Breast Cup Core, Breast Cup, and Method of Making Same

Abstract

There is provided an injection molded breast cup core and a breast cup core having a plurality of through holes. There is also provided a breast cup, a bra, or a shapewear comprising such a breast cup core as well as a mold for manufacturing such a breast cup core. A method of injection molding a breast cup core is also provided.

Description

FIELD OF THE INVENTION

The present invention relates to a breast cup core, a breast cup of a brassiere or shapewear, and methods of making the same.

BACKGROUND OF THE INVENTION

Brassieres (bras) and shapewear comprise two breast cups. Shapewear generally includes a body portion in addition to the breast cups, such that the shapewear extends from the chest to the waist. It is sometimes preferable to have thin breast cups for both bras and shapewear. Thin breast cups are typically formed of fabric alone or fabric layers with a thin layer of foam positioned therebetween. However, such thin breast cups generally do not provide much support and do not by themselves maintain a desirable cup shape.

Thus, there remains a need for thin breast cups which are supportive to the wearer's breasts and which maintain their shape.

SUMMARY OF THE INVENTION

The present invention aims to solve the aforementioned problems.

A first aspect of the present invention provides an injection molded breast cup core. A second aspect of the present invention provides a breast cup core having a plurality of through holes.

The breast cup core may be formed from a thermoplastic rubber material.

The breast cup core according to the first aspect of the invention preferably has a plurality of through holes. Preferably, the plurality of through holes are arranged in a predetermined pattern, such as a lace pattern or a geometrical pattern. The plurality of through holes may comprise regularly shaped holes, which may each have a diameter of at least 1 mm. Through hole density may vary across the breast cup core.

The breast cup core may have regions of varied thickness. An increased thickness is preferably formed at the underarm region and/or at the lower peripheral region. An increased thickness may be formed at an apex region that corresponds to the wearer's nipple area.

The breast cup core preferably extends across substantially the whole of the breast cup. A substantial portion of the cup core may comprise a thickness of about 1 mm.

The breast cup core may comprise an underwire molded with the breast cup core.

Another aspect of the present invention provides a breast cup comprising an inner layer of material, an outer layer of material, and an injection molded breast cup core sandwiched between the inner layer and the outer layer.

The inner and outer layers of the breast cup may be joined about a periphery of the cup by sewing or hemming.

The breast cup may further comprise an underwire. The underwire may be molded with the breast cup core or attached to an inner side of the inner layer of material, or even be attached to an outer side of the outer layer of material.

The inner and outer layers of the breast cup may be both formed from a fabric material.

Alternatively, the inner layer may be formed from a fabric material and the outer layer is formed from a lace material.

Alternatively, the inner layer of material and the outer layer of material may each comprise a fabric layer laminated with a foam layer. The foam is preferably polyurethane foam. The foam layer may have a thickness of about 1 mm. The inner layer of material, the cup core, and the outer layer of material may be molded together.

Another aspect of the present invention provides a brassiere comprising an injection molded breast cup core.

Another aspect of the present invention provides a shapewear comprising an injection molded breast cup core.

The present invention also provides a method of manufacturing a breast cup core described above. A method is provided for manufacturing a breast cup core by injection molding the breast cup core from a material suitable for injection molding.

The method preferably further comprises forming a plurality of through holes in the breast cup core. The plurality of through holes may be formed during the injecting molding of the breast cup core. Preferably, the plurality of through holes is formed in a predetermined pattern. The plurality of through holes may be formed as regularly shaped through holes. The holes may be formed with a diameter of at least 1 mm. The plurality of through holes may be formed in a lace pattern or a geometrical pattern.

Injection molding the breast cup core may comprise forming the breast cup core with regions of varied thickness. Injection molding the breast cup core may comprise forming the breast cup core with an increased thickness at the underarm region and/or at the lower peripheral region. Injection molding the breast cup core may comprise forming the breast cup core with an increased thickness at an apex region that corresponds to the wearer's nipple area

The method may further comprise molding an underwire with the breast cup core in the process of injection molding.

