USOO6997.775B2
`
`(12) United States Patent
`Jagaric et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 6,997,775 B2
`*Feb. 14, 2006
`
`(54)
`
`(75)
`
`BRA PAD CONSTRUCTION
`
`Inventors: Andrea Jagaric, New York, NY (US);
`Nathalie Martinet, New York, NY
`(US); Judith Grigor, New York, NY
`(US); Bull Lau, Kwai Chung (HK)
`
`(73)
`
`Assignee: Victoria's Secret Stores, Inc., New
`York, NY (US)
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`This patent is Subject to a terminal dis
`claimer.
`
`(21)
`(22)
`(65)
`
`(63)
`
`(51)
`
`(52)
`
`Appl. No.: 11/054,185
`
`Filed:
`
`Feb. 9, 2005
`
`Prior Publication Data
`US 2005/0208875 A1
`Sep. 22, 2005
`
`Related U.S. Application Data
`Continuation-in-part of application No. 10/911,269,
`filed on Aug. 4, 2004, and a continuation-in-part of
`application No. 10/804,403, filed on Mar. 19, 2004.
`
`Int. Cl.
`(2006.01)
`A4 IC 3100
`U.S. Cl. ............................... 450/57; 450/39; 2/267
`
`(58) Field of Classification Search .................. 450/39,
`450/38, 54–57; 2/455, 267,268,463, 92;
`623/7, 8; 156/245; 264/257, 258, 291, 292,
`264/294, 145,148, 152-157, 160, 163,554
`See application file for complete Search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`2,664,571 A *
`1/1954 Kempel ....................... 450/57
`2.834,352 A *
`5/1958 Murry .......
`... 450/57
`2,867,818 A
`1/1959 Creamer ........................ 623/7
`2.896,631 A *
`7/1959 Wilfred .....
`... 450/51
`3,620.222 A * 11/1971 Lester .......
`... 450/57
`4,008,029 A * 2/1977 Shokite .....
`... 425/157
`4,080,416 A * 3/1978 Howard .....
`... 264/258
`4,250,137 A * 2/1981 Riedler .............
`... 264/554
`6,042.608 A
`3/2000 Ishikawa et al. ............... 623/7
`6,881,123 B1
`4/2005 Klakauskas .................. 450/39
`* cited by examiner
`Primary Examiner-Gloria M. Hale
`(74) Attorney, Agent, or Firm-Colucci & Umans; Peter C.
`Michalos, Angelo Notaro
`(57)
`ABSTRACT
`
`
`
`A method of manufacturing a bra pad having a thicker
`Summit area, as well as the pad itself, includes holding a
`sheet of resilient and formable material of uniform thick
`neSS, Such as thermoplastic foam, and forming the sheet to
`have a graduated thicker Summit area corresponding to each
`Summit of a bra or bra-like garment for including the pad,
`and a Surrounding thinner area. Each pad thus has a thicker
`Summit area for extending over the Summits of the breasts.
`
`36 Claims, 10 Drawing Sheets
`
`102
`
`105
`
`108
`
`116
`
`109
`
`123
`
`NIKE-1038
`p. 1
`
`

`

`U.S. Patent
`U.S. Patent
`
`Feb. 14, 2006
`Feb. 14, 2006
`
`Sheet 1 of 10
`Sheet 1 of 10
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`US 6,997,775 B2
`US 6,997,775 B2
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`14
`
`10
`
`16
`
`;0 1
`
`Sa- Na AN
`FIG. 1
`FIG. 1
`
`18
`8
`
`12
`12
`
`18
`18
`
`
`
`
`
`FIG. 2
`
`p. 2
`
`

`

`U.S. Patent
`U.S. Patent
`
`Feb. 14, 2006
`Feb. 14, 2006
`
`Sheet 2 of 10
`Sheet 2 of 10
`
`US 6,997,775 B2
`US 6,997,775 B2
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`
`
`__f 24
`
`14
`
`30
`
`10
`
`26
`
`16
`
`18
`
`FIG.3
`
`~
`
`19
`
`16a
`
`FG. 4
`FIG. 4
`
`17
`7
`
`p. 3
`
`

