UPLIFT BRASSIERE

Abstract

A molded brassiere comprising or including, a breast cup region defined at least by (i) an interior panel that includes a foam ply (herein after “interior foam ply”) and (ii) an exterior panel that includes a foam ply (herein after “exterior foam ply”), said interior and exterior panels being laminated with each other defining a breast cup region that includes two breast cups and an intermediate bridge region extending there between, wherein the interior and exterior panels are laminated with each other save at least at a region where, for each breast cup, a pocket is defined between the interior and exterior panels, the pocket being located extending from the lower perimeter region of the breast cup towards the neckline of the breast cup, the interior panel at said pocket having lower curvature than said exterior panel so that said pocket provides an air gap between said interior and exterior panels.

Description

REFERENCE TO RELATED APPLICATIONS

The present application claims benefit of U.S. Provisional Patent Application No. 60/890,097, filed on Feb. 15, 2007, the disclosure of which has been incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to an uplift brassiere.

BACKGROUND OF THE INVENTION

Uplift brassieres are known. Such are also known as cleavage brassieres. Common uplift brassieres (hereinafter “bras”) may incorporate appropriately placed padding to displace breast tissue near the bottom of a breast to thereby displace the breast tissue upwards and thereby enhance cleavage or uplift. Pads may come in the form of a pouch of a gel or liquid captured between layers of the bra at the breast cups.

Pads are effective in creating an uplift of the breasts. However the incorporation of pads between layers of the bra can be time consuming and expensive. Two pads are required to be manufactured, one for each breast cup. These are then required to be handled and positioned in an appropriate location during the manufacturing process to be captured between layers of the bra. This added material cost and handling can increase the cost of goods manufactured.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide an uplift brassiere that does not require the incorporation of a separate pad and/or that will at least provide the public with a useful choice.

Accordingly in a first aspect the present invention consists in a molded brassiere comprising or including,

a breast cup region defined at least by (i) an interior panel that includes a foam ply (herein after “interior foam ply”) and (ii) an exterior panel that includes a foam ply (herein after “exterior foam ply”), said interior and exterior panels being laminated with each other defining a breast cup region that includes two breast cups and an intermediate bridge region extending there between, wherein the interior and exterior panels are laminated with each other save at least at a region where, for each breast cup, a pocket is defined between the interior and exterior panels, the pocket being located extending from the lower perimeter region of the breast cup towards the neckline of the breast cup, the interior panel thereby offering the capacity to bulge towards the body of the wearer to thereby encourage, in use, a general uplift of the breast.

Preferably the exterior panel includes a zone of higher density foam defined by said exterior foam ply, said zone being present adjacent said pocket.

Preferably the exterior panel includes a zone of higher density foam defined by said exterior foam ply, said zone being present adjacent said pocket and extending at least at its upper perimeter, beyond the upper perimeter of the pocket.

Preferably the interior panel includes a zone of higher density foam defined by said interior foam ply, said zone being present adjacent said pocket.

Preferably the interior panel includes a zone of higher density foam defined by said interior foam ply, said zone being present adjacent said pocket and extending at least at its upper perimeter contiguous the upper perimeter of the pocket.

Preferably a layer of flexible material having non-stretch properties is provided intermediate of and laminated with the said interior and exterior panels 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.

Preferably the exterior panel includes the exterior foam ply and a fabric ply laminated to each other, the exterior foam ply positioned interior more the fabric ply.

Preferably the exterior foam ply and the interior foam ply are laminated with each other save at least at the pocket region.

Preferably the exterior foam ply and the interior foam ply are laminated to each other save at least at the pocket region.

Preferably the interior panel includes the interior foam ply and a fabric ply laminated to each other, the interior foam ply positioned exterior more the fabric ply.

Preferably an exterior more ply of fabric material may be positioned to the exterior side of the exterior panel.

Preferably an interior more ply of fabric material may be positioned to the interior side of the interior panel.

Preferably at least one of the exterior and interior more plies of fabric material layer are laminated with said interior and exterior panels and extend beyond the perimeter of interior and exterior panels to provide at least in part, at least that part of the brassiere defining chest strap(s).

Preferably said interior and exterior foam plies laminated directly to each other save for at said pocket and at said flexible material having non-stretch properties.

Preferably said flexible material having non stretch properties is provided extending at said bridge region only.

Preferably said flexible material having non stretch properties is captured intermediate of said interior and exterior foam plies.

Preferably said flexible material having non stretch properties is a woven fabric material.

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 to resist a pulling apart of the breast cups.

Preferably said interior and exterior panels are coextensive with each other.

Preferably the foam and fabric plies of each of the interior and exterior panels are coextensive each other.

Preferably said breast cup region is of a shape defining only the breast cups and said bridge but not said chest strap(s).

