JP3133255U - bra - Google Patents

Abstract

An object of the present invention is to provide a molded brassiere that eliminates an end portion that is sewn facing the wearer's skin and that can give the user a sense of a selected product.
At least a core assembly including a first layer and a second layer made of a mold foam material, forming a mold bra that defines a bridge portion, and made of a non-stretchable flexible material. One layer is adjacent to or disposed between one of the first layer and the second layer and is laminated at the bridge portion, and the flexible material having non-stretchability is a bridge. The first layer portion and the second layer portion made of a fabric material are disposed outside the core assembly and are laminated with the core assembly on the inner side and the outer side, respectively, and enclose the core assembly. The third layer is joined to the first layer portion in the vicinity of the lowermost periphery of the core assembly, covers the lowermost periphery, and extends toward other than the lower periphery.
[Selection] Figure 31

Description

    The present invention relates to a brassiere that improves the feeling of wearing on the body, that is, the comfort of wearing, and particularly relates to a brassiere that has a reduced number of seams.

  Bras (hereinafter referred to as bras) are generally manufactured from a number of component parts. These component parts are formed into a three-dimensional shape by either cutting and re-sewing, or heating and pressure forming. The molded component elements are then assembled into a bra by sewing.

  In a garment such as a bra that is in contact with the wearer's skin, any untreated edges can become unpleasant if the garment is worn for a long time. Considering the three-dimensional nature of clothing, the removal of such untreated edges and seams is complicated and cumbersome.

  In view of the above problems, an object of the present invention is to provide a brassiere that does not include an end portion that is sewn at least partially facing the wearer's skin, and / or a brassiere that makes at least a general user feel selective. Is to provide.

  From a first aspect, the present invention provides a mold brassie, which is laminated to at least a first layer of mold foam material, and preferably also a second layer of mold foam material. A core assembly comprising a first layer (hereinafter referred to as a core assembly), wherein the core assembly defines two bust cup portions and a bridge portion that is an intermediate extending between the two bust cup portions; At least one layer made of a flexible material having elasticity is provided adjacent to or between one of the first layer and the second layer made of the mold foam material of the bridge portion. The bridge portion is laminated with the first and second layers made of mold foam material, and the non-stretchable flexible material straddles the bridge portion. A direction parallel to the direction from the cup to the cup is oriented so that the core assembly does not expand and contract, and at least a first layer and a second layer, each comprising at least a fabric material, are provided on both sides of the core assembly. Each of the core assemblies is laminated on the inner side and the outer side, preferably includes the core assembly, and further includes a third layer at least joined to the first layer in the vicinity of a lowermost peripheral edge of the core assembly, The three layers cover the lowermost peripheral edge and extend toward the remaining peripheral edge of the core assembly.

  From a second point of view, the present invention provides a mold brassie, which is laminated to at least a first layer of mold foam material, preferably also a second layer of mold foam material. A core assembly comprising a first layer, wherein the core assembly defines two bust cup portions and a bridge portion that is an intermediate between the two bust cup portions, and has a non-stretchable flexibility. At least one layer of material is provided adjacent to one of the first and second layers of the mold foam material of the bridge portion, or in the middle of both, and from the mold foam material at the bridge portion. The flexible material that is laminated with the first and second layers and has the non-stretch property extends across the bridge portion in a direction parallel to the direction from the cup to the cup. The core assembly is oriented so as not to expand and contract, and the core assembly is non-stretchable, and is provided with first and second layer portions made of at least a fabric material on both the inner and outer surfaces thereof, The first layer portion is laminated on the inner side of the core assembly, the second layer portion is joined to the first layer portion at the lower end of the lower peripheral edge of the core assembly, and the second layer portion is Folded to the outside of the core assembly so as to enclose the periphery of the core assembly, and the joint between the first and second outer layer portions has no untreated end or has a seam on the outside. It is arranged in the vicinity of the lower periphery of the mold brass so that it does not.

  Preferably, an intermediate fabric layer is captured and provided between the core assembly and at least one of the first layer portion and the second layer portion made of a fabric material, and the intermediate fabric layer is laminated to the core. Configure as follows.

  Preferably, the non-stretchable flexible material is a bi-directional, non-stretchable woven fabric material, and is non-stretchable past the bridge portion parallel to the cup-to-cup direction of the core assembly. Oriented so that the sex direction spreads.

Preferably, the layer made of a non-stretchable flexible material is configured to be captured and provided in the middle of the first layer and the second layer made of a mold foam material.

  Preferably, the first layer and the second layer made of foam material have the same degree of spread as each other, and both layers define the periphery of the core assembly.

Preferably, the core assembly is configured to define a bust cup portion, the bridge portion, and more preferably a shape that defines at least a portion of a shoulder strap other than a chest strap (s). .

  Preferably, the chest strap extends outward from both ends of the core assembly forming region provided in the mold brassiere.

Preferably, two underwire structures are provided between the first layer and the second layer made of foam material, and each structure has a configuration adjacent to each bust cup portion.

  Preferably, the first layer and the second layer made of foam material have a configuration in which they are directly laminated to each other except for the non-stretchable flexible material and the two underwire structures.

  Preferably, the underwire structure is composed of an elongated member having rigidity and a casing made of a flexible material including at least a part thereof.

  Preferably, the casing is made of a fabric material.

