JP3114959U - bra - Google Patents

Abstract

An object of the present invention is to provide a brassiere that reduces the amount of stitches required compared to the majority of bras available on the market. Furthermore, at least it is to provide a seamless breast cup structure that provides people with useful choices.
A brassiere 1 is comprised of an assembly of panels that are laminated together to define a single structure that incorporates a chest band 2 and two breast cup shapes 3. The chest bands 2 can be provided with clasps or locking elements that can interact with each other at their free ends 4, 5, allowing the free ends 4, 5 to be coupled together. To do. In addition, a single chest strap of the panel and shoulder straps 6, 7 can be provided that are secured to the appropriate area of the panel cup assembly, such that the shoulder straps from the wearer of the brassiere can be provided. It makes it possible to perform shoulder support.
[Selection] Figure 1

Description

  The present invention relates to a brassiere, and more particularly to a brassiere that incorporates a seamless breast cup structure, the overall brassiere having a negligible amount of stitches joining the various components of the brassiere together.

  The details of the structure of brassieres (hereinafter referred to as “bra”) have been developed over the years. Structural details have evolved with the introduction of new materials and new processes that can be used to manufacture brassieres. Like most consumer products, manufacturers strive to reduce the cost of goods sold. A reduction in the cost of goods sold comes from the use of less expensive materials. With respect to brassiere technology, however, significant savings in the cost of the brassiere can be achieved by reducing the man-hours required to manufacture the brassiere. Many bras available on the market contain multiple panels of material that need to be cut and joined. Although cutting can be automated, for sewing the panels together, this is largely done by a person. A bra's breast cup may consist of multiple panels, each of which needs to be sewn together, and the entire breast cup must then be sewn to the chest band and then to the shoulder strap There is. Peripheral stitches or overlocks to ensure that both edges of the brassiere material are not frayed further need to be added to the brassiere. Such things are also done by people.

  Therefore, it can be seen that the labor component of the overall cost can be relatively high to produce a brassiere.

  Accordingly, it is an object of the present invention to provide a brassiere that reduces the amount of stitches required compared to the majority of brassieres available on the market. Furthermore, it is an object of the present invention to provide a seamless breast cup structure that at least provides people with useful choices.

  Furthermore, the object of the present invention is to produce a seamless breast cup structure and related brasses incorporating such a structure in order to reduce the labor content of manufacturing the brassiere or at least provide people with a useful choice. Is to provide a method.

In a first aspect, the present invention provides:
A core assembly of at least a first layer of molded foam material and a second layer of foam material laminated to the first layer, the core assembly comprising two breast cup regions and a gap therebetween A layer of flexible material defining an extended intermediate bridge region and having non-stretchable properties is formed between the first layer and the second layer of molded foam material in the bridge region. The flexible material fed in the middle and laminated and having non-stretch properties is at least molded, oriented so that the core assembly is non-stretchable across the bridge region parallel to the cup direction from the cup A core assembly of a first layer of foam material and a second layer of foam material laminated with the first layer;
A first outer layer and a second outer layer, at least each of the fabric material layers being disposed on the outermost side to enclose the core assembly, and each on each side of the core assembly; Laminated to the core assembly, wherein the first outer layer and the second outer layer extend beyond the periphery of the core assembly to supply at least a portion of a brassiere that defines one or more chest straps. In a molded brassiere that includes a first outer layer and a second outer layer that extend.

  The first layer and the second layer of the foam are preferably laminated directly to each other except for the flexible material having non-stretchable properties.

  Preferably, the flexible material having non-stretchable properties is supplied extending only to the bridge region.

  Preferably, the flexible material having non-stretchable properties is positioned between the first and second layers of the molded foam material.

  The flexible material having non-stretchable properties is preferably a woven fabric material.

  The flexible material having non-stretchable properties is a woven fabric material having bi-directional and non-stretchable properties, and the non-stretchable orientation is parallel to the cup direction from the cup of the core assembly. It is preferably oriented to extend over the entire bridge area.

  The first layer and the second layer of the foam are preferably coextensive with one another.

