DE102019202385A1 - 3D fleece bra and manufacturing process - Google Patents

Abstract

The present invention provides a bra (200), in particular a sports bra (200), comprising a fabric made of a nonwoven material (100), the fabric (100) having a contour by applying fibers (510) to a three-dimensional substrate which is similar to a portion of a body is obtained so that a shape of the fabric of the bra (200) 10 is determined at least in part by the application of the fibers (510).

Description

Technical area

The present invention relates to a brassiere (bra), in particular to a sports bra, and to a method for producing such a bra.

Technical background

Bra construction is typically based on the use of foam cups between multiple layers of fabric. Other components of the bra are then either sewn or connected to the fabric.

For example, the prior art document discloses US 2011/0068507 A1 a molding of cups by means of a thermoforming process. The process begins with a flat sheet of fleece material and creates a 3D shape of the cup as part of an additional post-production process. To complete the bra, the cups can be processed like a traditional cut and sewn garment. Further revealed KR 101 183 200 a bra, wherein the carrier part consists of a non-woven material pressed in a U-shape. In addition, disclosed EP 3 419 450 a constructed bra with pre-configured lockout and stretch zones where the stretch properties can be adjusted through one or more knitting or weaving techniques and / or materials throughout the bra. The knitted or woven bra can include zones with different elasticities through specific knitting and stitch orientations or weaving techniques.

However, the conventional manufacturing techniques of bras and the bras known from the prior art have various disadvantages. For example, it is awkward to start with a flat sheet and only achieve a 3D shape as part of a post-production process, as this requires additional manufacturing steps. Finalizing such bras can go through several different manual assembly process steps and is therefore inefficient and costly. In addition, such composite bras with molded cups or knitted / woven features may require multiple seams or connections to combine different parts of the bra, creating discomfort for the wearer.

The problem on which the present invention is based is therefore to improve bras and their production in such a way that the above-described disadvantages of the prior art are at least partially overcome.

Summary of the invention

The above problem is at least partially solved by the subject matter of the independent claims of the present application. Exemplary embodiments of the invention are defined in the dependent claims.

In one embodiment, the present invention provides a bra, in particular a sports bra, comprising a fabric made of a nonwoven material, the fabric being obtained by applying fibers to a three-dimensional substrate with a contour that is similar to a portion of a body , so that a shape of the material of the bra is determined at least in part by the application of the fibers.

The claimed invention thus represents a bra, wherein the three-dimensional shape of the bra can already be at least partially formed during the process of applying the fibers to a contoured substrate. The need to carry out one or more additional shaping and reshaping steps in a post-production phase can therefore be reduced or even omitted entirely.

In some embodiments of the present invention, the substrate is at least a front portion of a woman's torso. In addition, the substrate can be a complete female torso and the fibers of the bra fabric can be applied to all sides of the torso. Thus, the shape of the bra can be determined solely by the application of the fibers without an additional molding step.

In this way, the true three-dimensional shape of the bra can only be achieved during the application process, including the bust, left and right sides and the back of the bra. Therefore, all kinds of time consuming and costly post-production molding processes can be unnecessary, or at least kept to a minimum.

Furthermore, in some embodiments, the nonwoven material comprises a first zone with a first areal density of nonwoven material and a second zone with a second areal density of nonwoven material. In addition, the second zone can have a different, in particular higher, modulus of elasticity than the first zone.

The control of the surface density of the applied nonwoven material and the modulus of elasticity makes it possible to use the various zones by simply adapting the application process to one precisely set the desired stiffness or flexibility.

In some embodiments of the present invention, the bra includes at least two second zones that can be placed under the breasts when the bra is worn. In addition, the bra can include at least two first zones that are adapted to be positioned over the breasts when the bra is worn. The surface density of the first zone can be between 300 and 1000 grams per square meter (gsm) and / or the density of the second zone can be between 600 and 2000 gsm.

In a further embodiment, the present invention comprises a third zone with a third areal density, wherein the third zone can have an areal density which is lower than the areal densities of the first and second zones. In addition, the third zone can comprise perforations and furthermore can be adapted so that it can be arranged between the breasts and / or on the back when the bra is being worn.

The introduction of several zones of different surface densities, the number of zones not being limited to the numbers in the aforementioned embodiments, offers a possibility of precisely planned support as a more or less direct result of the application process.

