Abstrict A method of manufacturing a bra 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 summit of a bra or bra-like garment for including
the pad, and a surrounding thinner area. Each pad thus has a thicker
summit area for extending over the summits of the breasts.
Claims What is claimed is:
1. A method of manufacturing a bra pad, comprising: holding a sheet
of resilient and formable material having a uniform thickness in
a shaving mold having a graduated recess, with at least some of
the material in at least one recess of the shaving mold; and removing
some of the material from the sheet of resilient and formable material
by shaving, to leave a graduated sheet of the material having at
least one graduated thicker summit area corresponding to the recess
of the shaving mold, and a surrounding thinner area of the graduated
sheet forming the bra pad shape.
2. A method according to claim 1 wherein the material of the sheet
is thermo-formable material, the method including thermo-forming
the graduated sheet.
3. A method according to claim 1 including cutting a bra pad out
of the graduated sheet by culling some of the surrounding thinner
area of the graduated sheet around the summit area.
4. A method according to claim 1 wherein the graduated sheet has
a pair of spaced apart summit areas.
5. A method according to claim 1 including adhering to the graduated
sheet, a further sheet of resilient and formable material and then
forming the graduated sheet with the adhered further sheet of material
to form a bra pad.
6. A method according to claim 1 wherein the removing of material
by shaving step comprises passing a cutting tool across the sheet
of resilient and formable material having a uniform thickness, while
the sheet is held in the shaving mold with at least some of the
material in the at least one recess of the shaving mold.
7. A bra pad comprising: first sheet of resilient and formable
material having an initial uniform thickness and from which some
material has been removed to leave a graduated sheet of the material
having at least one graduated thicker summit area, and a surrounding
thinner area; and a further sheet of resilient and formable material
adhered to the graduated sheet of resilient and formable material
forming the bra pad.
8. A pad according to claim 7 wherein the sheets of resilient
and formable material each comprise thermoplastic material.
9. A pad according to claim 8 wherein the thermoplastic material
is polyurethane foam.
10. A pad according to claim 7 wherein the further sheet of resilient
and formable material adhered to the graduated sheet of resilient
and formable material has a fabric laminate on outer surfaces of
each sheet of material which is opposite from a surface at which
the sheets of material are adhered to each other.
11. A pad according to claim 7 wherein the removing of some of
the material to leave the graduated sheet of the material is performed
by shaving.
12. A pad according to claim 11 wherein the shaving step comprises
passing a cutting tool across the sheet of resilient and formable
material having a uniform thickness, while held with at least some
of the material in the at least one recess of a shaving mold.
13. A molded breast cup for a brassiere including a molded to a
cup form and laminated structure of a first panel of a flexible
foam material and a second panel of flexible material, said first
and second panels being substantially coextensive to each other
and define a breast cup perimeter shape, wherein said first panel
of flexible foam material is of varying thickness, providing a zone
of greater thickness at a region or regions away from said perimeter
more than regions of lesser thickness more proximate to said perimeter,
said first panel having said varying thickness introduced by a contouring
of a first major side thereof, an opposite second major side thereof
being uncontoured other than having been formed to said cup shape.
14. A molded breast cup as claimed in claim 13 wherein said first
panel is a flexible foam material.
15. A molded breast cup as claimed in claim 13 wherein said second
panel is a flexible fabric material.
16. A molded breast cup as claimed in claim 13 wherein said zone
of greater thickness is located where, in use, a nipple of the wearer
of said brassiere incorporating said breast cup is normally located.
17. A molded breast cup as claimed in claim 16 wherein said first
panel is of a uniform thickness save for at said zone of greater
thickness.
18. A molded breast cup as claimed in claim 17 wherein a transition
of thickness between said zone of greater thickness and said uniform
thickness region of said first panel of flexible foam material is
without sudden thickness change.
19. A molded breast cup as claimed in claim 18 wherein said transition
of thickness between said zone of greater thickness and said uniform
thickness region of said first panel of flexible foam material is
with of a smooth transition.
20. A molded breast cup as claimed in claim 13 wherein said first
panel is of a uniform thickness save for at said zone of greater
thickness, the zone of greater thickness having a maximum thickness
at the center of said zone and being of a gradually reducing thickness
towards the perimeter or the zone.