`

`U.S. Patent
`U.S. Patent
`
`Feb. 14, 2006
`Feb. 14, 2006
`
`Sheet 3 of 10
`Sheet 3 of 10
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`US 6,997,775 B2
`US 6,997,775 B2
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`34
`34
`
`32
`32
`
`19
`49
`
`47
`17
`
`
`
`FIG. 5
`
`48
`
`44
`
`16a
`16a
`
`40
`
`33
`33
`
`48
`
`Ag
`
`32
`
`49
`
`=
`
`47
`
`16a
`
`F.G. 6
`FIG. 6
`
`46
`46
`
`42
`42
`
`AG
`46
`
`J
`/
`
`p. 4
`
`

`

`U.S. Patent
`
`Feb. 14, 2006
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`Sheet 4 of 10
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`US 6,997,775 B2
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`
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`16a, 32
`
`FIG. 8
`
`p. 5
`
`

`

`U.S. Patent
`U.S. Patent
`
`Feb. 14, 2006
`Feb. 14, 2006
`
`Sheet 5 of 10
`Sheet 5 of 10
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`US 6,997,775 B2
`US 6,997,775 B2
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`52
`92
`
`54
`54
`
`19
`
`1 N.
`
`17
`
`FG. 9
`FIG. 9
`
`p. 6
`
`

`

`U.S. Patent
`U.S. Patent
`
`Feb. 14, 2006
`Feb. 14, 2006
`
`Sheet 6 of 10
`Sheet 6 of 10
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`US 6,997,775 B2
`US 6,997,775 B2
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`440
`114
`110 114
`
`
`
`113
`113
`
`115
`115
`
`108
`108
`109
`109
`
`i
`x
`y
`ty
`
`
`
`116
`116
`
`111
`411
`
`
`
`
`
`p. 7
`
`p. 7
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`

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`U.S. Patent
`U.S. Patent
`
`Feb. 14, 2006
`Feb. 14, 2006
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`Sheet 7 of 10
`Sheet 7 of 10
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`US 6,997,775 B2
`US 6,997,775 B2
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`110
`110
`
`109 —
`
`109
`
`120
`120
`
`121
`
`FIG. 12
`FIG. 12
`
`p. 8
`
`p. 8
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`

`

`U.S. Patent
`
`Feb. 14, 2006
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`Sheet 8 of 10
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`US 6,997,775 B2
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`1O2
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`1O5
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`
`
`p. 9
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`

`

`U.S. Patent
`
`Feb. 14, 2006
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`Sheet 9 of 10
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`US 6,997,775 B2
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`119
`N
`
`FIG. 14
`
`FIG 15
`
`116
`
`124
`
`113
`
`117
`108
`
`11 O
`
`11 O
`
`p. 10
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`

`

`U.S. Patent
`U.S. Patent
`
`Feb. 14, 2006
`Feb. 14, 2006
`
`Sheet 10 0f 10
`Sheet 10 of 10
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`US 6,997,775 B2
`US 6,997,775 B2
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`
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`108
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`116
`
`109
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`123
`
`FIG. 17
`
`110
`
`p. 11
`
`p. 11
`
`