  Preferably, the casing is bonded to one side or each side of the opposing surfaces of the first layer and the second layer made of foam material by an adhesive.

  Preferably, the casing is a tubular sock-shaped body having a closed end, and an elongated member having the rigidity is disposed therein.

  Preferably, the first layer and the foam layer (s) have the same spread degree.

  Preferably, the second layer and the foam layer (s) have the same degree of spread.

  According to a further aspect of the present invention, a molded brassiere is provided, wherein the molded brassiere comprises a core assembly comprising at least a first layer of molded foam material, two bust cup portions and an intermediate extending therebetween. A first layer and a second layer, each of which is made of a mold farm material, are disposed on both the inner and outer sides of the core assembly, and the first layer is disposed on the inner side of the core assembly. Laminated, the second layer is joined to the core assembly and preferably to the first layer at the lower end of the lower periphery of the core assembly inside the core assembly and encloses around the core assembly Thus, it is folded back to the outside of the core assembly.

  There is also provided a method of manufacturing a molded component assembly for a brassiere according to the present invention, which comprises at least a first layer of molded foam material, and preferably a second layer of foam material. Preferably, a core made of a non-stretchable fabric material is provided on the core provided between the first layer and / or between the first and second layers, on the inner side of the core, and on the lower peripheral edge of the core. Adhering a layer of fabric material adjacent to and enclosing the fabric material layer around at least a portion of the outer lower periphery of the core and attaching the layer to at least a portion of the other peripheral region of the core It is comprised so that it may do.

  From a further aspect of the present invention, a mold brassiere having a core assembly is provided, the core assembly defining two bust cup portions, a surface close to the body (hereinafter referred to as an inner surface) and the opposite side thereof. A surface away from the body (hereinafter referred to as an outer surface), a core layer having at least one upper end and at least one lower end, a bridge portion extending between the bust cup portions, and an upper end and a lower end are defined. And an outer fabric layer extending from the outer surface of the core assembly around at least a portion of a lower end of the core assembly to the inner surface of the core assembly, and the outer fabric layer is folded outward along the lower end. Forming an outer flap, the outer flap being secured to the inner surface of the core assembly.

Preferably, the outer fabric layer is composed of at least one layer made of mold foam material and at least one layer made of fabric material.

  Preferably, the core layer includes at least one layer made of a mold foam material and at least one layer made of a fabric material.

  Preferably, the outer fabric layer extends from the outer flap, around the lower end of the core assembly, further past at least a portion of the outer surface of the core assembly, and around the upper end of the core assembly. It extends to the inner surface.

  Preferably, the outer fabric layer is secured to the inner surface of the core assembly toward its upper end.

  Preferably, the outer flap is fixed to the inner surface of the core assembly toward the lower end of the core assembly.

  Preferably, the outer flap is fixed to the inner surface of the core assembly toward the lower end thereof by an ultrasonic welding method.

  Preferably, the outer fabric layer is secured to the inner surface of the core assembly toward its upper end by bonding with an adhesive.

  Preferably, the outer fabric layer is fixed to the inner surface of the core assembly toward the upper end thereof by an ultrasonic welding method.

  Preferably, the core assembly comprises an underwire assembly of at least one elastically flexible and curved elongated member.

  An underwire assembly is secured to the outer surface of the core layer.

  Preferably, the underwire assembly further comprises a sheath sleeve disposed around the elongated member.

  Preferably, the core assembly includes a chest strap member fixed to the core layer toward the outside of each bust cup portion.

  Preferably, the chest strap member is fixed to the core layer in the fixing region.

  Preferably, the back strap portion is fixed to the core layer by sewing.

  Preferably, the back strap is fixed to the core layer by ultrasonic bonding.

  Preferably, each chest strap is comprised of at least one set of ultrasonically bonded fabric layers having an upper end and a lower end.

  Preferably, the fabric layers are joined together toward the lower end of the fabric layer.

  Preferably, the lower ends of each of the pair of fabric layers of the chest strap are folded back toward each other and joined at a surface adjacent to the fabric layer.

  Preferably, each chest strap comprises an elongated strap having elasticity.

  The elastic elongated band is made of natural or synthetic rubber.

  Preferably, the core assembly includes a shoulder strap that is fixed to the core layer toward the upper end above each bust cup region.

  Preferably, the outer fabric layer is configured to overlap with at least one fixing region extending from the inner surface of the core layer to the outer surface of the core layer.

  Furthermore, the present invention can be said to be broadly constituted by parts, elements, and features described or pointed out individually or collectively in the present specification, and two or more of the parts, elements, or features described above. It can also be said that it is composed of any or all combinations of things. In addition, each integer value described in the present application is described as having an equivalent numerical value known in the technical field related to the present invention, and these known equivalent values are also described individually. Should be understood as being incorporated herein.

"Internal", "external" or similar terms mean what should be understood in relation to the bra wearer's body. For example, “inner” or “inner” or “inner part or region” means a component closer to the surface side of the bra that is closer to the wearer's body than a component of the bra that is further away from the wearer's body. It is a relative term. Unless specified, “inner” does not mean “innermost”. Similarly, it goes without saying that the above point also applies to terms such as “external” or “external”.

  “Inside” or “inside” and “outside” or “outside” as used herein are interpreted according to the generally defined terms “closer to the body” and “further away from the body”, respectively. Should.