  Preferably, the core assembly is shaped to define not only the breast cup and the bridge, but also the one or more chest straps.

  Preferably, the chest strap extends outwardly from each side of the core assembly that provides the region of the molded brassiere.

  The first layer and the second layer of the foam are preferably coextensive.

  The first layer and the second layer of the foam are laminated directly to each other except where the flexible material having non-stretchable properties is supplied, and the breast cup region is laminated with the lamination of the core assembly. It is preferable to be molded there at the same time.

  Preferably, two wire-filled structures are fed in between the first sheet and the second layer, each one being close to the breast cup region.

  Preferably, the wire-filled structure comprises a rigid elongate member and a casing of flexible material around at least a portion of the rigid elongate member.

  The casing is preferably a fabric material.

  Preferably, the casing is adhered to one or each of the facing surfaces of the first and second layers of foam with an adhesive.

  Preferably, the casing is a tubular sock-shaped body in which the rigid elongate member is positioned and the sock-shaped body has hermetically sealed ends.

  Preferably, the first outer layer is an assembly of laminated plies of fabric material plies fed out of the assembly and foam plies fed inward of the fabric material plies.

  Preferably, the foam layer ply of the outer layer is laminated to the core assembly.

  Preferably, the fabric material ply and the foam ply of the outer layer are coextensive.

  Preferably, the second outer layer is a laminated ply assembly of fabric material plies fed out of the assembly and foam plies fed inward of the fabric material plies.

  The foam layer ply of the second outer layer is preferably laminated to the core assembly.

  The fabric material ply and the foam ply of the outer layer are preferably coextensive.

In a second aspect, the present invention provides:
Placing a core assembly of a first layer of foam material and a second layer of foam material, between them, in the middle of the two mold parts of the molding machine, a flexible material having non-stretchable properties The layers are sandwiched, each part defining two cup-defining molding surfaces of complementary shape, and the layer of flexible fabric material is located in the middle region of the two cups Disposing a core assembly of a first layer of material and a second layer of foam material; and molding the core assembly by facing the mold parts together.
Its alignment with each other, thereby subjecting the core assembly to a molding force that, in cooperation with heat, immutably presses the two cup shapes,
Trimming the core assembly to define a shape around the molded core assembly including the two cup shapes and a bridge region extending therebetween;
Sandwiching the molded core assembly between two outer layers of flexible material including an outer layer of fabric material;
Trimming the two outer layers to define a perimeter including a chest fixation strap circumference;
A method of manufacturing a molded component assembly for a brassiere comprising:

  Forming the second layer of foam material into the first layer of foam material disposes the second layer proximate to the first layer; and the second sheet and Accomplished by applying a force that presses the first layer together, and with the appropriate residence time of the application of heat and pressing, thereby bonding the first layer and the second layer together Is preferred.

  Prior to forming the first and second layers of foam, it is preferred that a wire-filled structure is fed between the first and second layers.

In another aspect, the invention provides:
Taking the form of a core assembly of at least a first layer of molded foam material and a second layer of foam material laminated to the first layer, the core assembly comprising two breast cup regions and A layer of flexible material defining an intermediate bridge region extending therebetween and having non-stretchable properties is formed in the bridge region in the first layer and the second layer of the molded foam material. The flexible material fed in the middle, laminated and having non-stretchable properties is oriented so that the co-assembly is non-stretchable across the bridge area and parallel to the cup direction from the cup A core assembly of at least a first layer of molded foam material and a second layer of foam material laminated to said first layer And a step to take,
Sandwiching a core assembly between a first outer layer and a second outer layer, each of which is composed of at least a layer of fabric material to wrap around the core assembly, and is disposed most outwardly; and A first outer layer, each laminated with the core assembly on each side of the core assembly, wherein the first outer layer and the second outer layer extend beyond the periphery of the core assembly. Sandwiching the core assembly between the layer and the second outer layer;
Further, there is a method of making a brassiere comprising the step of peripheral trimming so as to provide the one or more brassiere chest straps.