`

`1
`BRA PAD CONSTRUCTION
`
`US 6,997,775 B2
`
`2
`Other patents of interest to the present invention are:
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This is a continuation-in-part of application Ser. No.
`10/804,403 filed Mar. 19, 2004 entitled A BRASSIERE
`AND RELATED BREAST CUP CONSTRUCTION, and
`application Ser. No. 10/911,269 filed Aug. 4, 2004 entitled
`PADS HAVING ACENTRAL SUMMIT FOR BRAS AND
`THE LIKE, both of which are incorporated here by refer
`CCC.
`
`FIELD AND BACKGROUND OF THE
`INVENTION
`
`15
`
`The present invention relates generally to the field of bras
`and related garments, and in particular to a new and useful
`method and pad product having a thicker central Summit
`area for use in bras, camisoles, slips, Swimsuits or any other
`breast covering garment where padding is desired.
`It is known to provide resilient pads in bras to accentuate
`the figure. Padded bras are not always desirable, however.
`Bras without pads are also known but these have limited
`ability to enhance the figure.
`Recently, materials for the manufacture of brassieres have
`been developed that allow for more convenient manufacture
`of a brassiere.
`Traditionally the cup forms of a brassiere have, in order
`to introduce a three dimensional cup shape therein, consisted
`of several panels which have been sewn or otherwise affixed
`together. With the advent of moldable synthetic materials
`Such as foam and Synthetic fabric materials, cup forms are
`now moldable into a Single panel of material or assembly of
`panels of materials to define the three dimensional cup form.
`The ability to mold material to define a cup form of a
`desirable shape has allowed the manufacturing process to be
`Simplified or accelerated. AS well as providing Support to a
`breast of a wearer, the cup forms are often also required for
`additional benefits to the wearer.
`Some women prefer that a brassiere conceals Some if not
`all of the regions of the breasts. For modesty, it is desirable
`that the nipples of a wearer at all times remain unnoticeable
`from the exterior of the brassiere and any over garment that
`may be worn by the wearer. Molded cup forms of brassieres
`that are currently available generally do not provide for any
`enhancement to the cup form for Such purpose. Molded cup
`forms are normally of a Substantially even thickness acroSS
`the body of the cup and while it may be possible to increase
`the thickness of the cup in order to thereby reduce the
`visibility of the nipples of a wearer to the exterior of the
`brassiere, Such increasing thickneSS may add to the cost of
`manufacture of the brassiere. Furthermore it is undesirable
`for increased thickness of the brassiere to exist at its perim
`eter if the presence of the brassier entirely, is to be as
`unobtrusive as possible. It is desirable for the perimeter of
`the bra to be relatively thin So that it has the appearance of
`feathering in with the skin of the wearer.
`The patent prior art contains various relevant examples.
`U.S. Pat. No. 4,013,750 discloses a method for making
`brasserie pad pre-forms which can produce a bra pad having
`a thicker central region than its Outer regions. A mold
`apparatus is utilized which produces a Substantially conical
`pad of polyester fibers with a summit which is thicker than
`the periphery of the conical pad. Also see U.S. Pat. No.
`3,947,207.
`
`25
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`U.S. Pat No.
`
`2,507,543
`2,565,400
`2,616,093
`2,627,368
`2,702,769
`2,845,974
`3,164,655
`3,186,271
`3,311,007
`3,417,755
`3,464,418
`3,502,083
`3,800,650
`4,351,211
`5,017,174
`5,299,483
`
`Inventor(s)
`
`Prager
`Skeoch
`Talalay
`Jantzen
`Alderfer
`Ashton et al.
`Howard et al.
`Kaiser
`McGee
`Howard et al.
`Silverman
`Howard et al.
`Schroder
`AZZolini
`Gowrylow
`Ber-Fong.
`
`U.S. Pat. No. 2,627,368 to Jantzen discloses a method of
`making curved pad filler in which a mold is provided with
`a concave part for receiving a part of a blank of material. A
`means are provided for pushing or pressing the blank into
`the concave part of the mold. A Sharp moving knife is passed
`between the mold and the pressing element, resulting in a
`curved shoulder pad filler and uniformly tapered portions
`extending from the thick end to a feathered edge.
`U.S. Pat. No. 3,186,271 to Kaiser discloses an apparatus
`and method for producing shaped articles consisting of foam
`Such as Sponges and cushions.
`Neither the Jantzen nor the Kaiser patents teach or Suggest
`a sheet of material having a pair of thicker areas positioned
`So that they correspond to the location where the central
`Summit of the bra pad will be when it is completed.
`U.S. Pat. Nos. 3,164,655, 3,417,755 and 3,502,083 to
`Howard et al. disclose molding of a blank to give it a desired
`shape and contour but fail to teach or Suggest forming a
`foam sheet of material having a pair of thicker areas posi
`tioned So that their position corresponds to the location
`where the central Summit of the bra pad will be when it is
`completed after thermoforming.
`U.S. Pat. No. 2,616,093 to Talalay discloses an apparel
`pad Such as a shoulder or breast pad, which as a concavo
`complex shape with a thickness graduated from a relatively
`thick portion to a relatively thin portion using different
`pieces of material to build up the pad.
`U.S. Pat. No. 3,311,007 to McGee discloses an apparatus
`for producing at least one contoured Surface upon a foamed
`material pad but is very different from the present invention
`because it teaches the effects of cutting a foam member
`which is compressed by a male mold portion against an
`opposite flat mold portion, and thus, the contour of the
`Shaved material is based on the shape of the male mold
`portion. McGee fails to teach contouring of an article based
`on a foam material being pressed to cover and penetrate a
`receSS before the foam material is shaved.
`U.S. Pat. No. 2,727,278 to Thompson discloses a method
`of making a molded composite bra, in which the thickness
`of filler material in each bra pad has a Summit thickness
`greater than the thickneSS Surrounding the Summit. The
`process for making the molded bra is however very different
`from the present invention and does not teach shaving a
`material compressed into a receSS.
`The remaining patents disclose other pad-related technol
`ogy which are distinguishable from the invention, and they
`are enclosed for general reference.
`
`p. 12
`
`

