the above-described bras require various processes and handling steps to produce the finished product. Such manufacturing methods may be time-consuming and costly. 
         [0004]    If a foam pad is provided in a bra, there may be difficulty in controlling the thickness of foam during manufacture. A precursor panel of foam is usually subjected to compression forming to introduce a cup shape into the pad. The forming will also usually result in a variation of the thickness of the foam pad so formed. After the compression forming of the foam pad, the foam might recover towards it original shape or in an unpredictable and undesired way and the resultant bra may be of a shape that is unpredictable, undesirable and/or not repeatable from bra to bra so manufactured. 
         [0005]    Accordingly it is an object of the present invention to provide a bra that can be manufactured more simply or which will at least provide the public with a useful choice. 
       SUMMARY OF THE INVENTION 
       [0006]    In a first aspect the present invention consists in an injection molded component for incorporation with other components to form a padded brassiere, said component comprising an injection molded material unitarily defining two breast cups and a bridge connecting the two breast cups wherein at each breast cup the molded material varies in thickness to define a pad like formation for said brassiere. 
         [0007]    Preferably said material is latex. 
         [0008]    Preferably said material includes latex. 
         [0009]    Preferably said material includes latex and a stabilising agent. 
         [0010]    Preferably a precursor to said material is a liquid latex. 
         [0011]    Preferably said material includes a coloring agent. 
         [0012]    Preferably at each breast cup the variation in thickness defines the greatest thickness at a centrally located zone of the breast cup and with gradual reduction in thickness from the zone towards the periphery of the breast cup. 
         [0013]    Preferably said component consists of said injection molded material and at least one layer of other material. 
         [0014]    Preferably said at least one layer of other material is injection molded latex. 
         [0015]    Preferably said at least one layer of other material is a ply of fabric laminated to said injection molded material. 
         [0016]    Preferably said injection molded material is captured between two covering plies. 
         [0017]    Preferably said covering plies are fabric plies. 
         [0018]    Preferably said covering plies are fabric plies laminated to said injection molded material. 
         [0019]    Preferably said at least one layer of other material is a reinforcing web extending across said bridge. 
         [0020]    Preferably said reinforcing material is of a unidirectionally substantially non-stretchable material. 
         [0021]    Preferably said substantially non-stretchable material is gauze. 
         [0022]    Preferably said substantially non-stretchable material is a plastic film. 
         [0023]    Preferably said reinforcing material is embedded in said injection molded material. 
         [0024]    Preferably shoulder straps and/or clasps are attached to the molded brassiere component. 
         [0025]    Preferably said injection molded material defines at least part of chest band wings. 
         [0026]    Preferably said injection molded material defines at least part of shoulder straps. 
         [0027]    Preferably an underwire structure is embedded in said injection molded material contiguous each cup. 
         [0028]    Preferably at least one of the inner and outer surfaces of said injection molded material is to define at least part of the exposed surfaces of said brassiere. 
         [0029]    Preferably at least one of an embossing, an aperture and a recess is defined at said exposed surfaces of said brassiere. 
         [0030]    Preferably said injection molded material is defined by a liquid injection molding process. 
         [0031]    Preferably said layer is unitary and homogenous. 
         [0032]    In a second aspect the present invention consists in a molded brassiere component manufactured in a single injection molding process. 
         [0033]    In a third aspect the present invention consists in a component of a brassiere comprising a unitary layer of injection molded material defining two breast cups and a bridge portion therebetween, the component at each breast cup being of a varying thickness to define a pad like structure. 
         [0034]    In a fourth aspect the present invention consists in a brassiere that includes the component as described with reference to the first aspect of the invention. 
         [0035]    Preferably shoulder straps are engaged to said component. 
         [0036]    Preferably said component comprises two different injection molded material compositions co-molded to each other, each material composition offering a different characteristic to the other. 
         [0037]    Preferably said different characteristic relates to different colors. 
         [0038]    Preferably said different characteristic relates to different strength properties. 
         [0039]    Preferably said different characteristic relates to different textures. 
         [0040]    In a fifth aspect the present invention consists in a garment that includes the component as described with reference to the first aspect of the invention. 
         [0041]    In a sixth aspect the present invention consists in a method of producing a brassiere or a brassiere component comprising the steps of:
       (i) injecting a moldable and settable material into a mold that defines a cavity with opposed walls for forming the concave and convex sides of two breast cups and a bridge extending between said breast cups wherein the opposed walls at each of the breast cups are of varying separation from each other;   (ii) allowing the material to set in the mold;   (iii) ejecting the set material from the mold; and   (iv) repeating steps (i) to (iii) cyclically.       
 
         [0046]    Preferably the mold is preheated prior to step (i). 
         [0047]    Preferably the material is a heat curable material. 