Preferably said chest straps extend outwardly from each side of said breast cup region.

Preferably said interior and exterior plies of foam are co extensive each other.

Preferably two underwire structures are provided intermediate of said interior and exterior panels, one each adjacent a respective breast cup.

Preferably said underwire structure comprises a rigid elongate member and a flexible material casing about at least part of said rigid elongate member.

Preferably said casing is a fabric material.

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.

Preferably said casing is a tubular sock within which said rigid elongate member is located, the sock having closed distal ends.

Preferably, in use, said interior panel at said pocket, presses more against said breasts than said exterior panel.

In a second aspect the present invention consists in a method of manufacturing a molded component assembly for a brassiere comprising:

placing an exterior panel that includes a foam ply that includes, at each region of the exterior panel at where a breast cup is to be mold formed into said exterior panel, a zone of increased thickness that is located extending from the to be defined lower regions of the breast towards the neckline of the breast cup, into a molding device and mold forming the breast cup(s) shape into the exterior panel and to homogenise the thickness of the foam ply at least at the breast cup(s) so that the zone is of a higher density foam than the foam surrounding the zone,

placing an interior panel that includes a foam ply that includes, at each region of the interior panel at where a breast cup is to be mold formed into said interior panel, a zone of increased thickness that is located extending from the to be defined lower regions of the breast towards the neckline of the breast cup, into a molding device and mold forming the breast cup(s) shape into the interior panel and to homogenise the thickness of the foam ply at least at the breast cup(s) so that the zone is of a higher density foam than the foam surrounding the zone,

laminating the interior and exterior panels with each other in a manner so that their cups(s) agree and in a manner wherein no lamination occurs of the panels at where the zone of higher density foam of the interior panel is located so as to define a pocket at this zone between the interior and exterior panels.

Preferably at least one of the interior and exterior panels are of a size to allow two breast cups and a bridge extending between the breast cups to be molded into panel(s).

Preferably the method includes the subsequent steps of trimming said molded and laminated interior and exterior panels to define a molded assembly which includes two cups forms and a bridge region extending there between.

Preferably one of the exterior panel and interior panel also includes an underwire structure placed, prior to lamination of the interior and exterior panels, so as to be captured between the panels.

Preferably one of the exterior panels and interior panel includes a layer of flexible material having non stretch properties placed, prior to lamination of the interior and exterior panels, so as to become captured between the panels.

Preferably prior to molding of said panels, an underwire structure is provided intermediate of said first and second layer.

In a further aspect the present invention consists in a method of manufacturing a molded component assembly for a brassiere comprising:

laminating (i) an exterior panel that includes a foam ply that includes, at each region of the exterior panel at where a breast cup is mold formed into said exterior panel, a zone of increased foam density that is located extending from the lower regions of the breast towards the neckline of the breast cup with (ii) an interior panel that includes a foam ply that includes, at each region of the interior panel at where a breast cup is mold formed into said interior panel, a zone of increased foam density that is located extending from the lower regions of the breast towards the neckline of the breast cup,

in a manner so that their cups(s) agree and in a manner wherein no lamination occurs of the panels at where the zone of higher density foam of the interior panel is located so as to define a pocket at this zone between the interior and exterior panels.

Preferably the zone of the interior panel has an upper perimeter that is lower than the perimeter of the zone of the exterior panel.

In a further aspect the present invention consists in a molded brassiere comprising or including,

a breast cup region defined at least by (i) an interior panel that includes a foam ply (herein after “interior foam ply”) and (ii) an exterior panel that includes a foam ply (herein after “exterior foam ply”), said interior and exterior panels being laminated with each other defining a breast cup region that includes two breast cups and an intermediate bridge region extending there between, wherein the interior and exterior panels are laminated with each other save at least at a region where, for each breast cup, a pocket is defined between the interior and exterior panels, the pocket being located extending from the lower perimeter region of the breast cup towards the neckline of the breast cup, the interior panel at said pocket having lower curvature than said exterior panel so that said pocket provides an air gap between said interior and exterior panels.

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.

Where reference herein is made to interior and exterior or similar terminology in relation to component parts or items of the bra or part of the bra, it is meant to be understood to be in relation to the body of the wearer of the bra. For example the “interior” or “inner side” or “inner region” is a relative term to denote that an item is more proximate the face side of the bra that is more proximate to the body of the wearer than items of the bra that are more distal the body of the wearer. “Inner” does not mean “inner most” unless specified. This similarly applies to terms such as “outer” or “exterior”.

By seamless is meant the bra is visibly substantially seamless, in that the edges of the bra are finished in a seamless way, for example by ultrasonic welding, or by folding the edge of an outer layer over and affixing it to an inner layer by a non-stitching means, or by some other means that is substantially without seams. Seams may however be found inside the bra structure where it is not externally visible, or in visibly less conspicuous externally at places such as the region where the shoulder strap is attached to a bra cup region, or the region where hook or eye tape is connected to the chest bands.