`

`
`
`US 6,997,775 B2
`
`FIG. 3 is a view similar to FIG. 2 with the shaving
`
`FIG. 9 is a view of a pair of bra pads constructed in
`
`4
`3
`BRIEF DESCRIPTION OF THE DRAWINGS
`A need remains for an improved pad, as well as a method
`
`
`
`
`for producing such a bra pad, which adds some padding
`In the drawings:
`
`
`effect to the bra but in a very subtle manner so that the
`FIG. 1 is a side elevation view of an open shaving mold
`
`
`
`
`
`padding is barely perceptible.
`
`
`5 used to make the pads and to practice the method of the
`
`
`
`present invention with a sheet of polyurethane foam material
`SUMMARY OF THE INVENTION
`therebetween;
`
`FIG. 2 is a view similar to FIG. 1 of the shaving mold in
`It is an object of the present invention to provide a method
`
`
`
`
`
`
`
`its closed position and with a shaving device in an initial
`
`
`
`of manufacturing a bra pad having a thicker central summit
`10 position of use;
`
`
`
`area, as well as the pad itself and the apparatus for manu­
`
`
`
`
`
`
`facturing the pad, comprising holding a sheet of uniform
`
`apparatus in a final position;
`
`
`
`thickness, resilient and formable material, such as thermo­
`FIG. 4 is a side elevational view of a shaved or graduated
`
`
`
`plastic foam, and forming the sheet to have one or two
`
`
`
`
`sheet component of the bra pad in accordance with the
`
`
`
`thicker summit areas corresponding to the summits of the
`
`15 present invention;
`
`
`
`bra or bra-like garment (here called a bra for any garment in
`FIG. 5 is a view similar to FIG. 4 of an assembled
`
`
`
`
`which the pads are ultimately used). Each pad thus has a
`
`
`
`pre-form of the bra pad according to the present invention;
`
`
`thicker summit area for extending over the summits of the
`
`
`
`FIG. 6 is an exploded view of a forming mold with the
`
`
`breasts of a wearer of the bra.
`
`
`
`pre-form bra pad between the mold halves thereof;
`
`
`
`A further object of the invention is to provide the bra pad
`20
`
`
`
`component for FIG. 7 is a sectional view of a formed
`
`
`made in accordance with the method of the invention.
`
`
`
`creating two foam pads of the present invention;
`
`
`
`
`
`A further object of the present invention is to provide a bra
`
`
`
`FIG. 8 is a top plan view of the formed component of FIG.
`
`
`
`or brassiere which includes molded cup forms which address
`7;
`
`
`
`the above mentioned limitations of the prior art or which will
`
`
`
`
`
`
`
`at least provide the public with a useful choice.
`25
`
`
`accordance with the present invention;
`
`
`
`
`
`It is a further object of the present invention to provide a
`
`
`FIG. 10 is an exploded sectional view through an assem­
`
`
`
`molded cup form for a brassiere including a laminated
`
`
`
`bly of panels prior to being formed and laminated together
`
`
`
`
`structure of a first panel of a flexible foam material and a
`
`
`
`for the purposes of providing the bra cup, according to
`
`
`second panel material, the first and second panels being
`
`
`
`
`invention; of the present 30 another embodiment
`
`
`substantially coextensive to each other and define a breast
`
`
`
`FIG. 11 is a sectional view through an assembly of panels
`
`
`
`
`cup perimeter shape, wherein the first panel of flexible foam
`
`of FIG. 10, prior to being molded;
`
`
`
`
`material is of varying thickness, providing a zone of greater
`FIG. 12 illustrates two panel assemblies of the invention,
`
`
`
`
`thickness at a region or regions away from the perimeter as
`
`
`
`prior to being laminated together and prior to being formed
`
`
`
`
`
`compared to regions of lesser thickness more proximate to
`
`
`
`elements; 35 into a three dimensional cup form by molding