         [0048]    Preferably the material includes latex. 
         [0049]    Preferably prior to ejection, the injected settable material is positioned in a mold cavity that includes space for the injection of a second material to be affixed to the settable material. 
         [0050]    Preferably prior to injecting the moldable and settable material into the mold, a ply of material is introduced into the mold, said ply of material is to be embedded into the settable material. 
         [0051]    This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, 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 deemed to be incorporated herein as if individually set forth. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0052]    The invention will now be described by way of example only and with reference to the drawings in which: 
           [0053]      FIG. 1  is a side view of a mold used to produce a bra of the present invention; 
           [0054]      FIG. 2  is a side view of the mold of  FIG. 1  in use; 
           [0055]      FIG. 3  is a front view of a bra illustrating embossed patterns; 
           [0056]      FIG. 4  is a cross-sectional view of a preferred embodiment of the bra; 
           [0057]      FIG. 5  is a cross-sectional view of an alternative embodiment of the bra; 
           [0058]      FIG. 6  is a cross-sectional view of another alternative embodiment of the bra; 
           [0059]      FIG. 7  is a front view of the bra illustrating a reinforcing web at the bridge of the bra between the breast cups; and 
           [0060]      FIG. 8  is a front view of a single breast cup. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0061]    In the most preferred embodiment, the bra  6  as for example shown in  FIG. 3  is made by having all or the majority of it made by injection molding of latex. 
         [0062]    Latex, harvested from for example the rubber tree may be used for the injection molding process. Processing of raw latex may occur to increase its elasticity and strength. Additives such as ammonia may be added to preserve the latex. Anti-coagulants may be added to prevent the latex from coagulating prior to injection molding. Flame-retardants may also be added. Latex is naturally translucent and may be color dyed by the addition of color additives. Latex is the preferred material but other suitable rubber or similar materials may also be used. 
         [0063]    The latex in its precursor form may be conditioned as desired to allow it to be injection molded such as by liquid injection molding. 
         [0064]      FIG. 1  shows a cross section of a mold  1  in an open position that may be used in the injection molding of a bra of the present invention. The mold  1  consists of two parts, a first mold  2  and a second mold  3 . When the mold  1  is closed and clamped under pressure as shown in  FIG. 2 , the first mold  2  and the second mold  3  defines a hollow cavity therebetween. Latex may be injected to fill the mold cavity to form a bra or components for a bra. Latex is introduced into the hollow space through runners  4 . Though two runners are shown in  FIG. 2 , one or more runners may be used. The runners  4  are positioned at an unobtrusive or obscure part of the bra so that any indication of molding flash is minimised. Vents or outlets  5  may be provided for the release of excess latex. 
         [0065]    The injection molding process occurs cyclically. Cycle times are controlled by the curing time of the latex. Pumping systems can deliver the liquid latex to the mold that may be pre or post heated. The liquid latex is injected directly into the heated mold. Molding and curing takes place inside the heated mold cavity. Typically, latex is able to cure at room temperature. Thus, temperatures above room temperature and pressures above atmospheric pressures will accelerate the curing. After the latex is cured, the mold opens and the bra is ejected from the mold. The mold then closes again and the entire process may be repeated. 
         [0066]    Injection molding allows accurate control of the thickness, shape and size of the resultant product. Injection molding also offers high production rates, design flexibility, repeatability within tolerances, low labour and minimum scrap losses. An injection-molded bra may also be produced in a single piece with no lamination required. 
         [0067]      FIG. 3  shows an injection-molded bra  6  or part of a bra. Injection molding also allows embossing or patterns  7 , branding  8  and/or logo of the manufacturer to be conveniently and accurately defined by defining such features in the molds. 
         [0068]      FIG. 4  shows a cross-sectional view of an injection-molded bra  6 . The thickness of the material  9 , in this case latex, can be variable across the area of the bra. The thickness of the bra is determined accurately by the mold design. Being able to control the thickness of the bra means that reinforcement and tensile strength can be accurately controlled and repeated at where it is needed. For example, if extra padding is required, the thickness of the cup areas may be increased. 
         [0069]    Other than controlling the thickness, injection molding also provides the flexibility of injecting two dissimilar materials to form a two layer bra.  FIG. 5  shows a cross-sectional view of part of a bra with two layers  9  and  10 . This may be achieved by first molding the first layer between a first and a second mold that defines a cavity of a shape and size of the first layer, where upon curing or partial curing of the first layer, a third mold portion may substitute the second mold portion to define a cavity between the first layer and the third mold portion into which the second layer may be injected. Where the first layer is in a partially cured state, the injection of material to define the second layer may create a stronger bond between layers through there being a partial fusion of material at their interface. Alternatively, layers  9  and  10  could be the same material but with two different colours. The layers may be coextensive. 