As used herein the term “and/or” means “and” or “or”, or both.

As used herein “(s)” following a noun means the plural and/or singular forms of the noun.

The term “comprising” as used in this specification means “consisting at least in part of”. When interpreting statements in this specification which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as “comprise” and “comprised” are to be interpreted in the same manner.

BRIEF DESCRIPTION OF DRAWINGS

A preferred form of the present invention will now be described with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of a pre-molding stage interior panel assembly,

FIG. 2 is a perspective view of a pre-molding stage exterior panel assembly,

FIG. 3 is a plan view of the exterior panel assembly showing variation in thickness of the foam ply,

FIG. 4 is a sectional view through section AA of FIG. 3,

FIG. 5 is a plan view of the interior panel assembly to illustrate variation in thickness,

FIG. 6 is a sectional view through section BB of FIG. 5,

FIG. 7 is a sectional view through a molding device illustrating the positioning of the exterior panel assembly prior to mold forming of the exterior panel assembly,

FIG. 8 is a plan view of the molded exterior panel assembly including the positioning of an optional underwire assembly at each breast cup,

FIG. 9 is a close up view of the bridge region of the panel assembly of FIG. 8 illustrating the positioning of a bridge panel,

FIG. 10 is a plan view of the exterior panel illustrating the positioning of additional panel or panels of material,

FIG. 11 is a plan view of part of the exterior panel assembly illustrating the positioning of further optional panels of material,

FIG. 11a is a sectional view through the assembled panel assembly illustrating the approximate position of the underwire assembly,

FIG. 12 is a sectional view through section CC illustrating an example of approximate positioning of panels and components at section CC,

FIG. 13 is a sectional view through a molding device illustrating the positioning of the internal panel assembly prior to mold forming,

FIG. 14 is a plan view of the molded external panel assembly illustrating the zone of higher density foam previously having been the zone of increased thickness of the pre-molded precursor interior panel assembly,

FIG. 15 is a sectional view through a molding and/or laminating device including the illustration of the positioning of the interior and exterior molded panels prior to their bonding, preferably by lamination, together,

FIG. 16 is a front view of components defining at least part of the breast cup region for incorporation with other bra components, illustrating the pocket that may be formed between the internal and external panel assemblies,

FIG. 17 is a sectional view through section EE of FIG. 16,

FIG. 18 is a sectional view through section FF of FIG. 16,

FIG. 19 illustrates a variation to the formation of the present invention wherein each breast cup may be separately defined and incorporate the features and optional features herein described wherein each component can then be fastened together at the bridge region,

FIG. 20 illustrates the incorporation of the components defining the breast cup or breast cup region and other components capable of being engaged or fastened therewith to define a bra, and

FIG. 21 is a plan view of a bra of the present invention.

With reference to FIG. 21 there is shown a bra 100 that may generally be defined by a breast cup region 102, chest bands 103 and 104 and shoulder straps 105 and 106. The shoulder straps 106 and 105 may extend between the breast cup region 102 and each of the chest bands 103 and 104 respectively.

Such over the shoulder straps may however be optional as it is envisaged that the bra may also be of a strapless version. Indeed whilst reference is herein made to a bra, it is envisaged that the assembly of panels component parts and items to define such, may alternatively be incorporated into other garments such as, for example, evening dresses or bathing suits or similar.

At the ends of each of the chest bands may be fasteners 107 and 108 that are mutually cooperative to allow for the bra to be fastened about the chest of a wearer.

The bra may be seamless and made from materials at least some of which are molded or moldable and that are engaged to each other preferably at least in part by lamination.

As can be seen with reference to FIG. 20 the components defining the breast cup region 102 may be fastened to the components defining the chest band 103 and the shoulder strap 106. Such fastening may occur by adhesive and/or ultrasonic welding or other forms of welding and/or by stitching. Stitching is not the preferred form of joining. In the most preferred form the bra of the present invention is a seamless bra that incorporates little or no stitching at all and preferably no visible stitching.

The breast cup region 102 preferably defines two breast cups 109 and 110 that are adjacent to each other and between which may extend an intermediate bridge region 111. At least some of the material components defining the breast cups 109 and 110 are continuous over the entire breast cup region 102, including across the bridge region 111. Alternatively some or all of the material components may only be present at least part of the breast cups 109 and 110.

In the preferred form, at least one of the material components of the breast cup region 102 is continuous over the breast cup region 102 and preferably also over the bridge region. However in alternative forms each of the breast cups 109 and 110 may be separately predefined as for example shown in FIG. 19 and may be affixed together at the bridging region 111 to define, once assembled, the breast cup region 102.