`
`
`
`
`the perimeter. Preferably the zone of greater thickness is
`FIG. 13 is a plan view of a cup form having been molded
`
`
`
`
`located where, in use, a nipple of the wearer of the bra
`
`
`
`and trimmed to define a perimeter suitable for incorporation
`
`
`
`incorporating the breast cup is normally located.
`as part of a brassiere;
`
`
`
`Preferably the first panel is of a uniform thickness save for
`FIG. 14 is a sectional view through an alternative con-
`
`
`
`
`
`
`
`the zone of greater thickness, the zone of greater thickness
`11;
`
`
`
`to that of FIG. 40 figu ration of an assembly of panels
`
`
`having a maximum thickness at the center of the zone and
`
`FIG. 15 is an alternative to FIG. 14;
`
`
`
`
`being of a gradually reducing thickness toward the perimeter
`
`
`FIG. 16 is a perspective view of a brassiere incorporating
`of the zone.
`
`the cup forms of the invention;
`The second panel is disposed to the first major side of the
`
`
`
`
`
`FIG. 17 is a sectional view through section 17-17 of
`
`
`
`
`first panel, to form a coextensive planar assembly which is
`
`
`
`
`to that according 45 FIG. 13 wherein the assembly of panels
`
`
`molded to define a cup shape into the planar assembly and
`
`shown in FIG. 12 is provided; and
`
`
`
`
`then any excess non-cup shape defined regions are removed
`FIG. 18 is a sectional view through section 17-17 of
`
`
`
`from the assembly.
`
`
`
`FIG. 13 wherein an assembly of panels as shown in FIG. 14
`
`
`
`
`This invention may also be said broadly to comprise in the
`is provided.
`
`parts, elements and features referred to or indicated in this 50
`
`
`
`
`DESCRIPTION OF THE PREFERRED
`
`
`
`
`
`specification, individually or collectively, and any or all
`EMBODIMENTS
`
`
`
`combinations of any two or more of said parts, elements or
`features, and where specific integers are mentioned herein
`
`
`
`
`which have known equivalents in the art to which this
`
`Referring now to the drawings, in which like reference
`
`
`
`invention relates, such known equivalents are incorporated
`
`
`
`
`
`
`numerals are used to refer to the same or functionally similar
`55
`
`herein as if individually set forth. For the purposes of
`
`
`
`FIG. 1
`
`
`
`elements, shows a shaving mold generally designated
`
`
`illustrating the invention, there is shown in the drawings a
`
`
`
`
`
`
`10 comprising a lower shaving mold portion 12 and an upper
`form which is presently preferred, it being understood,
`
`
`
`
`
`
`shaving mold portion 14 with a thickness of e.g. 7 mm
`however, that this invention is not limited to the precise
`
`
`
`
`
`
`Although polyu rethane foam 16 therebetween. polyu rethane
`
`arrangements shown.
`
`
`
`60 foam is illustrated, any thermo plastic foam material can be
`
`
`
`
`The various features of novelty
`
`
`
`
`used according which characterize the to the present invention and in fact any
`
`
`invention are pointed
`
`formable material out with particularity in the claims can be used which is resilient and is
`
`
`annexed to and forming a part of this
`
`
`
`capable disclosure. For a better of being formed into a permanent yet resilient
`
`
`
`
`
`
`
`
`understanding of the invention, its operating advantages and three-dimensional shape. The shaving mold halves or por­
`
`
`
`
`
`
`
`specific objects attained by its uses, reference is made to the 65 tions 12 and 14 can be made of wood, plastic, metal or other
`
`
`
`
`
`
`
`
`accompanying drawings and descriptive matter in which a suitable rigid material. Lower mold half 12 contains a pair
`
`
`
`
`
`
`
`preferred embodiment of the invention is illustrated. of recesses 18 in its upper surface which are positioned so
`
`p. 13
`
`