  Each of the two outer layers is preferably fixed on opposite sides of the core assembly by adhesive molding.

  Each of the two outer layers is preferably secured to opposite sides of the core assembly by an adhesive.

  Adhering the shoulder strap and the back clasp to the chest strap is preferably accomplished by ultrasonic welding.

  Preferred embodiments of the present invention will now be described with reference to the accompanying drawings.

  Referring to FIG. 1, a front view of a brassiere manufactured by the method described herein is shown.

  The brassiere 1 is composed of an assembly of panels that are laminated together to define a single structure incorporating a chest band 2 and two breast cup shapes 3. The chest bands 2 can be provided with clasps or locking elements that can interact with each other at their free ends 4, 5, allowing the free ends 4, 5 to be coupled together. To do. In addition, a single chest strap of the panel and shoulder straps 6, 7 can be provided that are secured to the appropriate areas of the panel cup assembly, such that the shoulder straps from the wearer of the brassiere can be provided. It makes it possible to perform shoulder support.

  For shoulder straps, though, it is optional that the bra is envisioned to have a strapless deformation. Indeed, referring to the most preferred form of the present invention functioning as a brassiere, the assembly of the panel for defining the above may alternatively be, for example, an evening dress, a swimsuit, or the like It is envisioned that it can be incorporated into other clothing.

  Reference is made here to a preferred method of construction describing a particular assembly of panels that can be supplied to produce the brassiere of FIG.

  Referring to FIG. 2, two precursor layers, panels of material, or sheets, or plies (hereinafter referred to as “layers”) are shown, and the first layer 8 is preferably 3.1 mm thick. Made of the same foam material.

  The second layer 9 is a friendly foundry Ltd. Fabric material such as a product well known by the model number CMF-7440MU made. This is a fabric and is made from 80% Tatel and 20% lycra.

  The foam is preferably, for example, a polyurethane foam having a density of 30d to 40d.

The fabric layer 9 may have a configuration of approximately 80% Tacel 40d / 34f, 20% lycra 40d, and a weight of, for example, 190 g / m ² . Referring to FIG. 4, a foam panel 8 and a fabric panel 9 for supplying the panel outer assembly are laminated together. The first outer panel assembly 10 is composed of a foam layer 8 laminated to a fabric layer 9. These layers are generally coextensive with one another and are preferably laminated together using glue such as glue HM-1 from Forbo Switch Adhesives SA. This glue fixes the fabric and foam during drying without heating. It is sprayed on at least one of the facing surfaces of the foam panel 8 or the fabric panel 9. The surface of the foam panel 8 that does not face the fabric panel 9 is further made by Ultra Energy Adhesive Trading Co. , Ltd., Ltd. Sprayed with glue such as RM-30. This glue dries without sticking, but sticks when heated in the mold during the molding process shown in FIG. 15 and described below.

  Referring to FIG. 3, there is shown a foam panel 11 and a fabric panel 12 that are laminated together to define a second outer panel assembly as shown in FIG. 5, as well as the foam panel 8 and the fabric panel 9. Yes. The foam panel 11 comprises a foam such as EWA35 from Inoac Corporation, which is polyurethane and is 1.7 mm thick.

  The fabric panel 12 is preferably the same as the fabric panel 9. The second outer panel assembly 13 is supplied inside the brassiere (when fully manufactured) and the first outer assembly 10 is supplied outside the brassiere. The fabric panels 9, 12 are supplied as the outermost panels of the brassiere. Again, the surface of the foam panel 11 that does not face the fabric panel 12 is further covered with Ultra Energy Adhesive Trading Co. , Ltd., Ltd. Sprayed with glue such as RM-30.

  As part of the brassiere of the present invention, a wire buried underneath can be supplied incorporated into the brassiere. The wire-filled structure is composed of a wire 20 that is substantially rigid but somewhat flexible, and has a diameter of 2 mm, for example, as shown in FIG. The wire can be made from a material such as stainless steel. The wire is positioned in the sock shaped body 21. For example, as shown in FIG. 8, the sock-shaped body is sealed at the end portions 22 and 23. The sock shape can be made from a material such as TRICOT. Sealing at the sock-shaped ends 22, 23 can be achieved using an ultrasonic machine to bond. Wired assembly 25 is then ready for subsequent use. A brassiere, however, cannot incorporate wires that are buried underneath in its final shape.