In some embodiments of the present invention, the fabric does not include a seam in an area around the chest. In addition, in a further embodiment the bra does not comprise a seam.

An embodiment of the present invention with a bra, in particular a sports bra, without seams, offers a unique possibility of wearing comfort, in particular during sports. In addition, the elimination of sewing threads and / or gluing with adhesive or the like leads to a more cost-efficient and time-efficient manufacturing process.

The nonwoven material of the bra can consist of meltblown fibers of a single material class of thermoplastic materials, in particular a thermoplastic polyurethane (TPU). In addition, the bra can comprise a closure means which is made from the same single material class of thermoplastics, in particular TPU. In addition, the bra can consist exclusively of the individual material class, in particular TPU.

Thus, in one embodiment of the present invention, the main parts or even the entire bra are made from a single class of thermoplastic materials such as TPU, including fasteners, hooks, buckles and elastic bands. This is a decisive advantage to enable easier recycling of the entire product.

In a further embodiment, the present invention provides a method of making a bra, comprising the steps of providing a three-dimensional substrate having a contour that is similar to a portion of a body and applying fibers to the three-dimensional substrate to form a fabric of the bra To provide nonwoven material, wherein a shape of the fabric can be determined at least partially by the application.

For example, the method can include the section of a body as at least a front section of the upper body of a woman. In addition, the upper body of the woman can have a shape based on data obtained by three-dimensional scanning of a variety of women.

In this way, using three-dimensional scanning of a variety of women as a template for making a bra, the present invention can define a new sizing system that can help women find the most appropriate bra.

In a further embodiment, the present invention provides a method in which an areal density of the applied fibers varies over the three-dimensional substrate. For example, the variation in the surface density can be achieved by varying an application time and / or a distance between the three-dimensional substrate and a fiber source for a first and a second section of the three-dimensional substrate.

Additionally, in some embodiments, the present invention provides a method of controlling application time and / or spacing by moving the three-dimensional substrate with respect to the flow of meltblown fibers. For example, the three-dimensional substrate can be attached to a robotic arm that can move the three-dimensional substrate on a programmed path.

For some of the above embodiments it is a key factor to control the areal density that is required for individual areas of the bra to achieve different levels of support. The robot-controlled Process can allow flexibility in determining the placement and areal density of fibers according to performance and design requirements.

Another embodiment of the present invention is an individual three-dimensional substrate based on the scanning of a single body. For example, the individual substrate can be provided at least partially using additive manufacturing.

This process can make it possible to manufacture a highly customized bra, particularly a sports bra, extremely precisely and quickly, resulting in a product that conforms to the shape of an individual woman's body.

In a further embodiment, the present invention provides a method for cutting the nonwoven material to a desired pattern, in particular with a laser beam. For example, the pattern and / or the application process can be defined to allow a predefined stretch of the bra.

The method described can make it possible to trim the applied nonwoven material to a desired pattern by cutting selected areas directly, for example with one or more robot-controlled laser beams or a manual trimming method. This aspect of the invention further contributes to a highly efficient production, which here too can work individually according to the data of a single carrier.

Another embodiment of the present invention provides a method of forming a loop in the nonwoven fabric of the bra, in particular by ultrasonic welding. Such a production step obviates or reduces the use of additional closure means.

In addition, a large number of perforations can be provided in the fabric made of nonwoven material of the bra, in particular by laser cutting. For example, areas with higher air permeability can be created by creating holes with a high degree of design freedom in terms of size, shape and distribution in the bra.

Another embodiment of the present invention provides a method for applying the fibers to the three-dimensional substrate, the fibers comprising at least two different colors.

This aspect of the claimed method can make it possible to manufacture a feathery gradient bra, wherein the method is not limited to the number of the above-mentioned colors, but can actually include a plurality of fibers of different colors.

In a further embodiment, the present invention provides a method for manufacturing a bra according to one of the above-mentioned embodiments.