Additional components, layers or plies of material may be provided with the materials defining the breast cup region to those herein defined.

Variations to the bra shown in FIG. 21 may include where the chest bands 104 and 103 are unitary and may extend along the lower perimeter of the breast cup region 102. The bra may be a front opening bra where mutually cooperative fasteners are positioned at the bridge region 111 to allow the bra to be opened and fastened at that region.

The bra 100 preferably includes at least the lower regions of each of the breast cups 109 and 110, a zone 112 defined by materials component structure and/or materials characteristics that will facilitate, when the bra is being worn, in a displacement of breast tissue at least such lower regions to encourage uplift of the breast that may thereby enhance breast uplift and/or cleavage appearance. Each zone 112 is shown in phantom in FIG. 21 at each breast cup 109 and 110. Each zone 112 includes a pocket 33 formed between layers of the material components defining the breast cups 109 and 110. The zone 112 is generally provided at the lower regions of each of the breast cups 109, 110 to facilitate displacement of breast tissue from this region of the bra.

The pocket or pockets 33 may be defined in the bra as a result of the construction of the bra. The pocket or pockets, with an air gap across, at the zones 112 may be created only once the bra is being worn by the user, again as a result of the construction of the bra.

The steps in the manufacture of the bra or in manufacture of components for a bra which allow for such a pocket to be defined, will now be described by way of example.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

With reference to FIG. 1, there is shown a precursor interior panel assembly 1. The precursor exterior panel assembly 1 preferably consists of a foam ply 2 and a fabric ply 3. The interior panel assembly 1 preferably consists of at least the two plies 2 and 3 and may consist of additional plies such as further fabric ply or plies and/or foam ply or plies. Preferably the fabric ply 3 is laminated to the foam ply 2 in a coextensive manner.

In FIG. 2 there is shown an exterior panel assembly 4. The exterior panel assembly 4 preferably consists of coextensive plies 5 and 6. Ply 5 is preferably a foam ply and ply 6 is preferably a fabric ply. Similarly to the interior panel assembly 1, the exterior panel assembly 4 may include further plies of material. Such plies may or may not be coextensive with the plies 5 and/or 6.

The interior panel assembly 1 and exterior panel assembly 2 are to be laminated with each other such that the foam plies 2 and 5 are proximate most each other and the fabric plies 3 and 6 face away from each other.

The precursor interior panel assembly 1 is preferably of a constant thickness. The precursor exterior panel assembly 4 is preferably of a constant thickness. However prior to their lamination together one or both of the panel assemblies 1, 4 is preferably modified. Such modification is to introduce a variation in thickness in the panel assembly 1 and/or 4 at appropriate regions that, with subsequent processing, will lead to a variation in density.

With reference to FIG. 3, the exterior panel assembly 4 is shown with its foam ply 5 face up. Shown in phantom is an outline of a breast cup region to be formed. The panel assembly 4 has been modified by shaving or skiving or similar known foam thickness reducing techniques in order to introduce zones 8 at the breast cup region 7 of the foam ply 5. Two discrete zones 8 are shown although at this stage these may instead be joined across the bridge region.

The zone 8 at each breast cup region 109 and 110 is preferably of a plateau shape. The plateau region 8 is of a greater thickness than the surrounding panel region or regions. With reference to FIG. 4 it can be seen that the zone 8 is a plateau like shaped zone or at least a zone having increased thickness to the remainder of the foam ply 5 of the external panel assembly 4.

The region of increased thickness may include a gradual transition between the thinner regions of the foam ply 5 and the zone of increased thickness 8 at least about some perimeter regions of the plateau. As can be seen with reference to FIG. 4 the preferred plateau shaped zone 8 includes transition between it and the thinner regions of the foam ply 5. Formation of the zone 8 preferably occurs by a shaving or skiving of foam removing the portions shown in phantom in FIG. 4. Alternatively the thickness variation may be achieved by lamination of a foam plateau panel onto the foam ply 5 to build up the effective thickness of the foam.

In addition or alternatively, the interior panel assembly 1 may be modified in a similar manner to introduce zones 11. The zones 11 where both the exterior and interior panel assemblies are modified to introduce the zones 8/11, are preferably of a shape and size that is scaled down from the plan shape of the zones 8 of the exterior panel assembly 4. Such scaling is preferably in both axes of the Cartesian plane and is preferably done so that the zones 11 do not extend beyond the boundary of the zones 8 once the external and internal panel assemblies are laminated with each other.

FIG. 6 is a cross-section through section BB of FIG. 5 showing the zone or zones of increased thickness at section BB.

The exterior panel assembly 4 with its modified thickness may be introduced into a molding device consisting of upper and lower mold portions 14/15 for the introduction of the breast cups shape. The exterior panel assembly 4 is positioned in the molding device such that the foam ply 5 will be positioned on the concave side of the molded panel assembly and the fabric ply 6 is on the convex side.