  The meaning of seamless means that the brassiere is virtually visually seamless, and more specifically, the ends of the brassiere are finished in a seamless manner, such as ultrasonic welding, or the outer layer It is meant to be finished by a method by folding the ends and fixing them to the inner layer by means of seamless or otherwise finished by means of substantially no seams. However, the internal structure of the bra should be visible from the outside even if the seam is visible, and for example, where the shoulder strap is attached to the cup part of the bra, or for fastening such as a hook or eye tape. It may be visible as long as the stitches are not visually recognizable from the outside such as the part where the chest band part is connected by the member.

As used herein, the term “including or comprising” means “·· is formed by at least part of anything”. In other words, the interpretation of a statement in the present specification that includes the term includes all the features that are introduced by the term and all that is required, but that other features can also exist. Needless to say.

  The structure of the brassiere according to the present invention will be described in detail below.

The core layer or core laminate comprises a fabric layer 1 having a foam layer 2 to form an assembly 3 of laminated ply layers. Such assemblies are formed in a continuous process that forms a long sheet. Alternatively, the assembly may be formed as a number of discontinuous sheets. The laminate is formed by applying heat and pressure to the fabric layer 1 and the foam layer 2 by a known method. From the assembly consisting of the laminated ply layers 2, two rectangular elements 4 are cut. One of these constitutes the outer layer 5. The other one is used to form the inner layer. Additional elements are cut from the assembly 3 or from other laminates consisting of foam and fabric layers to form shoulder strap portions 24. The shoulder strap portion 24 is different from the structure of the inner layer and the outer layer, that is, in a preferred embodiment, it comprises another fabric layer, which is on the opposite side of the foam layer, i.e. fabric layer, foam layer, fabric It differs in that it is constructed in the order of layers.

  In a subsequent process, the rectangular element 4 is formed in the outer layer 5 by scraping the foam layer. The forming process forms a basic bra shape having a pair of bust (bra) cup portions and a bridge portion extending therebetween. In the preferred embodiment, this forming process forms a top 6 around the middle of each bra cup portion 17. However, in other embodiments, there is no forming step and only the overall thickness of the foam layer is reduced or the shape of other regions is deformed to change the shape and / or density. In some embodiments, the outer layer 5 has no fabric layer and the bra outer layer is formed by the outermost fabric layer 27 (see below).

  The underwire structure 7 is configured by enclosing an arc-shaped metal underwire 8 in a sock-shaped body 10 made of a fabric material 9 that is closed at both ends by barbs 11. The fabric material can also be folded back and sewn or closed by heat sealing or the like.

  Subsequently, in order to give the outer layer 5 a three-dimensional shape before being molded, the outer layer 5 that has been thinly cut is then placed between the upper platen 12 </ b> A and the lower 12 </ b> B of the molding machine 12. Subsequently, the platen and 12A and 12B are combined and pressure and, in the preferred embodiment, heat is applied to impart a three-dimensional shape to the outer layer. The layer thus molded has a region of the bra cup part 17 which is clearly molded.

  Subsequently, the adhesive 13 is sprayed by the spraying machine 15 on the foam layer side of the molded outer layer 19. The adhesive 13 may take any form, for example, heat or chemical (two pot) activated adhesive, contact adhesive, self-curing adhesive (self-adhesive). setting) or a similar form. There is an underwire structure 7 on the foam layer 2 side of the outer layer 19, and in the preferred embodiment, near the lower peripheral edge 16 of each bra cup portion 17 in the foam layer 2 of the molded outer layer 19, by a suitable adhesive. Glued and fixed and positioned. Subsequently, the first bridge layer 18 made of a non-stretchable flexible fabric material is bonded in the preferred embodiment between the bridge portion 56 in the foam layer 2 of the outer layer 19, that is, between the two bra cup portions 17. Is positioned and arranged. A further or second bridge layer 57 made of a slightly stretchable flexible fabric material has an overall “W” shape, and along the underwire structure 7, a bridge portion. It is placed and positioned past 56 and on the first bridge layer 18 in a preferred embodiment by gluing. Finally, a portion of the foam layer 21 having a “U” shape is placed and positioned on top of the second bridge layer 57 along each underwire structure 7, for example by gluing. In other embodiments, the underwire structure 7 may itself be coated with an adhesive or the foam layer 2 of the outer layer 5 may be melted, for example by ultrasonic techniques, or heat and / or pressure. May be arranged. Furthermore, the above is a preferred stacking order, and in other embodiments, this stacking order may be different.

The inner layer 20 cut from the laminated ply layer assembly 3 shown in FIG. 1 is subsequently thinned and bent. The molding process of the inner layer 20 is the same as the molding process of the outer layer except that the direction of the inner layer is opposite to that of the outer layer. In the molding direction of the inner layer 20, the male (upper) platen 12A is disposed to face the fabric layer 1, and the female (lower) platen 12B is disposed to face the foam layer 2 of the inner layer 20. Is done. The inner layer 20 may be thinned and molded many times before reaching this point. In a preferred embodiment, the molding machine is similar with respect to the formation of the outer layer 19, but the molding machine platen, or platen, is different.