Figure list

• 1 eine Abbildung eines dreidimensionalen Stoffes aus Vliesmaterial, das auf dem Oberkörper einer Frau aufgebracht ist; und
• 2a eine Ausführungsform, die schematisch einen Sport-BH auf dem Oberkörper einer Frau aus drei verschiedenen Blickrichtungen darstellt; und
• 2b eine schematische Zeichnung, die die Positionen mehrerer Zonen mit unterschiedlicher Flächendichte auf dem Oberkörper einer Frau veranschaulicht; und
• 3 eine weitere Ausführungsform, die verschiedene Zonen eines Sport-BHs einschließlich Perforationen und Bindungen veranschaulicht; und
• 4 ein Diagramm, das den Zusammenhang zwischen dem Elastizitätsmodul des Vliesmaterials und der aufgebrachten Fasermenge in Gramm pro Quadratmeter darstellt; und
• 5 eine Veranschaulichung eines Faseraufbringungsprozesses zur Herstellung einer Ausführungsform eines BHs, wobei der Aufbringungsprozess über einen Roboterarm gesteuert wird.

Aspects of the present invention are described in more detail below with reference to the accompanying figures. These figures show:

• 1 an illustration of a three-dimensional fabric made of non-woven material, which is applied to the torso of a woman; and
• 2a an embodiment schematically showing a sports bra on the upper body of a woman from three different viewing directions; and
• 2 B a schematic drawing illustrating the positions of several zones with different surface densities on the upper body of a woman; and
• 3 another embodiment illustrating various zones of a sports bra including perforations and ties; and
• 4th a diagram showing the relationship between the modulus of elasticity of the nonwoven material and the amount of fiber applied in grams per square meter; and
• 5 Figure 4 is an illustration of a fiber application process for making an embodiment of a bra, the application process being controlled by a robotic arm.

Detailed description of some exemplary embodiments

In the following, exemplary embodiments of the present invention are described in more detail, based on a bra, in particular a sports bra. While specific combinations of features are described below in relation to the exemplary embodiments of the present invention, it is to be understood that the disclosure is not limited to such embodiments. In particular, not all features need to be present in order to practice the invention, and the embodiments can be achieved by combining certain features of an embodiment with one or more features another embodiment can be changed. While the following illustrates embodiments of the present invention in relation to a sports bra and methods adapted for providing a sports bra, it should be understood that the same methods can be used to provide different garments for different parts of the body.

1 represents a non-woven material 100 represents that by applying the fibers 510 (see. 5 ) on a three-dimensional substrate in the shape of a woman's torso 110 is made with the fibers 510 of the fabric 100 applied to all sides of the torso. Thus the shape of the substance 100 essentially through the application of the fibers 510 determined without an additional shaping step and can also result in a bra with no or at least a reduced number of seams. This method of making an embodiment that is nearly completely molded during a manufacturing step can provide a bra with a reduced number of components, but without compromising on performance.

2a Figure 12 shows an illustration of a sports bra 200 made by applying fibers 510 on a three-dimensional substrate in the shape of a woman's torso 110 was produced. Here there is already an additional trimming step using a laser or a manual method (not shown) for cutting the nonwoven material 100 is done on a desired pattern. The sports bra 200 can have perforations 210 to reach areas with higher air permeability. This can also be achieved by laser cutting with a high degree of design freedom with regard to the size, shape and distribution of the perforations 210 can be achieved.

The sports bra also contains 200 from 2a a closure means 220 that can be magnetic or work with some other suitable mechanism. In one embodiment, such closure means are made from the same class of material as the fibers of the sports bra 200 , preferably TPU. It was found that this class of material enables the application of fibers, which result in a flexible nonwoven material 100 leads, but also to stable locking means 220 manufacture, e.g. by injection molding suitable hooks etc.

In addition, the sports bra can 200 , as in 2a shown, several zones with different surface densities 230 , 240 and 250 included to provide the required stretch or stiffness at the respective points of the sports bra 200 to guarantee. Therefore, zones with a medium surface density can occur when wearing the bra 230 Placed over the breasts, which can provide a nifty combination of stretch and support. More zones that have a higher surface density 240 can have, can be arranged below the breasts to ensure the necessary support and compression, which is particularly required during exercise. 2a also shows a third zone 250 which is arranged between the breasts and on the back of the bra, which can have the lowest surface densities in combination with perforations in order to offer the wearer a comfortable air permeability. Exemplary values of the surface densities of an embodiment are shown in FIG 2a shown.