A molded exterior panel assembly 4 is shown in FIG. 8 wherein the panel assembly 4 has the breast cups of the breast cup region formed therein. As a result of molding of the shaved exterior panel, (a) breast cups are formed at the breast cup region, and (b) the thickness of the foam layer 5 should be approximately constant since the molding will even the thickness or at least cause any difference in the thickness to not be readily noticeable. A change in foam density will result with a higher density being defined at the zones 8.

After the forming of the three dimensional breast cups, underwire assemblies may be placed on the foam ply 5 at or immediately adjacent the lower regions of the breast cups. The underwire assembly may consist of a plastic strip and/or a metal wire that may or may not be encased within a sock such as a fabric sock. Preferably two underwires 16 are provided, one for each breast cup.

The placement and securing of the underwire 16 and other components may occur before the breast cup region 102 is trimmed from the remaining peripheral portions of the exterior panel 4 or after.

With reference to FIG. 9, a flexible but preferably non-stretch bridge panel 17 is placed to extend across the bridge 111 and at least partially onto each of the breast cups 109 and 110 of the exterior panel assembly 4. The underwire 16 may extend between the foam ply 5 and the bridge panel 17 as shown on the left hand side, or may sit on top of the bridge panel 17 such that the bridge panel 17 is between the underwire 16 and the foam ply 5.

The underwire or underwire structure 16 is preferably held in place with the panel 4 by the use of an adhesive. Such an adhesive may be provided to at least tack the underwire in place.

With reference to FIG. 10 there is shown a further assembled layer of material provided to cover the underwire structure 16 and preferably at least in part also the flexible but non-stretch material bridge panel 17. This additional material is optional. It is preferably is of a gauze material. The gauze 19 is preferably of a W shape extending over the underwires and across the bridge 111. Alternatively the gauze may terminate at the boundaries of the bridge panel 17 and may not necessarily extend across the bridge 111.

The gauze may also be applied by the use of an adhesive such as an adhesive spray or adhesive tacking, to locate the gauze in position relative to the external panel 4.

With reference to FIG. 11, a panel 20 may also be placed over the underwire structure 16. The panel 20 is preferably a foam panel that extends beyond the boundary of the underwire structure. Preferably the foam panel is of a smaller shape and size than the gauze panel 19.

In other embodiments of this invention, the components 16, 17, 19 and 20 may be placed in different order than those described herein with reference to the drawings.

With reference to FIG. 12 showing in cross-section the structure through section CC of FIG. 11, it can be seen that the underwire structure 16 is captured between gauze layers 19, foam layer 20, and the exterior panel assembly 2 including at the bridge region, the bridge panel 17.

Alternatively, the same set of materials 16, 17, 19 and 20 can be glued onto the foam layer 2 of the interior panel assembly 1 before lamination with the exterior panel 4.

FIG. 13 shows the interior panel assembly 1 located intermediate of a molding device consisting of upper and lower molds 28/27 prior to mold closure and forming of three dimensional breast cups to define a modified panel 1 as shown in FIG. 14. Similarly, as a result of molding of the interior panel, (a) breast cups are formed at the breast cup region, and (b) the thickness of the foam layer 2 should be approximately constant since the molding will even the thickness or at least cause any difference in the thickness to not be readily noticeable. This will result in an interior molded panel of varying density, with a higher density defined at zones 11.

Modified panels 1 and 4 are then able to be laminated together in an overlying manner as for example shown in cross-sectional side view in FIG. 15. Panel assembly 4, preferably carrying (if such optional components are provided) the foam panel 20, bridge panel 17, underwire structures 16 and gauze panel 19, can be laminated together with the exterior panel 1 such that the breast cup regions of the panel are aligned with each other. Lamination of the panels 1 and 4 may occur by adhesion, heat and/or adhesion bonding and may require the application of pressure such as by way of pressures plate that may for example be between mold portions 127 and 128 as shown.

There are hence preferably two molding actions (as described with reference to FIGS. 7 and 13) and one laminating action (as described with reference to FIG. 15).

Lamination of the panels 1 and 4 in their condition described with reference to FIG. 15 is preferably over the entire surfaces of the respective breast cups of the panels save for at the regions where the pocket is to be created. With reference to FIGS. 16, 17 and 18 it can be seen that lamination has not occurred at the regions 8 and 11 of the interior and exterior panels 1 and 4. This results in a pocket 33 being defined between the panel 1 and 4 at and immediately adjacent and above each underwire structure 16. The underwire structure 16 is preferably positioned immediately below the perimeter of the denser foam area at the exterior panel (i.e. the original plateau area 8 at the foam layer of the pre-molded exterior panel 4).