`

`
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`US 6,997,775 B2
`
`6
`5
`
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`that they are near the central summit of each bra pad to thick, which completely encircle each summit area 17 and
`
`
`
`
`
`
`
`
`
`
`
`eventually be made in accordance with the present inven­have an inner area of e.g. 2 mm thick, so that a bra
`tion.
`
`
`manufactured with or containing the bra pads of the present
`
`
`
`
`
`
`FIG. 2 illustrates the shaving mold in its closed
`
`
`
`invention position will have a slightly thicker area 17, for example 3
`with the resilient formable sheet of material 16 pressed
`
`
`
`
`
`5 mm, over the summit of each breast summit, and thinner
`
`
`down onto the lower mold half so that some of the material
`
`
`
`material, e.g. tapering down to 1 mm, in thinner areas 19.
`
`
`
`of sheet 16 is pressed into each recess 18 but also a thickness
`
`
`
`FIG. 9 illustrates the pair of pads 52,54 which are cut from
`
`
`
`of material, for example at 20, remains along the shaving
`
`
`
`the molding of FIGS. 7 and 8 by cutting the surrounding
`mold halves.
`
`
`thinner area around the summit areas and are ready for use
`
`
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`10 in a bra, in a conventional manner. The pads 52,54 may also
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`A shaving apparatus generally designated 22 is also
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`be used in other garments for covering the torso of a woman
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`illustrated in FIG. 2 which comprises a movable carriage 24,
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`and which contain bra or bra-like structures such as bathing
`which carries a blade, knife or shaving member 26 that
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`suits, camisoles, and the like.
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`extends transversely the full width of material sheet 16
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`(perpendicular to the plane of FIG. 2). Blade 26 is also
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`With reference to FIG. 16 there is shown a bra or brassiere
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`positioned intermediate to the upper and lower shaving mold 15
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`101 including two breast cup constructions 102 which have
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`halves 14, 20 respectively so that a portion of the layer 20
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`been engaged to various other components of the brassiere
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`can be neatly shaved from the sheet 16. For this purpose,
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`101 such as for example body straps 103 and over the
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`member 26 may be heated (e.g., a cutting wire), may be
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`shoulder straps 104.
`mounted for movement like a band saw, may be reciprocally The breast cups 102 are engaged together at an interme­
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`vibrated back and forth like an electric knife or oscillated in 20 diate connection 105. The breast cups have a perimeter 106
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`any other appropriate way for cutting the foam material of and a body portion 107 inward of the perimeter 106. The
`sheet 16.
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`breast cup is of a form having been molded and to a large
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`extent is of a single structure comprising or consisting of a
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`With the shaving apparatus 22 activated to vibrate, heat or
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`plurality of overlying and preferably substantially coexten-
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`otherwise activate member 26, the carriage 24 is moved in
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`sive panels defining the assembly of the cup form. It is
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`the direction of arrow A and across the sheet 16 until it
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`reaches its final position
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`however shown in FIG. 3. In this position a envisaged that the breast cup of the present inven-
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`tion may have disposed therefrom or engaged thereto by
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`slice 30 has been made in sheet 16 thus achieving the
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`means of sewing or otherwise affixing additional panels
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`shaving effect. FIG. 4 shows the shaved component or
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`which may extend from the perimeter 106 of the cup form
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`graduated sheet 16a which is removed from the shaving
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`30 or may be associated with the cup form 102 intermediate of
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`mold after it is opened and which contains a pair of thicker
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`the perimeter 106 and define part of the body portion 107 of
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`material areas 17 at a summit e.g. of 5.5 mm thickness,
`the cup form.
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`surrounded by thinner material areas 19, e.g. 1 mm thick.
`The two breast cups 102 of the brassiere are substantial
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`FIG. 8 illustrates in dotted line the two summit areas 17 on
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`mirror image about the intermediate connection 105. Ref-
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`the rectangular and graduated sheet 16a which, in FIG. 8,
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`35 erence has been and will now be made to a single breast cup
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`has already been attached to as second outer cup sheet 32,
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`formed or to be formed from precursor materials, however,
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`e.g. 2 mm thick, shown in FIG. 5 which is also made of