Subsequently, the molded outer layer 19 and the molded inner layer 20 are installed in the molding machine 12. The molding machine 12 may be a molding machine as described above. In a preferred embodiment, the molding machine has a platen different from the molding machine that molded the inner layer and the outer layer, and the inner surface and the opposite side. A core assembly having an outer surface and an upper or upper peripheral edge 48 and a lower or lower peripheral edge 16. The layers 19 and 22 are arranged such that the respective foam layers 2 are arranged opposite to each other. Subsequently, two layers 19 and 22, an underwire structure 7, layers 18 and 57 made of fabric material, and a foam layer 21 and a molded outer layer 19 along the lower peripheral edge 16 of each bra cup portion 17 were molded. Pressure and / or heat is applied to form a stack of bridges sandwiched between the inner layer 22. Subsequently, the formed core assembly is cut out from the sandwiched stack. This cutting process can be made part of the molding process by placing a knife on the molding machine as part of the first or second action of the platen. Further, the unnecessary lamination may be cut out by the second operation of the platen. On the other hand, instead of molding, it may be performed by, for example, cutting by hand or other machining processes. The core assembly 23 has an outer side 65 of the bra, i.e., the outermost part for the wearer and an inner side 64 of the bra, i.e., the innermost part for the wearer.

  The shoulder strap portion 24 is formed from an assembly consisting of a pre-laminated ply layer with a foam layer sandwiched between two fabric layers, and is cored by two small pieces of fabric tape 25 with adhesive on one side. One end of the shoulder strap portion 24 is joined to the assembly 23 by covering the shoulder strap and the core assembly end with two small pieces of the fabric tape 25, or the The shoulder strap and the end of the core assembly are overlapped to cover the core assembly 23. Subsequently, the adhesive of the tape 25 melts and is immediately joined, for example by heating by ironing, or other melting technique depending on the adhesive used.

  Subsequently, the outer fabric layer or outermost fabric ply layer 27 is pre-formed by the molding process of the bullet 28 via the molding action by pressure and heat. Subsequently, the formed outermost fabric ply layer 27 is positioned and placed on the outer side 65 of the bra of the core assembly 23 using needles or pins 29.

  Below, the structure of the wing part 30 which forms the chest strap part of the brassiere 54 is described.

  The outermost fabric ply layer 30 </ b> A of each wing portion 30 of the brassiere 54 is cut out in advance from the fabric cut along the edge of the plastic ruler 35. Further, the innermost fabric ply layer 30B of each wing portion 30 is also cut out from the cut piece made of the fabric material. The innermost fabric ply layer 30B has an adhesive (whether activated or not) coated on one side with a protective paper 34 and is different from the pre-shaped plastic ruler 35 (used for the outer layer) Use the shape) to guide and cut. The outermost fabric ply layer 30A is longer than the innermost fabric ply layer and is used after being overlapped. Subsequently, the outermost fabric ply layer 30A is joined to the innermost fabric ply layer 30B of the wing portion 30 by sewing along the longest peripheral edge of each of the two layers, and the adhesive is sprayed in advance. An agent is between the two layers.

  Subsequently, the assembly of the sewed wing portion 30 is cut so as not to leave a seam along the joined periphery of the two layers, and at the same time, the two layers are sealed along the new periphery by an ultrasonic method. To form a joined peripheral edge 59.

  Further, a strip 58 (not necessary at this stage in the processing step but prepared early) is also formed by adhering the adhesive tape 39 on the elastic band 40. Subsequently, the strip having the adhesive tape on one side is fixed to the outermost fabric ply layer 30 </ b> A of the wing portion 30 along the peripheral edge 59 by the adhesive tape 39. Its purpose is to provide reinforcement and / or stretch along the joined perimeter 59.

  Subsequently, the outermost fabric ply layer 30A and the innermost fabric ply layer 30B in the wing portion are disposed between the two platens 62A and 62B, and then laminated together with the application of heat and / or pressure, and the chest strap 60 is Form. Subsequently, the formed chest strap 60 is trimmed along the periphery of the innermost fabric ply layer.

  The joining of the outermost fabric ply layer 27 and the chest strap 60 to the core assembly 23 will be described below.

  Each chest strap 60 is arranged so as to be sewn with its peripheral edge 63 facing outward, that is, so as to face the peripheral edge 61 of the cup of the core assembly 23. The periphery of the outermost fabric ply layer 27 is retracted so as not to be sewn here (although not shown, the outermost fabric ply layer is on the opposite side of the core assembly 23, that is, outside). Subsequently, the chest strap 60 is sewn in the fixing region (seam 36). This is most easily done with the inner side 64 of the bra of the core assembly facing up, but other methods are possible.

  Subsequently, the assembly consisting of the chest strap 60, the core assembly 23 and the outermost fabric ply layer 27 is turned over to show the outer side 65 of the bra. The outermost fabric ply layer 27 is unpinned and turned inside the core assembly 23, and subsequently oriented so that the shaped sphere of FIG. 15 is directed toward the inside 64 of the bra of the core assembly. Subsequently, the wing portion is further sewn from the outside of the core assembly to the core assembly.

  Subsequently, the outermost fabric ply layer 27 of the core assembly 23 is further stitched in a row so as to join the outermost fabric ply layer to the core assembly 23 along the lower peripheral edge 16 of the core assembly 23. Is sewn by.

  Thus, the core assembly 23, the chest strap 60, and the outermost fabric ply layer 27 are sewn. At this time, the chest strap end 63 faces the peripheral edge 61 of the core assembly 23. The main part of the chest strap 60 faces the inner side 64 of the bra. The outermost fabric ply layer 27 is illustrated with the sphere facing the inside 64 of the bra of the core assembly 23.