Save for the upper perimeter of the original plateau area(s) 8 of the exterior panel 4, the perimeter of the original plateau area at the exterior panel 4 may be laminated at the perimeter of the original plateau area 11 at the interior panel 1. Since the original plateau area(s) 8 at the exterior panel 4 covers preferably more than half of the original plateau area 11 of the interior panel 1, the upper perimeter of the original plateau area 11 at the interior panel 1 is laminated with the original plateau area 8 of the exterior panel 4 (at around the middle part of the original plateau area of the exterior layer).

Each of the two molding actions (i.e. the molding action in FIG. 7 and the molding action in FIG. 13) causes a predetermined shape to be formed at each bra cup region of the corresponding panel. The subsequent laminating action (i.e. the laminating action in FIG. 15) simply laminates the two panels together (except at the pocket 33 of each bra cup region) and does not change the predetermined shape already formed during the corresponding molding action.

Preferably the predetermined shape formed at each breast cup region of the exterior panel by the molding of the shaved exterior panel in FIG. 7 is the shape of a complete breast cup. Preferably the predetermined shape formed at each breast cup region of the interior panel by the molding of the shaved interior panel in FIG. 13 consists of the shape of a partial breast cup (at the area not covering the pocket 33) and the shape of the pocket 33 (at the area covering the pocket 33).

Since the predetermined shape at each breast cup region of the molded exterior panel and the predetermined shape at each breast cup region of the molded interior panel preferably does not change during the laminating action in FIG. 15, the shape of the corresponding breast cup region of each panel will be contiguous to each other except at the area covering the pocket 33.

Thus the shape of the pocket 33 is formed by the molding action in FIG. 13, rather than by the laminating action in FIG. 15.

The plateau 8 of the foam ply 5 of the pre-molded exterior panel 4 has the main function of keeping the breast cup region 102 in its intended shape particularly from an external view point. Since the density of the foam at where the plateau 8 was defined and after being molded, will be higher the foam thereat will be harder than the foam at the remaining part of the breast cup region 102. As such, when the bra is being worn, any change of shape of the breast cup region 102 will be resisted. This means that the outward aesthetic appearance can to a large extend be maintained.

The higher density foam sections of the exterior panel and the inner panel are stiffer than the lower density sections of the same panels. The stiffness tends to attribute to the maintenance of the pocket shape as much as possible when the bra is worn. The higher density foam sections at both the exterior panel and the inner panel (rather than just at one of the panels only) are desired primarily for providing a shape-keeping effect to the pocket. Therefore, it is not expected that an exterior most ply can provide a better shape-keeping effect to the pocket 33, although such exterior most ply may obscure any visually undesired deformation of the exterior and/or interior panels.

A change of shape of the breast cup region 102 may be caused by different forces applied on the bra when the bra is being worn.

Further, after lamination of the exterior panel 4 and the interior panel 1 together (FIG. 15), the upper perimeter of the pocket 33 is defined by a joining of the interior panel foam ply 2 with the exterior panel foam ply 5. As the original plateau of the foam ply 2 is smaller, the upper perimeter can be created at where a lower density part of the foam ply 1 joins the higher density part of the foam ply 5. A shape a shown in FIG. 17 may be created. A shelf like configuration for the breast may be defined. The interior panel 1 may apply a pulling down force on the exterior panel 4 when the interior panel at the pocket region 33 is supporting the breast of the wearer.

As the denser foam area at the exterior panel 4 is relatively hard it may provide a shape-keeping function for the brassiere.

The foam close to the neckline of the exterior panel may be of a lower density because there is not much force being applied thereon when the bra is being worn.

When the bra is worn, the breast cup region at the pocket 33 is pressed by the breast, thereby creating a force pushing both ends of the underwire (which was in its natural shape before the bra is worn) towards each other and also creating a force pulling the back straps towards this region. However, since the underwire and any other elastic components of the bra surrounding the chest and back of the wearer tend to return to their natural shapes, the shape of the pocket can be maintained as much as possible and thereby providing good support of the breast.

The denser foam area at the interior panel 1 (i.e. the original plateau area 11 at the foam layer of the pre-molded interior panel 1) may keep the pocket 33 in shape as much as possible since its higher density regions make the foam harder. There is no need to have the denser foam area of the interior panel bigger than the denser foam area of the exterior panel because any change of shape of the breast cup region at the interior panel when the bra is being worn should not be visible.

Because of (a) the stretching of the non-laminated area of each bra cup region of the interior layer towards the laminated area of the bra cup region of the core assembly and (b) the stretching of the said non-laminated area generally between two ends of the underwire structure resulting from the stiffness of the underwire structure, the non-laminated area of each bra cup region of the interior layer bulges towards the skin of the wearer, creating a hollow uplifting bra pad.

Given that the pocket does not include a pouch or pad, it will be lighter than a bra that does.