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`it will be appreciated that such reference is also reflective of
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`polyurethane foam material. Shaved or graduated sheet 16a
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`the provision of the same form of breast cup for the other cup
`forms an inner cup sheet.
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`to be incorporated into a brassiere.
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`As shown in FIG. 5, each of the cup sheets 16a and 32
`With reference to FIG. 13, there is shown a breast cup
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`may also include a laminate or fabric covering 33 and 34, 40
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`102.The breast cup is molded to a three dimensional form,
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`respectively, made, for example, of nylon or nylon with
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`such as a cup form appropriate for the purpose of supporting
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`spandex. This is a conventional covering for foam pads used
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`and covering in bras. It is important that in accordance with the present at least part of the breast of the wearer. The
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`invention, the laminate
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`breast 33 be on the outer inner surface of cup 102 has been molded from materials which, with
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`the inner cup sheet 16a so that it is not shaved away by the
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`45 reference to FIG. 10, may include a first panel of flexible
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`shaving apparatus 22 and that the outer cup sheet 32 have its
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`foam material 108, preferably a second panel of flexible
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`laminate 34 on its outer surface. This leaves the inner
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`foam material 109, a covering panel of flexible fabric
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`surfaces of panels 16a and 32 free to receive sprayed on
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`material 110 and a second panel of covering flexible fabric
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`glue. After the glue is sprayed on the two surfaces are
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`material 111. In an alternative form however as for example
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`pressed against each other to produce the single composite
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`50 shown in FIG. 14, the breast cup may be defined by a first
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`pre-form illustrated in FIG. 5.
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`panel of flexible foam material 108, the covering flexible
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`fabric material 110 and the second panel of covering flexible
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`In FIG. 6 a thermo-forming mold 40 is generally desig­
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`material without there being a provision of a second panel of
`nated 40 and, as illustrated, includes a lower female mold
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`flexible foam material 109.
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`portion or half 42 and an upper mold half or portion 44. The
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`pre-form 16a, 32 is positioned between the mold halves 42, 55
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`While reference herein is made to such panels being
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`44 with the summits 17 centered on a pair of recesses 46
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`directly affixed to each other preferably by laminating such
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`formed in the lower female mold half 42 which also corre­
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`as by heat and/or adhesive laminating, it will be appreciated
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`spond with a pair of male projections 48 formed in the male
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`that panels or panel assemblies consisting of plies of sheet
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`mold half 44. Each projection 48 may also include a slight
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`material may be provided intermediate of those panels.
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`recessed or flattened area 49 or an area which is shaped to 60
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`With reference to FIG. 10, there is shown a sectional view
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`keep from completely crushing the summit areas 17 of the
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`of the panels of the breast cup of the present invention
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`inner cup sheet 16a.
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`consisting of a first panel of a flexible foam material 108 and
`The mold halves are heated to the for
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`a second panel of a flexible appropriate level foam material 199.
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`molding the pre-form into a finished molding illustrated in Disposed
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`and preferably substantially coextensive with
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`FIGS. 7 and 8. The finished molding has a pair of spaced 65 the first panel of foam material 108 there is provided a panel
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`apart thicker summit areas 17, e.g. 5-6 mm thick, sur­of flexible fabric material 110. The laminated assembly of
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`rounded by the thinner surrounding areas 19, e.g. 1 mm the panel 108 and 110 may be provided from roll stock
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`p. 14
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`7
`material to be used in the method of the present invention.
`The fabric material 110 may for example be nylon and the
`foam material may for example be polyurethane. The foam
`panel 109 includes a first major surface 113 which is