Another aspect of the present invention provides a mold for injection molding a breast cup core, the mold comprising a cavity in the shape of a breast cup core for receiving injection molded material to form a breast cup core. The mold may be a two-part mold and further comprise a plurality of protrusions which extend across the cavity to form through holes in a breast cup core formed in the mold. The mold may comprise further protrusions that are adapted to hold an underwire in a predetermined position within the cavity.

Another aspect of the present invention provides a method of manufacturing a breast cup comprising injection molding a breast cup core; sandwiching the breast cup core between an outer layer of material and an inner layer of material; and joining the outer layer and the inner layer. The outer layer and the inner layer may be joined by sewing or hemming.

The method may further comprise providing an underwire. The underwire may be molded with the breast cup core in the process of injecting molding or attached to an inner side of the inner layer of material or to an outer side of the outer layer of material.

The inner and outer layers may be both formed from a fabric material. Alternatively, the inner layer may be formed from a fabric material and the outer layer may be formed from a lace material. Alternatively, the inner and outer layers may be each formed from a fabric layer laminated with a foam layer, preferably a polyurethane foam layer, in which case the method may further comprise joining the inner layer of material, the breast cup core, and the outer layer of material by molding.

A further aspect of the present invention provides a method of manufacturing a breast cup comprising the steps of molding a first layer of material comprising a fabric layer laminated with a foam layer, preferably a polyurethane foam layer, to form a breast cup shaped region; placing an injection molded breast cup core onto the molded first layer of material; placing a second layer of material comprising a fabric layer laminated with a foam layer, preferably a polyurethane foam layer, onto the breast cup core; and joining the first layer, the breast cup core and the second layer by molding. The method may further comprise providing an underwire, which may be molded with the injection molded breast cup core.

A further aspect of the present invention provides a method of manufacturing a brassiere comprising molding a first layer of material comprising a fabric layer laminated with a foam layer, preferably a polyurethane foam layer, to have a first breast cup shaped region and a second breast cup region; placing an injection molded breast cup core onto each of the breast cup shaped regions of the molded first layer of material; placing a second layer of material comprising a fabric layer laminated with a foam layer, preferably a polyurethane foam layer, onto the breast cup cores; and joining the first layer, the breast cup cores and the second layer by molding.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 shows a front view of an exemplary bra having a breast cup core according to the present invention;

FIG. 2 shows a cross section of the breast cup core of FIG. 1 along the line II-II;

FIG. 3 shows a cross section of the breast cup core of FIG. 1 along the line III-III;

FIG. 4 shows an exemplary breast cup having an underwire or underwire assembly being attached around a periphery of the breast cup;

FIG. 5A shows an exemplary mold for injection molding a breast cup core according to the present invention with an exemplary pattern of through holes;

FIGS. 5B and 5C show an exemplary mold for injection molding a cup core according to the present invention with another exemplary pattern of through holes;

FIG. 6 shows a side perspective view of a breast cup core in accordance with the present invention, with an enlarged view of a cross section of a through hole;

FIGS. 7A, 7B and 7C show three exemplary patterns of through holes;

FIG. 8 shows a comparative view of a conventional bra and a bra according to the present invention;

FIG. 9 shows an exemplary shapewear having breast cup cores according to the present invention; and

FIG. 10A and FIG. 10B show a cross section of the shapewear of FIG. 9 along the line X-X according to two embodiments of the present invention.

FIG. 11 shows an exemplary breast cup having a breast cup core sandwiched between an outer layer comprising an outer fabric layer laminated with an outer foam layer and an inner layer comprising an inner fabric layer laminated with an inner foam layer.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a breast cup core for use in a breast cup of a bra or in a shapewear. The term “breast cup core” in this application is intended to refer to a main body portion of a breast cup that substantially defines the structure and the shape of the breast cup. The breast cup core preferably extends across substantially the whole of the breast cup.