The fabric material used may be of a material known by model number CMF-7440MU of Friendly Foundate Ltd. This fabric is made of 80% Tactel and 20% lycra. 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/m2.

The foam used is preferably a polyurethane foam of a precursor density of, for example, 30-40d.

Adhesive used may be of a kind such as RM-30 of Ultra Energy Adhesive Trading Co., Ltd.

The bridge fabric may be 7118 of Goldspring Co. Ltd. It is preferably a piece of gauze which is 100% nylon.

One or all the molding processes occur preferably at an upper mold temperature of 180° C. to 200° C. and the lower mold is preferably of 180° C. to 200° C. The dwell time holding the mold portions together is for example 120 seconds.

Claims

1. A molded brassiere comprising or including,

a breast cup region defined at least by (i) an interior panel that includes a foam ply (herein after “interior foam ply”) and (ii) an exterior panel that includes a foam ply (herein after “exterior foam ply”), said interior and exterior panels being laminated with each other defining a breast cup region that includes two breast cups and an intermediate bridge region extending there between, wherein the interior and exterior panels are laminated with each other save at least at a region where, for each breast cup, a pocket is defined between the interior and exterior panels, the pocket being located extending from the lower perimeter region of the breast cup towards the neckline of the breast cup, the interior panel thereby offering the capacity to bulge towards the body of the wearer to thereby encourage, in use, a general uplift of the breast.

2. A molded brassiere as claimed in claim 1 wherein the exterior panel includes a zone of higher density foam defined by said exterior foam ply, said zone being present adjacent said pocket.

3. A molded brassiere as claimed in claim 1 wherein the exterior panel includes a zone of higher density foam defined by said exterior foam ply, said zone being present adjacent said pocket and extending at least at its upper perimeter, beyond the upper perimeter of the pocket.

4. A molded brassiere as claimed in claim 1 wherein the interior panel includes a zone of higher density foam defined by said interior foam ply, said zone being present adjacent said pocket.

5. A molded brassiere as claimed in claim 1 wherein the interior panel includes a zone of higher density foam defined by said interior foam ply, said zone being present adjacent said pocket and extending at least at its upper perimeter contiguous the upper perimeter of the pocket.

6. A molded brassiere as claimed in claim 1 wherein a layer of flexible material having non-stretch properties is provided intermediate of and laminated with the said interior and exterior panels 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.

7. A molded brassiere as claimed in claim 1 wherein the exterior panel includes the exterior foam ply and a fabric ply laminated to each other, the exterior foam ply positioned interior more the fabric ply.

8. A molded brassiere as claimed in claim 1 wherein the exterior foam ply and the interior foam ply are laminated with each other save at least at the pocket region.

9. A molded brassiere as claimed in claim 1 wherein the exterior foam ply and the interior foam ply are laminated to each other save at least at the pocket region.

10. A molded brassiere as claimed in claim 1 wherein the interior panel includes the interior foam ply and a fabric ply laminated to each other, the interior foam ply positioned exterior more the fabric ply.

11. A molded brassiere as claimed in claim 1 wherein an exterior more ply of fabric material may be positioned to the exterior side of the exterior panel.

12. A molded brassiere as claimed in claim 1 wherein an interior more ply of fabric material may be positioned to the interior side of the interior panel.

13. A molded brassiere as claimed in claim 1 wherein an exterior more ply of fabric material may be positioned to the exterior side of the exterior panel, and wherein an interior more ply of fabric material may be positioned to the interior side of the interior panel, and wherein at least one of the exterior and interior more plies of fabric material layer are laminated with said interior and exterior panels and extend beyond the perimeter of interior and exterior panels to provide at least in part, at least that part of the brassiere defining chest strap(s).

14. A molded brassiere as claimed in claim 6 wherein said interior and exterior foam plies are laminated directly to each other save for at said pocket and at said flexible material having non-stretch properties.

15. A molded brassiere as claimed in claim 6 wherein said flexible material having non stretch properties is provided extending at said bridge region only.

16. A molded brassiere as claimed in claim 6 wherein said flexible material having non stretch properties is captured intermediate of said interior and exterior foam plies.

17. A molded brassiere as claimed in claim 6 wherein said flexible material having non stretch properties is a woven fabric material.

18. A molded brassiere as claimed in claim 6 wherein 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 to resist a pulling apart of the breast cups.

19. A molded brassiere as claimed in claim 1 wherein said interior and exterior panels are coextensive with each other.

20. A molded brassiere as claimed in claim 1 wherein the exterior panel includes the exterior foam ply and a fabric ply laminated to each other, the exterior foam ply positioned interior more the fabric ply, and wherein the interior panel includes the interior foam ply and a fabric ply laminated to each other, the interior foam ply positioned exterior mote the fabric ply, and wherein the foam and fabric plies of each of the interior and exterior panels are coextensive each other.