         [0070]      FIG. 6  shows another cross-sectional view of a bra with two different materials and/or colours. In this bra, layer  11  only covers a partial layer of the bra at the chest band and not the entire bra. 
         [0071]      FIG. 7  illustrates a reinforcing web or material  12  that may be provided at the bridge of the bra  6  between breast cups. The reinforcing material  12  is preferably unidirectionally substantially non-stretchable, i.e. the reinforcing material  12  is substantially non-stretchable in the cup-to-cup direction but may be relatively stretchable in other directions. The reinforcing material  12  may be provided to offer additional tensile strength between the cups. The bridge region requires reinforcement because the tensile force pulling the bra cups apart in the cup-to-cup direction can be high. The reinforcing material  12  may, for example, be of a substantially non-stretchable plastic film or gauze. The reinforcing material  12  may be embedded into the latex bra  6  or latex bra component at the time of molding. This may occur by placing the reinforcing material in the mold before the latex is injected. The reinforcing material  12  may also be laminated by heat and/or pressure and/or adhesive after the latex bra  6  is molded. 
         [0072]    The reinforcing material  12  may also be introduced to be embedded into the latex bra component or bra or be placed on one side of the latex bra component or bra by injection molding of the reinforcing material such as by the process as described above in relation to  FIGS. 5 and 6 . The reinforcing material may be an injection moldable material that, when cured, has the desired strength characteristics. 
         [0073]    The reinforcing material may be provided at any location of the latex bra or latex bra component where it may provide additional strength. In fact it may be provided over a substantial portion or even the whole of the latex bra or bra component. 
         [0074]    There may also be included an embedded underwire assembly at or near the lower periphery of a or each cup to provide further support. The underwire assembly may comprise a wire or strip of metal or plastic encased in a sock made of for example fabric. Similar to the reinforcing material  12 , the underwire assembly may be embedded into the latex bra component or bra at the time of molding. 
         [0075]    The injection-molded bra  6  may be the finished product with minimal stitching to add on the shoulder straps  61  and clasps  62 . The shoulder straps  61  and clasps  62  may also be added on by stitching or by ultrasonic welding or other suitable method. Alternatively, the or parts of the shoulder straps may become fastened during injection molding or may be unitary with the rest of the bra. This may, however, be undesirable as the shoulder straps may not be adjustable. 
         [0076]    The bra may position clasps  62  so that the bra is either back opening or front opening. The back clasps may be positioned on the chest straps. The front clasps may be positioned at the bridge area between the cups. Different molds may be made for different designs of bra. 
         [0077]    Where reference herein is made to an injection molded bra or the like it is to be understood to mean that the entire bra may be made by injection molding or a substantial part is made by injection molding wherein components such as shoulder straps and clasps may be separately formed, or that parts of the bra such as the breast cups or components within the breast cups are made by injection molding. Also such injection molded bra or bra components may be used in conjunction with plies of fabric and/or foam to be laminated therewith in a process as for example described in U.S. patent application Ser. No. 11/479,572 which is hereby incorporated by way of reference. 
         [0078]    Further processing of the injection molded bra  6  is also possible. The injection-molded bra  6  may also be used as an injection-molded bra core. Layers of fabric and/or foam may be added to envelope the bra core. Fabric and/or foam may be added on the inner side, or on the outer side, or both. There may be one or more plies of fabric and/or foam on the inner and outer layer. Addition of fabric layers offers the flexibility of adding fabric patterns, which may not be achieved by embossing. Fabric and/or foam layers may also offer comfort to the wearer. The fabric and/or foam layers may be laminated by heat and/or pressure and/or adhesive after the bra core is injection-molded. Subsequently, shoulder straps and clasps may be added. In this regard, we again refer to U.S. application Ser. No. 11/479,572 by way of reference, with the foam bra core described therein substituted by an injection-molded bra core. 
         [0079]    Where reference herein is made to inward and outward or similar terminology, it is meant to be understood to be in relation to the body of the wearer of the bra. For example the “innermost” or “inward” or “inner side” or “inner region” is the face side of the bra that is more proximate to the body of the wearer than the more outward portions of the bra or its components or subassemblies. 
         [0080]    The injection-molded bra core may also be manufactured as a single cup  13  as shown in  FIG. 8 . Additional fabric and/or foam layers may be laminated as described above to define other parts of the bra. 
         [0081]    Though the invention has been described with reference to a bra, it may also be used in the manufacture of a bikini, swim wear, or incorporated as part of a dress. 
         [0082]    It is to be understood that the scope of the invention is not limited to the described embodiments and therefore numerous variations and modifications may be made to these embodiments without departing from the scope of the invention as set out in the claims.