Shapewear usually includes a breast portion having two breast cups and a body portion for supporting and/or shaping the wearer's chest and waist areas, either as an integral piece or a plurality of pieces joined together. A core may be provided to define the structure and the shape of a shapewear which extends across the breast portion and the body portion, the core including two breast cup cores. The core of a shapewear may be formed as an integral piece or multiple pieces.

FIG. 1 shows a bra 1 according to an embodiment of the present invention. The bra 1 comprises two breast cups 10 connected by a bridging portion 12, a breast band 14 and a shoulder strap 16 extending from each breast cup 10 to the breast band 14. The breast cup 10 comprises a breast cup core according to the present invention. According to a first aspect of the present invention, the breast cup core is injection molded. According to a second aspect of the present invention, the breast cup core has a plurality of through holes, where the breast cup core is made by injection molding or any other suitable manufacturing process.

FIG. 2 and FIG. 3 illustrate cross sections of an exemplary breast cup core 100 that can be used to form the breast cups 10. Preferably, the breast cup core 100 is formed of a thermoplastic rubber material or a thermoplastic elastomer. However, the breast cup core may be formed from any suitable materials, such as PU (polyurethane) gel, latex, or silicone.

The breast cup core 100 can be made thin and with the desired shape, preferably corresponding to the shape of the desired breast cup. The thickness across the breast cup core can be varied according to needs, for example, by designing the injection mold appropriately. For example, the breast cup core may be made thicker at the underarm region and/or at the lower peripheral region where enhanced support is usually desired. Of course, varied thickness may not be necessary and the breast cup core according to the present invention may have a uniform thickness. A substantial portion of the breast cup core may be provided with a thickness of about 1 mm, since the relatively strong tensile strength of a breast cup core formed from, for example, thermoplastic rubber or elastomer, is able to the provide the desired support and maintain the desired shape at this thickness. Other regions of the cup may have increased thickness. In these regions of increased thickness, the thickness of the breast cup core may be anywhere between 1 mm to 5 mm, and preferably between 1 mm and 3 mm.

Because of the relatively strong tensile strength of the breast cup core material, the shape of the breast cup core is normally not changed by the presence of the wearer's nipple. However, the thickness at the apex region of the breast cup core may be increased to further conceal the nipple, for example, by designing the injection mold appropriately. The exemplary breast cup core 100 shown in FIGS. 2 and 3 has increased thickness at the apex region 102 and at the underarm and lower periphery region 104.

The breast cup core 100 preferably has a plurality of through holes 110 which may be arranged in a predetermined pattern, although any pattern may be used. An enlarged view of a through hole is shown in FIG. 6. The through holes provide breathability of the breast cup core. The through holes may be any suitable size or in any suitable shape. The density of the through holes may vary across the breast cup core, as shown in FIGS. 7A-7C. By changing the density of the through holes, it may be possible to vary the stretchability of the breast cup core, as well as its breathability.

The through holes are preferably regularly shaped. The pattern of the through holes also affects the elasticity or stretchability of the breast cup core. A region having more holes generally has a greater stretchability than another region having fewer holes. Varied elasticity over different regions of the breast cup core may be accomplished by varying one or more of the though hole pattern, the through hole density, the through hole size, or the breast cup core thickness.

The pattern of the through holes may be chosen to provide the desired breathability, stretchability, elasticity and/or desired aesthetic effects. Examples of suitable patterns of through holes are shown in FIGS. 7A, 7B and 7C. FIG. 7A shows an embodiment in which the though holes are arranged in a geometrical pattern, resembling a flower pattern. FIG. 7B shows another embodiment in which the through holes are arranged in a lace pattern. The through holes shown in FIG. 7C have circular shapes. The through holes are preferably at least 1 mm or 2 mm in diameter (or have a similar area if the through holes are of a different shape). In these example patterns, the through holes provide less stretchability and elasticity at the underarm region and/or lower periphery region, thereby providing enhanced support in these regions. As mentioned above, these regions may alternatively or additionally be made with an increased thickness to enhance support.