21. A molded breast cup as claimed in claim 13 wherein said first
major side of said first panel is disposed to the second panel.
22. A molded breast cup as claimed in claim 13 wherein said first
major side of said first panel is engaged to the second panel.
23. A molded breast cup as claimed in claim 13 wherein said first
panel is engaged to the second panel.
24. A molded breast cup as claimed in claim 13 wherein said first
panel is a unitary panel.
25. A molded breast cup for a brassiere including a molded cup
form and laminated structure of a first panel of a flexible foam
material and a second panel of a flexible material, said first and
second panels being substantially coextensive to each other and
define a breast cup perimeter shape, wherein said first panel of
flexible foam material is of varying thickness, providing a zone
of greater thickness at a region or regions away from said perimeter
more than regions of lesser thickness more proximate to said perimeter,
said first panel consisting of a first ply of foam material uniform
thickness and a second ply of material engaged therewith in a manner
to create said zone of greater thickness.
26. A molded breast cup as claimed in claim 25 wherein said second
ply is of a foam material.
27. A molded breast cup as claimed in claim 13 wherein a first
panel of fabric material overlies said assembly to the concave side
of its said cup shape.
28. A molded breast cup as claimed in claim 27 wherein said first
panel of fabric material is laminated to one of said first panel
of flexible foam material and second panel.
29. A molded breast cup as claimed in claim 13 wherein a second
panel of fabric material overlies said assembly to a convex side
of said cup shape.
30. A molded breast cup as claimed in claim 28 wherein said second
panel of fabric material is laminated to the other of said first
flexible foam material and said second panel.
31. A molded breast cup as claimed in claim in 13 wherein said
first panel is disposed at the concave side of said cup shape and
said second panel is disposed at the convex side of said cup shape.
32. A molded breast cup as claimed in claim in 13 wherein said
first panel is disposed at the convex side of said cup shape anti
said second panel is disposed to concave side of said cup shape.
33. A molded breast cup as claimed in claim in 13 wherein said
first and second panels contain no seams, lines of stitching inward
of a region immediately adjacent said perimeter.
34. A molded breast cup as claimed in claim in 13 containing no
seams lines or stitching inward of a region immediately adjacent
said perimeter.
35. A brassiere incorporating a breast cup as claimed in claim
13.
36. A method of forming a molded breast cup comprising: laminating
(a) a first planar panel of a first ply of flexible foam material
end a second ply of flexible Foam material engaged to a first major
side of said first ply said first panel is of varying thickness
such having been defined by the provision of said second ply to
said first ply to create a zone which is of greater thickness at
a region or regions away from the perimeter more, than at regions
of lesser thickness more proximate to said perimeter, with (b) a
second panel of flexible material wherein said second panel is disposed
to the first major side of said first panel, to form a coextensive
planar assembly; molding said planar assembly to define a cup shape
into said planar assembly; and removing any excess non cup shape
defined regions from said assembly.
Description 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. 4013750 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. 3947207.
Other patents of interest to the present invention are:
TABLE-US-00001 U.S. Pat. No. Inventor(s) 2507543 Prager 2565400
Skeoch 2616093 Talalay 2627368 Jantzen 2702769 Alderfer 2845974
Ashton et al. 3164655 Howard et al. 3186271 Kaiser 3311007
McGee 3417755 Howard et al. 3464418 Silverman 3502083 Howard
et al. 3800650 Schroder 4351211 Azzolini 5017174 Gowrylow
5299483 Ber-Fong.
U.S. Pat. No. 2627368 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. 3186271 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. 3164655 3417755 and 3502083 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. 2616093 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. 3311007 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. 2727278 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 above
mentioned 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 20 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 16a 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 16a 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 16a forms an inner cup
sheet.
As shown in FIG. 5 each of the cup sheets 16a 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 16a 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 16a 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 16a, 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
16a.
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 a pair of spaced apart 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 5254 which are cut from the
molding of FIGS. 7 and 8 by cutting the surrounding thinner area
around the summit areas and are ready for use in a bra, in a conventional
manner. The pads 5254 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 199.
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 113A 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.
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