21. A molded brassiere as claimed in claim 13 wherein said breast cup region is of a shape defining only the breast cups and said bridge but not said chest strap(s).

22. A molded brassiere as claimed in claim 13 wherein said chest strap(s) extend outwardly from each side of said breast cup region.

23. A molded brassiere as claimed in claim 1 wherein said interior and exterior plies of foam are co extensive each other.

24. A molded brassiere as claimed in claim 1 wherein two underwire structures are provided intermediate of said interior and exterior panels, one each adjacent a respective breast cup.

25. A molded brassiere as claimed in claim 24 wherein said underwire structure comprises a rigid elongate member and a flexible material casing about at least part of said rigid elongate member.

26. A molded brassiere as claimed in claim 25 wherein said casing is a fabric material.

27. A molded brassiere as claimed in claim 25 wherein said casing is adhered to one or each of the facing surfaces of said interior and exterior foam plies by an adhesive material.

28. A molded brassiere as claimed in claim 27 wherein said casing is a tubular sock within which said rigid elongate member is located, the sock having closed distal ends.

29. A molded brassiere as claimed in claim 1 wherein, in use, said interior panel at said pocket, presses more against said breasts than said exterior panel.

30. A method of manufacturing a molded component assembly for a brassiere comprising:

placing an exterior panel that includes a foam ply that includes, at each region of the exterior panel at where a breast cup is to be mold formed into said exterior panel, a zone of increased thickness that is located extending from the to be defined lower regions of the breast towards the neckline of the breast cup, into a molding device and mold forming the breast cup(s) shape into the exterior panel and to homogenise the thickness of the foam ply at least at the breast cup(s) so that the zone is of a higher density foam than the foam surrounding the zone,

placing an interior panel that includes a foam ply that includes, at each region of the interior panel at where a breast cup is to be mold formed into said interior panel, a zone of increased thickness that is located extending from the to be defined lower regions of the breast towards the neckline of the breast cup, into a molding device and mold forming the breast cup(s) shape into the interior panel and to homogenise the thickness of the foam ply at least at the breast cup(s) so that the zone is of a higher density foam than the foam surrounding the zone,

laminating the interior and exterior panels with each other in a manner so that their cups(s) agree and in a manner wherein no lamination occurs of the panels at where the zone of higher density foam of the interior panel is located so as to define a pocket at this zone between the interior and exterior panels.

31. A method as claimed in claim 30 wherein at least one of the interior and exterior panels are of a size to allow two breast cups and a bridge extending between the breast cups to be molded into panel(s).

32. A method as claimed in claim 30 wherein the method includes the subsequent steps of trimming said molded and laminated interior and exterior panels to define a molded assembly which includes two cups forms and a bridge region extending there between.

33. A method as claimed in claim 30 wherein one of the exterior panel and interior panel also includes an underwire structure placed, prior to lamination of the interior and exterior panels, so as to be captured between the panels.

34. A method as claimed in claim 30 wherein one of the exterior panels and interior panel includes a layer of flexible material having non stretch properties placed, prior to lamination of the interior and exterior panels, so as to become captured between the panels.

35. A method as claimed in claim 30 wherein prior to molding of said panels, an underwire structure is provided intermediate of said first and second layer.

36. A method of manufacturing a molded component assembly for a brassiere comprising:

laminating (i) an exterior panel that includes a foam ply that includes, at each region of the exterior panel at where a breast cup is mold formed into said exterior panel, a zone of increased foam density that is located extending from the lower regions of the breast towards the neckline of the breast cup with (ii) an interior panel that includes a foam ply that includes, at each region of the interior panel at where a breast cup is mold formed into said interior panel, a zone of increased foam density that is located extending from the lower regions of the breast towards the neckline of the breast cup,

in a manner so that their cups(s) agree and in a manner wherein no lamination occurs of the panels at where the zone of higher density foam of the interior panel is located so as to define a pocket at this zone between the interior and exterior panels.

37. A method as claimed in claim 36 wherein the zone of the interior panel has an upper perimeter that is lower than the perimeter of the zone of the exterior panel.

38. A molded brassiere comprising or including,

a breast cup region defined at least by (i) an interior panel that includes a foam ply (herein after “interior foam ply”) and (ii) an exterior panel that includes a foam ply (herein after “exterior foam ply”), said interior and exterior panels being laminated with each other defining a breast cup region that includes two breast cups and an intermediate bridge region extending there between, wherein the interior and exterior panels are laminated with each other save at least at a region where, for each breast cup, a pocket is defined between the interior and exterior panels, the pocket being located extending from the lower perimeter region of the breast cup towards the neckline of the breast cup, the interior panel at said pocket having lower curvature than said exterior panel so that said pocket provides an air gap between said interior and exterior panels.