The breast cup core according to the present invention may further comprise an underwire or underwire assembly which has an underwire encased within an underwire sock or an underwire channel. The underwire or underwire assembly may be at least partially surrounded by the breast cup core material. FIG. 10A and FIG. 10B show an exemplary arrangement in which an underwire or underwire assembly 21 is formed with a breast cup core 20.

FIGS. 5A-5C show exemplary molds according to the present invention for forming a breast cup core. The exemplary mold shown in FIGS. 5A-5C comprises a cavity in the shape of a breast cup core for receiving injection molded material to form a breast cup core. The mold 200 may be a two-part mold having a first half portion 210 and a second half portion 220. The first half portion 210 has a concave breast cup core region 212 and the second half portion 220 has a corresponding convex breast cup core region 222.

The mold may further comprise a plurality of protrusions which extend across the cavity of the mold to form through holes in a breast cup core formed in the mold. The protrusions may be provided on one of the first half portion and the second half portion, or on both. FIG. 5A shows an example in which each half portion 210, 220 have a plurality of protrusions 214, 224 for forming through holes in a predetermined pattern. The protrusions 214, 224 are arranged to form through holes in a floral pattern (for example, as shown in FIG. 7A). FIG. 5B shows another example of a mold 200′ half which has protrusions 214′ for forming through holes in a circular shape (for example, in a pattern as shown in FIG. 7C). FIG. 5C shows an arrangement in which a first half portion 210′ and a second half portion 220′ of the mold 200′ have been assembled together.

The plurality of through holes can be formed by other means, for example punching, by mechanical or laser means, a hole through a formed breast cup core which has been manufactured by injection molding or any other suitable process.

The mold may further comprise at least one more protrusion for holding an underwire or underwire assembly in a predetermined position within the cavity so that the underwire or underwire assembly is formed with the breast cup core material in the process of molding. Of course, the underwire and underwire assembly may be formed with the breast cup core in any other suitable way. For example, a detent may be formed on the inner surface of one or both of the mold portions for accommodating an underwire or underwire assembly.

The mold 200 may be formed of any material suitable for injection molding, such as steel or aluminum. The mold may also be designed to have varied gaps at predetermined areas in the cavity so that the resulting breast cup core has varied thickness at the predetermined areas according to needs.

By using a mold of the present invention to manufacture breast cup cores, all of the features of the breast cup core described above can be provided by designing the mold appropriately. This may ensure a consistent quality of manufacture with increased flexibility in the design of the breast cup core.

The present invention also provides a breast cup that comprises a breast cup core 100 having one or more of the features described above. The breast cup core may be sandwiched between an inner layer of material and an outer layer of material. The inner layer, being the closest to the wear's skin, may be a fabric layer and the outer layer may be formed of a fabric or lace material. The outer layer may be attached to the inner layer around the periphery of the breast cup, for example by sewing and/or hemming. Other suitable attachment means may also be used, such as by welding or heat pressing. FIG. 10B shows an example of such a layered arrangement. In an alternative arrangement, as shown in FIG. 11, the outer layer comprises an outer fabric layer 326 laminated with an outer foam layer 322 and an inner layer comprising an inner fabric layer 328 laminated with an inner foam layer 324. A breast cup core 320 is sandwiched between the inner layer and the outer layer. The inner and outer layers, and the breast cup core, can be attached to one another during a molding process. FIG. 10A also shows an example of this arrangement. For a thin cup, the foam layer preferably has a thickness of about 1 mm.