  Referring to FIG. 9, there is shown a plan view of a layer of foam material 29 that will form a convex side that is disposed in the layer of material for the core assembly of the brassiere. Foam layer 29 is, for example, a polyurethane / memory foam, and is preferably a polyurethane foam / memory foam, such as EL58-4S made by Inoac Corporation that is 6 mm thick, for example.

  FIG. 10 is a plan view of a layer 30 of foam that will form a layer on the concave side of the core assembly of layers used in the brassiere of the present invention. The foam layer 30 is preferably a polyurethane foam / memory foam such as EL58-4S from Inoac Corporation, for example. Furthermore, it is preferable that the thickness is approximately 6 mm. FIG. 11 shows a plan view of a layer 31 of fabric that is incorporated as part of a core assembly of layers including layers 29 and 30.

  The fabric layer 31 is made of Goldspring Co. Ltd .. Made of fabric 7118 made of It is preferably a piece of gauze that is 100% nylon. This layer is included within the assembly to define a core assembly of layers that are fed intermediate the two foam panels 29, 30 of the core assembly. The fabric material layer 31 is supplied to be bonded to the middle of the foam layers 29, 30 in a region that defines a position between the two cup shapes 39, 40 that are molded into the core assembly 33. The fabric layer 31 is therefore located in the middle of the two cup shapes. Thereby, providing resistance to elasticity, if only the foam layers 29, 30 are fed into such an intermediate region, it will otherwise result in a region in the middle of the cup. It is important that the cups remain in a fixed arrangement with each other. Therefore, such a fabric layer is provided to reduce the elasticity of the core assembly in the middle region of the cup. In the most preferred form, such a central fabric layer 31 does not spread because it is supplied to the area under the breast cup. It merely spreads in the area of bridging between the breast cup shapes molded therein and preferably is not added. Nevertheless, in such a bridging area, foam panels are still being supplied. Each of the layers 31, 29, 30 and the laminated side of the sock-shaped body 21 of the wire-assembled assembly 25 is sprayed with adhesive and then assembled, but still remains planar. If used, the two wire-filled assemblies 25 are positioned in the middle of the foam layers 29, 30 at the appropriate location, where the cup shape is the layers 29, 30, 31, optionally, then out, or Will be molded into a core assembly 33 composed of any additional layers bonded in between. Molding of the assembly of layers 33 is then performed by the mold parts 34, 35. The mold parts 34, 35 have surface reliefs supplied to them for molding and introduction into the two cup-shaped core assemblies 33. The upper mold 34 is preferably at a temperature of 180 ° C. to 200 ° C., and the lower mold 34 is preferably at a temperature of 180 ° C. to 200 ° C. It is preferable that an adhesive is applied to the fabric material 31 on both sides. The residence time for holding the mold parts relative to each other is, for example, 120 seconds.

  Referring to FIG. 13, a cross-sectional view of the core assembly 33 is shown. FIG. 14 shows the core assembly 33 after its periphery has been trimmed to define the core cup assembly, where two cup shapes 39-40 are provided, providing the core cup assembly 33 as a single assembly. To remain connected to each other via the transition region 41. It can therefore be seen that the core cup assembly 33 is a single assembly of layers. With the exception of the fabric layer 31, all of the layers of the cup assembly are substantially coextensive with one another. If a wire-filled assembly is fed directly under each cup foam, the foam panels 29, 30 remain substantially coextensive with each other.