  The resulting assembly is subsequently trimmed and simultaneously joined using an ultrasonic method. The trimming width covers the seam 36 so that no seam remains along the lower periphery 16 of the assembly. The outermost fabric ply layer 27 is turned over to the inner side 64 of the bra of the core assembly 23.

  Subsequently, each chest strap 60 is turned over so that the free end of the chest strap is away from the core assembly 23, and then a small piece of fabric adhesive tape 25 is placed inside the core assembly 23 and on the chest strap. Iron on the largest joint. The tape 25 may be the same as that used for joining the strap portion 24 or may be joined by the same method.

Subsequently, the outermost fabric ply layer 27 is repositioned and placed on the outer side 65 of the bra of the core assembly using needles or pins, which are made by folding over the lower peripheral edge 16. The fabric ply layer is bonded and trimmed, covering the unprocessed edges and lower perimeter, and repositioned back to the outer 65 surface of the bra. The folded portion on the lower peripheral edge of the outermost fabric ply layer 27 forms an outer flap, and the end of the outermost fabric ply layer 27 is sewn to the core assembly 23. A seamless joint 67 is then formed on the inner side 64 of the bra. In a preferred embodiment, the seamless joint 67 is positioned above the lower peripheral edge 16. However, in other embodiments, it may be overlaid on the lower periphery 16 or may be crawled up to a higher position on the inner side 64 of the bra. In one embodiment, the outermost fabric ply layer 27 covers the anchoring area where the wings are sewn to the core assembly 23, thereby increasing comfort when the wearer wears the brassiere.

  Subsequently, the outermost fabric ply layer 27 is trimmed so that an edge or hem 66 is formed. The lip 66 is used to perform end coverage along the remaining peripheral edge 48 on top of the bra cup portion 17 and shoulder strap 55 of the core assembly 23, or at least a portion thereof. The adhesive tape 39 is applied to the edge 66 of the outermost fabric ply layer 27.

  Subsequently, the edge of the outermost fabric ply layer 27 is folded back around the upper periphery of the bra cup portion 17 and the shoulder strap, and FIG. 32 is a cross-sectional view showing the outermost fabric ply layer in detail. The fabric layer 1 composed of the molded inner layer 22 of the core assembly 23 is joined.

  Thereafter, the fastening members of the back strap, that is, the eyes 52 and hooks 51 are placed on the free end of the chest strap 60 by means of the adhesive tape 39. As shown in FIG. 34, the left chest strap 60 is provided with two hooks 51 in one vertical row, and the right chest strap 60 is provided with two eyes in three vertical rows. The hook 51 is joined from the inside of the chest strap 60 by an adhesive tape and ironing. The eye 52 is joined from the inside of the chest strap by a similar method, and appears on the outer surface through the cut 53 of the chest strap. A small strip of foam material is disposed on the hook portion by adhesive tape. Subsequently, the free end portion of each outermost fabric ply layer 27 extending outward from the fastening member of the back strap is folded back to cover the fastening member of the back strap.

  The hook appears on the inner surface through a fold in the folded free end of the outermost fabric ply layer. Subsequently, each shoulder strap is extended by connecting other components to the shoulder strap by ultrasonic methods, for example ultrasonic welding.

  FIG. 35 is a plan view of the finished product viewed from the outside.

  At the end of each chest strap 60, the hook 41 and eye 52 cooperate to secure the bra around the wearer's chest.

  The bra may be seamless and is composed of at least formed or formable material, and preferably at least partially joined together by lamination. In other embodiments, the brassiere 54 may be free of straps, or the seamless end may be incorporated into clothing other than the brassiere, and similar effects can be obtained.

The above description of the present invention includes preferred embodiments, and modifications can be made without departing from the scope of the present invention.

