Brassiere

Abstract

A molded bra of a layered assembly of a plurality of plies of flexible moldable material. The layered assembly generally defines two molded breast cups a bridge intermediate of the two breast cups and a chest band from which each of the molded breast cups are disposed. The assembly includes an outward ply of a fabric material presenting a first outermost surface of the bra to the convex side of the breast cups of the bra, and an inward ply disposed to the opposite side of the assembly where the first outermost ply is presented and presenting a second outermost surface of the bra to the concave side of the breast cups of the bra. The layered assembly includes at least the inward and the outward ply at the entire perimeter about the bra regions and wherein the outward ply has been folded at the perimeter to provide a hem affixed to the inward ply.

1 . A molded bra defined in part by a layered assembly of a plurality of plies of flexible moldable material, said layered assembly generally defining bra regions of two molded breast cups a bridge intermediate of said two breast cups and a chest band from which each of said molded breast cups are disposed, said assembly including 
 a. a first of said plies (herein after “outward ply”) of a fabric material presenting a first outermost surface of said bra to the convex side of the breast cups of said bra, and    b. at least one other of said plies (herein after “inward ply”) disposed to the opposite side of said assembly where said outward ply is presented, presenting a second outermost surface of said bra to the concave side of said breast cups of said bra    wherein the layered assembly includes at least the inward and outward ply at the entire perimeter about the bra regions and wherein said outward ply has been folded at the perimeter to provide a hem thereof affixed to the inward ply.    
   
   
       2 . A molded bra as claimed in  claim 1  wherein said hem of said outward ply is adhesively affixed to said inward ply.  
   
   
       3 . A molded bra as claimed in  claim 1  wherein the hem is provided about the entire perimeter about said bra regions.  
   
   
       4 . A molded bra as claimed in  claim 1  wherein said perimeter of said bra regions generally consists of (a) a lower perimeter extending along the bottom edge of said chest band, (b) an outer perimeter extending along the upper edge of at least the regions inward of the distal ends of the chest band and transitioning to extend adjacent or along the outer perimeter edges of each of said breast cups, and (c) a neckline perimeter extending along the upper edges of each of said breast cups.  
   
   
       5 . A molded bra as claimed in  claim 1  wherein the outward ply is parallel to but not laminated with the plies of the remained of the assembly, save for at said hem.  
   
   
       6 . A molded bra as claimed in  claim 1  wherein the assembly, at each of the breast cups includes at least one ply of a foam material.  
   
   
       7 . A molded bra as claimed in  claim 6  wherein the foam material provides a flexibly rigid cup form.  
   
   
       8 . A molded bra as claimed in  claim 1  wherein the chest band, at least at regions extending inwardly from the distal ends towards said breast cups, includes no foam plies.  
   
   
       9 . A molded bra as claimed in  claim 1  wherein the chest band includes no foam plies.  
   
   
       10 . A molded bra as claimed in  claim 1  wherein said outward ply and said inward ply are coextensive with each other.  
   
   
       11 . A molded bra as claimed in  claim 1  wherein said inward ply is of a single piece of material.  
   
   
       12 . A molded bra as claimed in  claim 1  wherein said inward ply is of a single piece of fabric material.  
   
   
       13 . A method of forming a hem at a perimeter of part of a chest band of a bra of a kind including a layered assembly of a plurality of plies of flexible moldable material said layered assembly generally defining bra regions of two molded breast cups, a bridge intermediate of said two breast cups and a chest band from which each of said molded breast cups are disposed, said method including, locating a rigid substrate intermediate of 
 a. a chest band region located region of a first of said plies (herein after “outward ply”) of a fabric material presenting a first outermost surface of said bra to the convex side of the breast cups of said bra, and    b. a chest band region located region of at least one other of said plies (herein after “inward ply”) disposed to the opposite side of said assembly where said first outermost ply is presented, presenting a second outermost surface of said bra to the concave side of said breast cups of said bra,    said substrate providing part of its perimeter immediately adjacent the edge of said chest band where said hem is to be formed to define a rigid edge for the folding there over of a hem region of said outward ply to engage said outward ply to the inward ply, and removing the rigid substrate from between said inward and outward plies.    
   
   
       14 . A method as claimed in  claim 13  wherein said outward ply is engaged to said inward ply by adhesion bonding at said hem region.  
   
   
       15 . A method as claimed in  claim 13  wherein said hem region of said outward ply is engaged to said inward ply by the use of an intermediate adhesive tape.