  The unit assembly 33 is then again bonded to the outer assembly of the panels 10, 13 by a molding device consisting of two mold parts 45, 46 each having a surface relief feature defining two cup shapes. Laminated. The panel assemblies 10, 13 are sized such that the assemblies 10, 13 are further large enough to supply a strap 2 extending from the cup region 3. A top mold in the molding process of the core assembly 33 with the outer panel assemblies 10, 13 is provided, the top mold being at a temperature of approximately 180 ° and the bottom mold being approximately 170 °. The residence time is, for example, 120 seconds. In addition to the heat used to ensure the lamination that takes place between the core assembly 33 and the outer panels 10 and 13, the core assembly is attached to both sides of the core assembly, Ultra Energy Adhesive Trading Co. It can be sprayed with an adhesive such as manufactured glue RM-30.

  The assembled outer panel assembly 10, 13 with the core assembly 33 molded into a suitable shape can then be trimmed to exhibit a shape as shown, for example, in FIG. Such trimming can be done manually, or Ever Green Ultrasonic Co. , Ltd., Ltd. It can be carried out ultrasonically by an ultrasonic machine such as the device EGR-053 made by the manufacturer or by the trimming roller 28. The ultrasonic trimming apparatus cuts and bonds both edges at the same time.

  As shown in the core assembly 33, the periphery is smaller than the trimmed periphery of the outer panel assemblies 10,13. Therefore, the core assembly 33 is positioned within the outer panel assembly 10,13.

  FIG. 17 shows the brassiere peripheral region 50 for the cross-section CC, with the outer panel assemblies 10, 13 being joined together at the periphery and positioned within the coassembly 33.

  Following trimming, peripheral components such as latches 4,5, shoulder straps can be secured to the breast cup assembly as shown in FIG. The shoulder strap is adjustable in length and the clasp can allow for adjustment of the size around the chest periphery of the brassiere. Such peripheral components are preferably coupled to the assembly of FIG. 16 using ultrasonic welding.

  Reference is made here to the product of the outer assembly 10, 13 comprising the foam layers 8, 11 and the fabric layers 9, 12, but either 10, 13 or both are fabric layers. It is sufficient to supply 9,12.

  The structure of the present invention is simplified by the fact that the core assembly is a single piece assembly of layers. Thus, the present invention does not require two independent cup-shaped orientations for sandwiching, or the outer layers of the fabric and foam are simply for such purposes. Only requires processing of a single core assembly. The brassiere can be manufactured substantially with little or no stitching.

1 is a front view of a brassiere (hereinafter referred to as “bra”) made by the method of the invention described below. FIG. FIG. 2 is a plan view of two layers of precursor material, above the foam material and below the fabric material that are laminated together. FIG. 3 is a plan view of a precursor layer of material, with foam material on the top and fabric material on the bottom. FIG. 3 shows the layers of FIG. 2 laminated together to define a precursor outer assembly using, for example, adhesive and / or thermal lamination. FIG. 4 is a perspective view of FIG. 3 laminated together to define a precursor outer assembly, the lamination being achieved by adhesive and / or thermal lamination. 1 is a perspective view of a wire-filled assembly incorporated into the brassiere of the present invention. It is sectional drawing about the cross section AA of FIG. It is sectional drawing about the cross section BB of FIG. FIG. 2 is a plan view of a precursor layer of foam material. FIG. 6 is a plan view of a precursor layer of another foam material. It is a top view of a precursor fabric layer. FIG. 12 is a cross-sectional view of a molding apparatus composed of an upper mold and a lower mold, in the middle of which the core assembly assembly and the wire-filled assembly of FIGS. 9, 10 and 11 are formed simultaneously. And a molded core assembly that positions the wire-filled assembly within the assembly, either directly below or in close proximity to each of the cups that are arranged for lamination and molded into layers. FIG. 13 is a cross-sectional view of two cup shapes of the assembly of layers shown in FIG. 12 after mold formation and lamination. FIG. 14 is a plan view of the flexible core assembly of FIG. 13 with peripheral trimming performed to define the core assembly of the layers. FIG. 15 is a cross-sectional view of a molding apparatus that supplies an upper mold part and a lower mold part, in the middle of which the flexible core assembly of FIG. 14 is arranged, and for them FIGS. The core precursor panel assemblies are positioned for subsequent molding and lamination of each other's plies. FIG. 16 is a plan view of an assembly of panels formed by the forming process of FIG. 15, with excess peripheral material trimmed. It is sectional drawing about the cross section CC of FIG.