2 B shows the torso 110 a woman from two different perspectives, on which several zones of different surface densities are exemplified 230 , 240 , 260 , 270 and 280 are designated. Similar to the description of 2a enable zones of medium (e.g. 300 - 1000 gsm) 230 and higher (e.g. 600-2000 gsm ) 240 Areal densities above and below the breasts when the bra is worn, a required stretch and / or support in the respective zones. It also shows 2 B a fourth zone 260 with a medium high (e.g. 300-1000 gsm ) Areal density, which is located on the shoulders when the bra is worn, to provide enough fleece material 100 to provide a long shelf life of a sports bra 200 especially in areas with high loads. Similar surface densities as in the fourth zone 260 can be used in areas (not shown) where other components can be attached (e.g. by gluing / bonding or ultrasonic welding) to ensure that the additional components make up the non-woven fabric 100 won't break or tear off. Another fifth zone 270 with a low surface density (e.g. 200 - 800 gsm ) can be used as a type of footprint to connect all the existing zones of the embodiment. It is also on the outside of the breasts, below the armpit, in 2 B a sixth zone 280 shown, which shows a gradual transition in area density (e.g. from 1000 to 500 gsm ) between the second zone 240 and the base density of the fifth zone 270 can cause.

3 shows a representation of another sports bra 200 . Again, the fleece material was used 100 trimmed to a desired pattern by laser cutting and / or manual operation (not shown). The sports bra 200 can have different zones with perforations 210 to achieve areas with higher air permeability by laser cutting. It also includes the sports bra 200 Closure means 220 , which can also consist of the material class TPU, or in another embodiment be magnetic or contain another locking mechanism. About that addition can be the sports bra 200 a traditional elastic lower band 300 made of TPU that is built into the garment, either with traditional manufacturing steps such as gluing or sewing, or through a selected application of higher density fibers that provide an amount of reduced stiffness compared to the other sections of the nonwoven material. The flexibility of the ligament must be adjusted so that a user's thorax can expand during a breathing cycle. In addition, another elastic band can be used 310 made of applied fibers or an additional material such as TPU can be provided, this tape 310 has a different elasticity than the surrounding fleece material. The connection between the elastic band 310 and the surrounding fleece material can be produced by gluing (not shown) or ultrasonic welding.

4th represents a diagram showing the relationship between the modulus of elasticity of the nonwoven material 100 and the amount of fiber applied 510 illustrated in grams per square meter. This relationship can be applied in one embodiment of the present invention to create specific stiffer or more flexible zones that provide an optimal level of chest movement / reduction in motion during medium and high load exercises. The surface density can be varied by varying an application time and / or a distance 520 the three-dimensional substrate to a source of fibers 530 can be achieved as in 5 shown.

5 Fig. 12 schematically shows an illustration of a fiber application process for making an embodiment of the present invention. The process can affect the torso 110 a woman included working on a robotic arm 500 is attached to the areal density of the applied fibers 510 set by moving the substrate along a programmed path (not shown). By varying an application time and / or a distance 520 of the substrate to a fiber source 530 can thus create different zones with surface densities 230-280 can be achieved. The three-dimensional substrate used herewith can be provided either by scanning a plurality of women to enable mass production or by scanning the body of a single woman to make a fully fitted bra. The substrate can be produced at least partially by additive manufacturing (not shown). After the application process, the fleece material 100 an embodiment with a predefined expansion with a laser beam or other cutting techniques (not shown) can be cut to a desired pattern. In addition, the perforations 210 and loops can be added using laser or ultrasonic welding. In addition, some embodiments may include different colors and a feathered transition may be provided through the use of fibers of a different color (not shown).

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• US 2011/0068507 A1 [0003]
• KR 101183200 [0003]
• EP 3419450 [0003]

Claims (33)