The breast cup may further comprise an underwire or an underwire assembly 18 comprising an underwire encased within an underwire sock or a channel. The underwire or underwire assembly 18 may be attached to the inner side of breast cup as shown in FIG. 4. Of course, the underwire or underwire assembly 18 may be attached to the breast cup in any other suitable manner. For example, the underwire or underwire assembly 18 (as shown in FIG. 10A and FIG. 10B) may be molded with the breast cup core in the process of injection molding as described above. Alternatively, the underwire or underwire assembly may be molded between inner and outer layers of a breast cup, along with the breast cup core. Alternatively, the underwire or underwire assembly may be attached to the outer side of the breast cup.

The breast cup core described above may form a part of a bra 1 as shown in FIG. 1 or a part of a shapewear 2 as shown in FIGS. 9, 10A and 10B. FIG. 10A shows a cross section of an exemplary arrangement of a shapewear comprising a core that includes a breast cup core 20, an outer layer comprising an outer fabric layer 26 laminated with an outer foam layer 22, and an inner layer comprising an inner fabric layer 28 laminated with an inner foam layer 24. The inner layer, the core, including breast cup core 20, and the outer layer may be molded together. FIG. 10B shows an alternative arrangement in which the foam layers are not included, that is, the shapewear 2 comprises a core comprising a breast cup core 20, an outer fabric layer 26 and an inner fabric layer 28. The inner layer 28 and outer layer 26 are preferably not attached completely to each other, for example, they may be attached only around the periphery of the shapewear 2.

The core, that includes a breast cup core 20, in the shapewear 2 as illustrated in FIGS. 10A and 10B is formed into one piece and extends over the breast and body portions of the shapewear. However, the core need not extend over the full extent of the shapewear and could alternatively be formed to only cover the breast cup area, as is used for bras. Similarly, although the core of the shapewear 2 and the shapewear itself are shown in one piece, this is not necessary and they may be formed of multiple pieces, for example the shapewear may comprise two separate breast cup cores that are incorporated into the shapewear.

FIGS. 10A and 10B has an underwire or underwire assembly 21 molded with the breast cup core 20. As shown in FIG. 10B, the underwire or underwire assembly 21 may be molded between the outer fabric layer 26 and the inner fabric layer 28 during the formation of the shapewear. The underwire or underwire assembly 21 may be attached to the shapewear in other suitable manners, for example, attached to the inner side of the inner fabric layer 28 or to the outer side of the outer fabric layer 26, or, in the case of a shapewear comprising foam layers, as shown in FIG. 10A, molded between inner and outer foam layers 24, 22, during the formation of the shapewear.

The present invention also provides a method of manufacturing a breast cup core by injection molding a breast cup core formed of a material suitable for injection molding. The breast cup core may be provided with one or more of the features described above. The method may use a mold as described above.

The present invention also provides a method of manufacturing a breast cup comprising the steps of injection molding a breast cup core; sandwiching the breast cup core according to the present invention between an outer layer of material and an inner layer of material; and joining the outer layer and the inner layer. According to a first aspect of the invention, the breast cup core is injection molded; According to a second aspect of the invention, the breast cup core has a plurality of through holes, where the breast cup core is formed from injection molding or any other suitable process. The outer layer and the inner layer may be joined by any suitable manner, including sewing and hemming. The breast cup core and breast cup may be provided with one or more of the features described above.

According to a preferred embodiment of the invention, the method of manufacturing a breast cup comprises the steps of molding a first layer of material comprising a fabric layer laminated with a foam layer to form a breast cup shaped region; placing a breast cup core according to the present invention onto the molded first layer of material; placing a second layer of material comprising a fabric layer laminated with a foam layer onto the breast cup core; and joining the first layer, the breast cup core and the second layer by molding. The breast cup core may be provided with one or more of the features described above. The method may further comprise trimming the molded layers of material to a breast cup shape.

The present invention also provides a method of manufacturing a brassiere comprising the steps of molding a first layer of material comprising a fabric layer laminated with a foam layer to have a first breast cup shaped region and a second breast cup region; placing a breast cup core according to the present invention onto each of the breast cup shaped regions of the molded first layer of material; placing a second layer of material comprising a fabric layer laminated with a foam layer onto the cup cores; and joining the first layer, the breast cup core and the second layer by molding. The breast cup core may be provided with one or more of the features described above. The two breast cup cores may be formed, and placed onto the breast cup regions, as an integral unit.