Preferred embodiments of the present invention are described below with reference to the accompanying drawings.
FIG. 6 illustrates a stack of fabric layers having a farm layer forming a laminated ply layer assembly, wherein one rectangular element is cut from the laminated ply layer assembly to form an outer layer. The outer foam layer is shown to be thinned so that a top is formed around the middle of each bra cup portion. FIG. 3 is a partially cutaway view showing an underwire structure in which a metal underwire is included in a sock-shaped body made of a fabric material that is closed at both ends by being clamped. In order to give the outer layer 5 a three-dimensional shape, the thinned outer layer 5 is shown placed between the platen upper part 12A and the lower part 12B of the molding machine 12 before being molded. The foam material side of the molded outer layer sprayed with an adhesive by a spraying machine is shown. An underwire structure is shown in which, for example, an adhesive is disposed in the vicinity of the lower peripheral edge of each bra cup portion on the foam layer of the molded outer layer from the inside or the inner surface of the molded outer layer. Fig. 4 shows a bridge on the foam layer of the outer layer, i.e. a layer made of a non-stretchable flexible fabric material placed, for example, by an adhesive, between two bra cups. Along the underwire structure and the bridge, another layer of flexible fabric material having a generally “W” shape, for example disposed by adhesive, is slightly stretchable. Fig. 3 shows an element consisting of a foam layer having a "U" shape, for example disposed by adhesive, along the W-shaped fabric material and each underwire structure. Fig. 2 shows an inner layer that is cut from the assembly of laminated ply layers shown in Fig. 1 before being molded and is scraped and placed between the platens of the molding machine. Shows an outer layer laminate having an inner layer for forming a core assembly by a molding machine prior to applying pressure and / or heat to form a laminate composed of two layers, an underwire structure and a fabric material or A layer of foam material is disposed between the outer and inner layers along the lower perimeter of each bra cup or bridge portion. Figure 3 shows the periphery of a trimmed core assembly. A shoulder strap formed from a pre-laminated ply layer assembly having a foam layer provided between the two fabric layers and joined to the core assembly by two elements of fabric tape coated with adhesive on one side One end of the shoulder strap is joined to the core assembly by wrapping a small piece of fabric tape over the joint, and the fabric tape adhesive melts and joins in the heated state, for example by ironing Is done. The outer and inner sides of the bra of the core assembly as seen from the side are shown. Fig. 5 shows the shaping of the outermost fabric layer with a bullet. The outermost fabric layer after shaping | molding is shown. FIG. 6 shows the outermost fabric layer placed on the outside of the core assembly using needles or pins. Fig. 4 shows the outermost fabric ply layer of each wing of a bra cut out from the fabric along the edges of a pre-shaped plastic ruler. Shows the innermost fabric ply layer of each wing of the bra cut from fabric material with adhesive coated with protective paper on one side, for guidance when cutting the edges of pre-shaped plastic rulers use. FIG. 6 shows the outermost fabric ply layer joined to the innermost fabric ply layer of the wing by sewing along the longest perimeter of each of the outermost fabric ply layer and the innermost fabric ply layer. 18. The outermost outermost fabric ply layer and the innermost fabric ply layer described in FIG. 18 are cut so as not to leave a seam along the joined periphery of the innermost fabric ply layer, and at the same time, the two layers are formed along the new periphery by an ultrasonic method. Adhere. Fig. 2 shows the adhesion of an adhesive tape on an elastic band. A method of fixing an elastic band having an adhesive tape on one side to the outermost fabric ply layer in the wing portion along the periphery of the joint portion with the innermost fabric ply layer will be described. The outermost fabric ply layer and the innermost fabric ply layer of the wings disposed between two platens before being laminated by application of heat and / or pressure are shown. Fig. 5 shows a stacked ply layer for each wing trimmed along the periphery of the innermost fabric ply layer. FIG. 6 shows a plan view of the inner surface of the core assembly, with the outermost fabric ply layer periphery being retracted so as not to be sewn, with the laminated ply layers of each wing facing outward, i.e., facing the core periphery of the core assembly And then the wings are sewn (not shown because the outermost fabric ply layer is located on the opposite side of the core assembly). FIG. 25 is a view similar to FIG. 24 seen from the other side of the core assembly, ie, from the outside, with the outermost fabric ply layer unpinned and flipped inside the core assembly, followed by a view toward the inner surface of the core assembly. The outermost