Bra (200), in particular a sports bra (200), comprising a fabric made from a nonwoven material (100), the fabric (100) being formed by applying fibers (510) to a three-dimensional substrate with a contour that corresponds to a section of a body is similar, is obtained, so that a shape of the fabric of the bra (200) is at least partially determined by the application of the fibers (510). BH (200) after Claim 1 wherein the portion of the body is at least the front part of the torso (110) of a woman. BH (200) after Claim 1 or 2 wherein the substrate is a complete female torso (110) and wherein the fibers (510) of the fabric (100) of the bra (200) have been applied to all sides of the torso (110). Bra (200) according to one of the Claims 1 - 3 wherein the shape of the bra (200) is determined solely by the application of the fibers (510) without any additional molding step. Bra (200) according to one of the Claims 1 - 4th wherein the nonwoven material comprises a first zone (230) with a first areal density of nonwoven material and a second zone (240) with a second areal density of nonwoven material. BH (200) after Claim 5 wherein the second zone (240) has a different, in particular higher, modulus of elasticity than the first zone (230). BH (200) after Claim 5 or 6th comprising at least two second zones (240) adapted to be positioned under the breasts when the bra (200) is worn. Bra (200) according to one of the Claims 5 - 7th comprising at least two first zones (230) adapted to be positioned over the breasts when the bra (200) is worn. Bra (200) according to one of the preceding Claims 5 - 8th wherein the surface density of the first zone (230) is between 300 and 1000 grams per square meter (gsm) and / or wherein the density of the second zone (240) is between 600 and 2000 gsm. Bra (200) according to one of the Claims 5 - 9 , further comprising a third zone (250) with a third areal density. BH (200) after Claim 10 wherein the third zone (250) has an areal density which is lower than the areal densities of the first (230) and the second zone (240). BH (200) after Claim 10 or 11 wherein the third zone (250) comprises perforations (210). Bra (200) according to one of the Claims 10 - 12 wherein the third zone (250) is adapted to be placed between the breasts and / or on the back when the bra (200) is worn. Bra (200) according to one of the Claims 1 - 13 wherein the fabric (100) has no seam in an area around the chest. BH (200) after Claim 14 wherein the bra (200) does not include a seam. Bra (200) according to one of the Claims 1 - 15th wherein the nonwoven material consists of meltblown fibers (510) of a single material class of thermoplastic materials, in particular a thermoplastic polyurethane, TPU. BH (200) after Claim 16 wherein the bra (200) comprises a closure means (220) which is made from the single material class of thermoplastic materials, in particular TPU. BH (200) after Claim 16 or 17th which consists exclusively of the individual material class, especially TPU. A method of making a bra (200) comprising the steps of: a. Providing a three-dimensional substrate having a contour that is similar to a portion of a body; b. Applying fibers (510) to the three-dimensional substrate to provide a fabric (100) of the bra (200) made of nonwoven material, a shape of the fabric (100) being determined at least in part by the application. Procedure according to Claim 19 wherein the portion of a body is at least the front portion of the torso (110) of a woman. Procedure according to Claim 20 wherein the torso (110) of the woman has a shape based on data obtained by three-dimensionally scanning a plurality of women. Method according to one of the Claims 19 - 21st , wherein an areal density of the applied fibers (510) varies over the three-dimensional substrate. Procedure according to Claim 22 wherein the variation of the surface density is achieved by varying an application time and / or a distance (520) of the three-dimensional substrate to a source of the fibers (510) for a first and a second section of the three-dimensional substrate. Procedure according to Claim 23 wherein the application time and / or the spacing (520) is controlled by moving the three-dimensional substrate with respect to the flow of meltblown fibers (510). Procedure according to Claim 22 or 23 wherein the three-dimensional substrate is attached to a robotic arm (500) that moves the three-dimensional substrate in a programmed path. Method according to one of the Claims 19 - 25th , further comprising the step of providing an individual three-dimensional substrate based on the scanning of a single body. Procedure according to Claim 26 wherein the single substrate is provided using additive manufacturing. Method according to one of the Claims 19 - 27 , further comprising the step of cutting the nonwoven material to a desired pattern, in particular using a laser beam. Procedure according to Claim 28 wherein the pattern and / or the application process is defined to provide a predefined amount of stretch to the bra. Method according to one of the Claims 19 - 29 , further comprising the step of forming a loop in the fabric of nonwoven material, in particular by ultrasonic welding. Method according to one of the Claims 19 - 30th , further comprising the step of providing a plurality of perforations (210) in the fabric (100) made of nonwoven material, in particular by laser cutting. Method according to one of the Claims 19 - 31 wherein step b comprises applying fibers (510) of at least two different colors. Method according to one of the Claims 19 - 32 , the method being adapted to wear a bra (200) according to any one of Claims 1 - 18th to provide.

Images