`exposed and a Second major Surface 114 against which the
`fabric panel 110 is laminated. In this precursor form of the
`assembly of panel 108 and 110, such an assembly is in an
`unmolded condition and in a natural State assumes a flat or
`planar condition.
`A second panel of flexible foam material 109 in assembly
`for example with a second panel of flexible fabric material
`111 is also provided. The second panel of foam material 109
`includes an exposed major Surface 115 and a covered major
`surface 116 against which the second flexible fabric panel is
`laminated. Like the assembly of panels 108 and 110, the
`panels 109 and 111 may be provided in a precursor form
`from a feed of roll Stock and in a natural State assume a
`Substantially planar or flat condition.
`The size of the resulting rectangular cut precursor panel
`assemblies is Such that when Subjected to molding in a
`molding machine to define the three dimensional cup form
`thereof, it is of a Sufficiently large size to define the entire
`desired cup form. The first panel of foam material 108 is
`preferably of a greater thickness X than the thickness Y of
`the second panel of foam material 109.
`With reference to FIG. 11, the first panel of foam material
`108 is formed to define a Zone of increased thickness 116.
`This Zone of increased thickness 116 is provided interme
`diate of the perimeter 117 of the assembly of panels 108,
`110. The Zone of increased thickness 116 is also provided
`inward (inward of the perimeter) of that region of the panel
`assembly 108, 110 into which a molded cup form to ulti
`mately define a breast cup of the present invention will be
`defined.
`Accordingly when formed to a cup form with the other
`panels to define the breast cup of the present invention as
`shown in FIG. 13, the Zone of increased thickness 116 is
`provided inward from the perimeter 106 of the breast cup. In
`the preferred form the first panel of flexible foam material
`prior to being molded is formed to be of a substantially
`constant thickness Zsave for the Zone of increased thickneSS
`116. In the most preferred form such contouring is by the
`Shaving of the panel to define the contoured shape on the
`first major side 113 of the precursor panel of flexible foam
`material 108 as disclosed in greater detail above.
`After having been formed/shaped the then contoured first
`major surface 113A of the first panel of flexible foam
`material 108 will include the Zone of increased thickness 116
`extending from regions of reduced thickneSS at or towards
`the perimeter of the panel assembly 108, 110. The Zone of
`increased thickneSS may for example be a dome shape as for
`example shown in FIG. 11 and of a constant diameter D.
`Alternatively the shape may be of a gradually undulation
`as for example shown in FIG. 14. So that the existence of
`this Zone of increased thickness in the final version of the
`brassiere is to a large extent disguised, it is preferred that the
`Zone of increased thickness 116 has a maximum thickneSS or
`Summit Substantially centrally within the Zone and provides
`a reduction in thickness towards the perimeter 119 of the
`Zone. Such reduction in thickness may be by a linear
`tapering, for example, shown in FIG. 14. In the most
`preferred form the second panel of flexible foam material
`109 is not subjected to any contouring. The first panel of
`flexible foam material 108 is subjected to contouring but
`only on the non-fabric Side of the first panel, opposite to
`panel 110.
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`US 6,997,775 B2
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`8
`The assembly of panels 108, 110 is then laminated with
`the assembly of panels 109, 111 in a molding device as for
`example shown in FIG. 12. The molding device consists of
`two mold portions 120 and 121 each having formed therein
`a profile or contour of a kind to introduce into the precursor
`assemblies of panels the three dimensional or cup form of
`the breast cup. The upper mold portion 120 for example
`includes a concave relief and the lower portion 121 provides
`a convex upstand of a Substantially complimentary shape to
`the concave receSS of the upper mold portion 120.
`The assemblies of panels 108, 110 and 109, 111 are
`positioned intermediate of the mold portions in a manner So
`that they overly each other in an appropriate condition
`(preferably coextensively) whereupon the two mold portions
`are then brought together. The two mold portions are pref
`erably heated. Additional adhesive may be placed interme
`diate of the assemblies So that both pressure adhesive and
`heat will ensure that a good laminated bond can be estab
`lished between the two subassemblies. Upon the formation
`of the cup form into the precursor panel or panel assemblies,
`the cup form can be trimmed from the molded precursor
`panels to define a perimeter shape Such as for example
`shown in FIG. 13. Part of the perimeter of the cup form 106
`may include an additional compression Zone 123 where the
`overlying panels of material have been Subjected to more
`enhanced compression than that of the main body portion
`107. Such additional compression Zones may serve the
`purpose of allowing for the cup to define a flange useful for
`the purposes of Securing the cup to other components of the
`brassiere.
`With reference to FIG. 13, it can be seen that upon the
`forming of a three dimensional form or cup form in the
`precursor materials as well as laminating the precursor
`materials together, will locate the Zone of increased thick
`ness 116 inward from the perimeter 106 of the breast cup
`102. The Zone of increased thickness 116 is provided within
`the body portion 107 of the breast cup 102. This Zone of
`increased thickness is positioned to correspond with the
`usual location of the nipple of the breast of a wearer of a
`brassiere incorporating the breast cup 102.
`With reference to FIG. 17 there is shown a cross sectional
`view through section 17-17 of FIG. 13 wherein the Zone of
`increased thickness 116 is shown to be provided to enhance
`the overall thickness of the breast cup in Such Zone. Thick
`ness B is greater than thickness C. While the thickness is
`perhaps only marginally greater at B than at C, a further
`enhancement to reduce the visibility of a nipple of a wearer
`through the breast cup is as a consequence of the higher
`density of material at the Zone of increased thickness 116.
`Once the breast cup has been formed, the Zone of increased
`thickness 116 will compress slightly Such compression
`enhancing the material density at this Zone thereby reducing
`the likelihood of observing the presence of the nipple
`through the breast cup. In the preferred form the thickness
`E is Substantia