fabric ply layer formed into 15 spheres is directed to the outermost fabric ply layer, and then the wing portion is further sewn to the core assembly from the outside of the core assembly. FIG. 6 is a partial cross-sectional view of the end of the core assembly showing the core and wing assembly and sewing with the outermost fabric ply layer, with the wing end facing toward the cup end of the core assembly and the wing body being the cup of the core assembly; Towards the inside, the outermost fabric ply layer shows spheres towards the inside of the core assembly. It is a top view of the assembly which sewn the core assembly, the wing part, and the outermost fabric ply layer, and the outermost fabric ply layer of the said core assembly was sewn on the core assembly along the lower peripheral edge of the said core assembly, and was sewn The outermost fabric ply layer is joined to the assembly and additional seams are added. FIG. 27 shows the assembly formed after being sewn as shown in FIG. 27, and at the same time trimmed and joined using an ultrasonic method, so that the trim width covers the seam so that no seam remains along the lower periphery of the assembly However, the outermost fabric ply layer is still inside out of the core assembly. The outermost fabric ply layer of the core assembly is turned over to cover the outer surface of the core assembly, and each wing is turned over with the free end away from the core assembly, followed by FIG. The same type of fabric adhesive tape as the shoulder strap and core assembly adhesive tape shown is used to reinforce the relatively weak joint of the adhesive part on the inside of the core assembly and on the largest joint of the wing part Iron it. (A) shows the outermost fabric ply layer of the core assembly repositioned outside the core assembly using a needle or pin, and (B) is a detailed cross-sectional view of the lower periphery, concealing the seam Shows the formation of a joint. (A) shows the trimmed outermost fabric ply layer, the edge covering the upper peripheral edge of the bra cup portion and the shoulder strap end of the core assembly is formed, and the adhesive tape is applied to the edge of the outermost fabric ply layer (B) shows a cross-sectional view detailing the outermost fabric ply layer, wherein an adhesive tape is adhered to the outermost fabric ply layer and placed under the core assembly. (A) shows a state in which the edge of the outermost fabric ply layer around the upper peripheral edge of the bra cup portion and the shoulder strap is folded, and (B) shows a cross-sectional view showing the outermost fabric ply layer in detail, The tape is glued to the outermost fabric ply layer and placed under the core assembly, and the outermost fabric ply layer and the adhesive tape are folded and joined inside the core assembly. FIG. 33 shows an unfinished product after the process described in FIG. 32. FIG. Fastening members of the back strap, such as clasps and hooks, are placed on the free end of the wing by adhesive tape, as shown in the figure, two hooks in the vertical row on the left wing and three vertical rows in the right wing There are two eyes each, the hooks are glued from the inside by adhesive tape and ironing, the eyes are glued from the inside of the wings in the same way, appear on the outer surface from the cuts of the wings, and by the adhesive tape A small piece of foam material is disposed on the hook portion, and the free end of each outermost fabric ply layer extending outwardly from the fastening member of the back strap is Folded to cover the dressing member, the hook is inward from the cut at the folded end of the outermost fabric ply layer. It appears on the surface. FIG. 4 is a plan view from the outside of a finished bra, showing a bust cup portion or bra cup portion 17, wing portions 30A and 30B as chest bands, and a bra 54 generally defining shoulder straps 55A and 55B, 55A and 55B extend between the bra cup portion 17 and the wing portions 30A and 30B, respectively. However, the shoulder strap as described above is optional, and the bra may not have a strap.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Fabric layer 2 Foam layer 3 Laminated ply layer assembly 4 Rectangular element 5, 19 Outer layer 6 Top part 7 Underwire structure 8 Metal wire 9 Fabric material 10 Sock-shaped body 11 Fastener 12 Molding machine 12A Platen upper part 12B Platen lower part 13 Adhesive 15 Spraying machine 16 Lower peripheral edge 17 Bra cup part 18 First bridge part 20, 22 Inner layer 21 Foam layer 23 having "U" shape Core assembly 24, 55, 55A, 55B Shoulder strap part 25 Fabric adhesive tape 27 Outermost fabric Ply layer 28 sphere
29 Needle or pin 30A Outermost fabric ply layer 30B of wing portion Inner fabric ply layer 33 of wing portion Adhesive 34 Protective paper 35 Plastic ruler 36 Seam 39 Adhesive tape 40 Elastic band 48 Upper end or upper peripheral edge of bra cup portion and shoulder strap 51 hook
52 eye
53 Cut
54 brassiere 56 bridge portion 57 second bridge portion 58 strip 59 joined periphery 60 chest strap 61 cup periphery 62A, 62B platen (platen)
63 Chest strap periphery 64 Bra inner 65 Bra outer 66 Edge 67 Seamless joint