Claims (22)

A molded bra,
A core assembly of at least a first layer of molded foam material and a second layer of foam material laminated to the first layer, the core assembly comprising two breast cup regions and a gap therebetween A layer of flexible material defining an extended intermediate bridge region and having non-stretchable properties is formed between the first layer and the second layer of molded foam material in the bridge region. The flexible material fed in the middle and laminated and having non-stretch properties is at least molded, oriented so that the core assembly is non-stretchable across the bridge region parallel to the cup direction from the cup. A core assembly of a first layer of foam material and a second layer of foam material laminated to the first layer;
A first outer layer and a second outer layer, at least each of the fabric material layers being disposed on the outermost side to enclose the core assembly, and each on each side of the core assembly; Laminated to the core assembly, wherein the first outer layer and the second outer layer extend beyond the periphery of the core assembly to supply at least a portion of a brassiere that defines one or more chest straps. A molded bra that includes a first outer layer and a second outer layer that extend.   The molded brassiere of claim 1, wherein the first and second layers of the foam are laminated directly to each other, except for the flexible material having non-stretchable properties.   The molded brassiere of claim 1, wherein the flexible material having non-stretchable properties is supplied extending only to the bridge region.   The molded bra of claim 1, wherein the flexible material having non-stretchable properties is positioned intermediate the first and second layers of the molded foam material.   The molded bra of claim 1, wherein the flexible material having non-stretchable properties is a woven fabric material.   The flexible material having non-stretchable properties is a woven fabric material having bi-directional and non-stretchable properties, and the non-stretchable orientation is parallel to the cup direction from the cup of the core assembly. The molded brassiere of claim 1, wherein the molded brassiere is oriented to extend over the entire bridge region.   The molded brassiere of claim 1, wherein the first and second layers of foam are coextensive with one another.   The molded brassiere of claim 1, wherein the core assembly is shaped to define not only the breast cup and the bridge, but also the one or more chest straps.   The molded brassiere of claim 1, wherein the chest strap extends outwardly from each side of the core assembly that provides an area of the molded brassiere.   The molded brassiere of claim 1, wherein the first and second layers of foam are coextensive.   The first layer and the second layer of the foam are laminated directly to each other except where the flexible material having non-stretchable properties is supplied, and the breast cup region is laminated with the lamination of the core assembly. The molded brassiere of claim 1, wherein the molded brassiere is molded there simultaneously.   The molded brassiere of claim 1, wherein two wire-filled structures are fed between the first sheet and the second layer, each one proximate to the breast cup region.   The molded bra of claim 12, wherein the wire-filled structure comprises a rigid elongate member and a casing of a flexible material around at least a portion of the rigid elongate member.   14. A molded brassiere according to claim 13, wherein the casing is a fabric material.   14. A molded brassiere according to claim 13, wherein the casing is adhered to one or each of the facing surfaces of the first and second layers of foam by an adhesive.   14. A molded brassiere according to claim 13, wherein the casing is a tubular sock-shaped body in which the rigid elongate member is located and the sock-shaped body has sealed ends.   The assembly of claim 1, wherein the first outer layer is a laminated ply assembly of fabric material plies fed out of the assembly and foam plies fed inward of the fabric material plies. Molded bra.   The molded brassiere of claim 17, wherein the foam layer ply of the outer layer is laminated to the core assembly.   The molded brassiere of claim 17, wherein the fabric material ply and the foam ply of the outer layer are coextensive.   The assembly of claim 1, wherein the second outer layer is a laminated ply assembly of fabric material plies fed out of the assembly and foam plies fed inward of the fabric material plies. Molded bra.   21. The molded bra of claim 20, wherein the second outer layer foam layer ply is laminated to the core assembly. 21. The molded bra of claim 20, wherein the fabric material ply and the foam ply of the outer layer are coextensive.

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