For shapewear, the same method can be used to form an integrated bra or an integrated bra and body, where the integrated shapewear is formed from molding the inner layer, the core and the outer layer, where the core comprises two separate breast cup cores that are placed on the inner layer; a number of core portions, comprising breast cup cores; a unitary core comprising two breast cup cores; or a unitary section comprising two breast cup cores and a body area.

Additionally, the method may further comprise providing an underwire or underwire assembly to the breast cup in any suitable manner, for example, molded with the breast cup core or attached to the inner or outer side of the breast cup.

By injection molding a breast cup core, the breast cup core can be a thin and elastic structure. The relatively strong tensile strength of the breast cup core material helps maintain the shape of the breast cup core and provide desired support. FIG. 8 shows a comparative view of a bra (lower figure) with breast cups having a breast cup core according to the present invention relative to a conventional bra (upper figure) having thin breast cups. It can be seen that the breast cup core according to the present invention maintains a desired cup shape whilst the conventional breast cup does not have the same desired cup shape and support.

In addition, injection molding allows various desirable features of the breast cup core to be provided simply by designing the mold accordingly. This increases the flexibility of breast cup core design.

While several illustrative embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Also, numerous features in different embodiments may be selectively combined to provide a desired effect. Such variations and alternate embodiments are contemplated, and can be made without departing from the scope of the invention as defined in the appended claims.

Claims

1. A breast cup comprising an inner layer of material, an outer layer of material, and an injection molded breast cup core sandwiched between the inner layer and the outer layer.

2. A breast cup of claim 1, wherein the breast cup core is formed from a thermoplastic rubber material.

3. A breast cup of claim 1, wherein the breast cup core has a plurality of through holes.

4. A breast cup of claim 1, wherein the through hole density varies across the breast cup core.

5. A breast cup of claim 1, wherein the breast cup core has regions of varied thickness.

6. A breast cup of claim 1, wherein the breast cup core extends across substantially the whole of the breast cup.

7. A breast cup of claim 1, further comprising an underwire molded with the breast cup core.

8. A breast cup of claim 1, wherein a substantial portion of the breast cup core comprises a thickness of 1 mm.

9. A breast cup of claim 1, further comprising an underwire wherein the underwire is attached to an inner side of the inner layer of material.

10. A breast cup of claim 1, wherein the inner layer of material and the outer layer of material each comprises a fabric layer laminated with a foam layer.

11. A breast cup of claim 1, wherein the inner layer of material, the breast cup core, and the outer layer of material are molded together.

12. A method of manufacturing a breast cup comprising:

injection molding a breast cup core for a breast cup;

sandwiching the breast cup core between an outer layer of material and an inner layer of material; and

joining the outer layer of material and the inner layer of material.

13. A method of claim 12, further comprising providing an underwire.

14. A method of claim 13, wherein the underwire is molded with the breast cup core in the process of injecting molding.

15. A method of claim 13, wherein the underwire is attached to an inner side of the inner layer of material.

16. A method of claim 12, wherein the inner and outer layers are each formed from a fabric layer laminated with a foam layer.

17. A method of claim 12, further comprising joining the inner layer of material, the breast cup core, and the outer layer of material by molding.

18. A method of manufacturing a breast cup comprising:

molding a first layer of material comprising a fabric layer laminated with a foam layer to form a breast cup shaped region;

placing an injection molded breast cup core onto the molded first layer of material;

placing a second layer of material comprising a fabric layer laminated with a foam layer onto the breast cup core; and

joining the first layer, the breast cup core and the second layer by molding.

19. A method of claim 18, further comprising providing an underwire.

20. A method of claim 19, wherein the underwire is molded with the injection molded breast cup core.