Claims (40)

A core assembly formed by laminating at least a first layer of mold foam material, preferably on a second layer of mold foam material, the core assembly passing between two bra cup portions and the bra cup portion. In the molded brassiere that defines the intermediate bridge portion that extends,
At least one layer of a non-stretchable flexible material is adjacent to one of the first and second layers of mold foam material, or the first and second layers And the non-stretchable flexible material passes through the bridge portion parallel to the direction from the cup to the cup, and is laminated with the first layer and the second layer at the intermediate bridge portion. The core assembly is oriented so that it does not stretch,
A first layer portion and a second layer portion, each comprising at least a fabric material, are disposed outside the core assembly and laminated with the core assembly on the inside and outside of the core assembly, respectively, and the first layer of the fabric material The portion and the second layer portion include the core assembly;
A third layer portion is joined to at least the first layer portion in the vicinity of the lowermost peripheral edge of the core assembly, and the third layer portion covers the lowermost peripheral edge and extends to a peripheral edge other than the lower portion of the core assembly. A molded brassiere characterized by being extended toward or toward it. A core assembly comprising at least a first layer of mold foam material, preferably laminated to a second layer of mold foam material, said core assembly extending between two bra cup portions and between the bra cup portions. In the mold bra that defines the bridge part of the intermediate body to be installed,
At least one layer of a non-stretchable flexible material is adjacent to one of the first and second layers of mold foam material, or the first and second layers And the non-stretchable flexible material passes through the bridge portion parallel to the direction from the cup to the cup, and is laminated with the first layer and the second layer at the intermediate bridge portion. The core assembly is oriented so that it does not stretch,
At least a first layer portion and a second layer portion made of a fabric material are disposed outside the core assembly, on both the inside and outside of the core assembly, and the first layer portion is laminated on the inside of the core assembly. The second layer part is joined to the first layer part at the lower end of the lower periphery of the core assembly, and the second layer part encloses the periphery of the core assembly. Folded outwards, the joint between the outer layers of the first and second layers is located towards the lower periphery of the mold brasser so that it does not have an untreated end or an outer seam Mold bra characterized by being made.   The structure having an intermediate fabric layer between the core assembly and at least one of the first layer portion and the second layer portion made of a fabric material laminated with the core assembly. The mold brassiere according to 1 and 2.   The non-stretchable flexible material is a bi-directional, non-stretch fabric material made of knitted fabric, and passes through the bridge portion parallel to the cup-to-cup direction of the core assembly in the non-stretch direction. The mold brassiere according to claim 1, wherein the mold brassiere is oriented so as to spread.   The mold according to claim 1 or 2, wherein the layer made of a non-stretchable flexible material is provided between the first layer and the second layer made of a molded foam material. bra.   3. The mold according to claim 1, wherein the first layer and the second layer made of foam material have the same degree of spread as each other, and both layers define a periphery of the core assembly. 4. bra.   The core assembly is formed from a shape defined only by at least a part of the bra cup portion, the bridge and preferably the shoulder strap other than the chest strap (s). Mold bra as described in 1.   The mold brassiere according to claim 7, wherein the chest strap extends outward from both ends of the core assembly forming region provided in the mold brassier.   The two underwire structures are provided between the first layer and the second layer made of foam material, and each structure is formed adjacent to each bra cup portion. Mold bra.   The first layer and the second layer made of foam material are directly laminated to each other except for the non-stretchable flexible material and the two underwire structures. Or the mold brassiere of 2.   10. The mold brassiere according to claim 9, wherein the underwire structure includes a rigid elongated member and a casing made of a flexible material enclosing at least a part of the rigid elongated member. .   The mold brassiere according to claim 11, wherein the casing is made of a fabric material.   The mold brassiere according to claim 11, wherein the casing is bonded to one or each of the opposing surfaces of the first layer and the second layer made of foam material by an adhesive.   The molded brassiere according to claim 1, wherein the casing is a tubular sock-shaped body with a closed end, and an elongated member having the rigidity is disposed therein.   The mold brassiere according to claim 1 or 2, wherein the first layer and the foam layer (including a plurality of foam layers) have the same degree of spread.   The mold brassiere according to claim 1 or 2, wherein the second layer and the foam layer (including a plurality of foam layers) have the same degree of spread. A core assembly comprising at least a first layer of mold foam material, the core assembly defining at least one bra cup portion, each of the first layer portion and the second layer portion of at least a fabric material comprising: Arranged outside and outside the core assembly, respectively, inside the core assembly, the first layer is laminated inside the core assembly, and the second layer is at its lower end of the lower periphery of the core assembly, A mold brassier that is joined to the core assembly, and preferably to the first layer, and is configured to be folded back to the outside of the core assembly so as to enclose the core assembly.   A core assembly having a body approaching surface and an opposite body separating surface, the core assembly including two bra cup portions, and a core layer defining at least one upper periphery and at least one lower periphery, and the bra cup An outer fabric layer including a bridge portion extending between portions and defining an upper periphery and a lower periphery, wherein the outer fabric layer is around a portion of the lower periphery of the core assembly. Extending from the body separation surface to the body approaching surface of the core assembly, the outer fabric layer being folded outward along its lower end to form an outer flap, the outer flap being the body approaching of the core assembly A mold brassiere characterized in that it is configured to be fixed to a surface.   19. The mold brassiere of claim 18, wherein the outer fabric layer comprises at least one layer of mold foam material and at least one layer of fabric material.   The mold brassiere according to claim 18, wherein the core layer comprises at least one layer made of a mold foam material and at least one layer made of a fabric material.   The outer fabric layer extends from the outer flap to the body access surface of the core assembly around the lower end of the core assembly, at least partially past the body separation surface of the core assembly and around the upper end of the core assembly. The mold brassiere according to claim 18, wherein the mold brassiere is provided.   The mold brassiere of claim 18, wherein the outer fabric layer is secured along the upper end thereof to oppose the upper end of the body access surface of the core assembly.   The mold brassiere according to claim 18, wherein the outer flap is fixed to a body approaching surface of the core assembly so as to face a lower end of the core assembly.   24. The mold brassiere according to claim 23, wherein the outer flap is fixed to the body approaching surface of the core assembly opposite to the lower end of the core assembly by ultrasonic welding means.   23. The mold brassiere according to claim 22, wherein the outer fabric layer is fixed to a body access surface of the core assembly opposite to the lower end of the core assembly by bonding of an adhesive.   23. The mold brassiere according to claim 22, wherein the outer flap is fixed to a body approaching surface of the core assembly opposite to an upper end of the core assembly by ultrasonic welding means.   19. The mold brassiere according to claim 18, wherein the core assembly comprises an underwire structure including at least one arcuate strip having elasticity and rigidity.   28. The mold brassiere according to claim 27, wherein the underwire structure is fixed to a body separation surface of the core layer.   28. The mold brassiere according to claim 27, wherein the underwire structure further comprises a sock-shaped body enclosing the strip.   The mold brassiere according to claim 18, wherein the core assembly includes a chest strap portion fixed to the core layer of each bra cup portion toward the outside.   The mold brassiere according to claim 30, wherein the chest strap portion is fixed to the core layer in a fixing region.   The mold brassiere according to claim 30, wherein each of the chest strap portions is fixed to the core layer by sewing.   The mold brassiere according to claim 30, wherein each of the chest strap portions is fixed to the core layer by ultrasonic bonding.   The mold brassiere according to claim 30, wherein each chest strap includes at least one set of ultrasonic bonded fabric layers each having an upper end and a lower end.   The mold brassiere according to claim 34, wherein the fabric layers of the chest strap have the same degree of spread as each other and are joined toward each other toward the lower end.   36. The mold brassiere of claim 35, wherein the lower ends of each of the pair of fabric layers of the chest strap are folded back in the directions of each other and joined at a surface adjacent to the fabric layer.   The mold brassiere according to claim 30, wherein each chest strap comprises an elongated strap having elasticity.   38. The mold brassiere according to claim 37, wherein the elastic slender strap is made of natural rubber or synthetic rubber. The mold brassiere according to claim 18, wherein the core assembly includes a shoulder strap fixed to the core layer toward an upper end of the bra cup portion above each bra cup portion region.   The mold brassiere according to claim 18, wherein the outer fabric layer is configured to overlap with at least one fixing region extending from a body approaching surface of the core layer to a body separation surface of the core layer. .

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