Brassiere and injection molded components therefor

Abstract

An injection molded component for incorporation with other components to form a padded brassiere. The component comprises an injection molded material unitarily defining two breast cups and a bridge connecting the two breast cups. At each breast cup the molded material varies in thickness to define a pad-like formation for the brassiere.

1 . An injection molded component for incorporation with other components to form a padded brassiere said component comprising an injection molded material unitarily defining two breast cups and a bridge connecting the two breast cups wherein at each breast cup the molded material varies in thickness to define a pad like formation for said brassiere 
   
   
       2 . A molded brassiere component as claimed in  claim 1  wherein the material is latex. 
   
   
       3 . A molded brassiere component as claimed in  claim 1  wherein the material includes latex. 
   
   
       4 . A molded brassiere component as claimed in  claim 1  wherein the material includes latex and a stabilising agent. 
   
   
       5 . A molded brassiere component as claimed in  claim 1  wherein a precursor to the material is a liquid latex. 
   
   
       6 . A molded brassiere component as claimed in  claim 1  wherein the material includes a coloring agent. 
   
   
       7 . A molded brassiere component as claimed in  claim 1  wherein at each breast cup the variation in thickness defines the greatest thickness at a centrally located zone of the breast cup and with gradual reduction in thickness from the zone towards the periphery of the breast cup. 
   
   
       8 . A molded brassiere component as claimed in  claim 1  wherein the component consists of said injection molded material and at least one layer of other material. 
   
   
       9 . A molded brassiere component as claimed in  claim 8  wherein the at least one layer of other material is injection molded latex. 
   
   
       10 . A molded brassiere component as claimed in  claim 8  wherein the at least one layer of other material is a ply of fabric laminated to the injection molded material. 
   
   
       11 . A molded bra component as claimed in  claim 1  wherein the injection molded material is captured between two covering plies. 
   
   
       12 . A molded brassiere component as claimed in  claim 11  wherein the two covering plies are fabric plies. 
   
   
       13 . A molded brassiere component as claimed in  claim 11  wherein the two covering plies are fabric plies laminated to the injection molded material. 
   
   
       14 . A molded brassiere component as claimed in  claim 8  wherein the at least one layer of other material is a reinforcing web extending across the bridge region of the brassiere component. 
   
   
       15 . A molded brassiere component as claimed in  claim 14  wherein the reinforcing web is of a unidirectionally substantially non-stretchable material. 
   
   
       16 . A molded brassiere component as claimed in  claim 15  wherein the substantially non-stretchable material is gauze. 
   
   
       17 . A molded brassiere component as claimed in  claim 15  wherein the substantially non-stretchable material is a plastic film. 
   
   
       18 . A molded brassiere component as claimed in  claim 14  wherein the reinforcing web is embedded in said molded material. 
   
   
       19 . A molded brassiere component as claimed in  claim 1  wherein shoulder straps and/or clasps are attached to the molded brassiere component. 
   
   
       20 . A molded brassiere component as claimed in  claim 1  wherein the molded material defines also at least part, the chest band wings. 
   
   
       21 . A molded brassiere component as claimed in  claim 1  wherein the molded material defines also at least part, the over the shoulder straps. 
   
   
       22 . A molded brassiere component as claimed in  claim 1  wherein an underwire structure is embedded in molded material contiguous each cup. 
   
   
       23 . A molded brassiere component as claimed in  claim 1  wherein at least one of the inner and outer surfaces of the molded material is to define at least part of the exposed surfaces of the brassiere. 
   
   
       24 . A molded brassiere component as claimed in  claim 23  wherein defined at the exposed surfaces of the at least one of the inner and outer surfaces of the molded material is at least one of an embossing and aperture and recess. 
   
   
       25 . A molded brassiere component as claimed in  claim 1  wherein the molded material is defined by a liquid injection molding process. 
   
   
       26 . A molded brassiere component as claimed in  claim 1  wherein the layer is unitary and homogenous. 
   
   
       27 . A molded brassiere component manufactured in a single injection molding process. 
   
   
       28 . A component of a bra assembly comprising a unitary layer of injection molded material defining two breast cups and a bridge portion therebetween, the component at each breast cup being of a varying thickness to define a pad like structure. 
   
   
       29 . A brassiere that includes the component as claimed in  claim 1 . 
   
   
       30 . A brassiere as claimed in  claim 29  wherein over the shoulder straps are engaged to the component. 
   
   
       31 . A brassiere as claimed in  claim 29  wherein the component consists of two different injection molded material compositions co-molded to each other and that each offer a different characteristic to the other. 
   
   
       32 . A brassiere as claimed in  claim 31  wherein the different characteristic relates to different colors. 
   
   
       33 . A brassiere as claimed in  claim 31  wherein the different characteristic relates to different strength properties. 
   
   
       34 . A brassiere as claimed in  claim 31  wherein the different characteristic relates to different textures. 
   
   
       35 . A garment that includes the component as claimed in  claim 1 . 
   
   
       36 . A method of producing a brassiere component comprising the steps of:
 (i) injecting a moldable and settable material into a mold that defines a cavity with opposed walls for forming the concave and convex sides of two breast cups and a bridge extending between said breast cups wherein the opposed walls at each of the breast cups are of varying separation from each other   (ii) allowing the material to set in the mold,   (iii) ejecting the set material from the mold,   (iv) repeating steps (i) to (iii) cyclically.   
   
   
       37 . A method as claimed in  claim 36  wherein the mold is preheated prior to step (i). 
   
   
       38 . A method as claimed in  claim 36  wherein the material is a heat curable material. 
   
   
       39 . A method as claimed in  claim 36  wherein the material includes latex. 
   
   
       40 . A method as claimed in  claim 36  wherein prior to ejection, the injected settable material is positioned in a mold cavity that includes space for the injection of a second material to be affixed to the settable material. 
   
   
       41 . A method as claimed in  claim 36  wherein prior to injecting the moldable and settable material into the mold, a ply of material is introduced into the mold that is to be embedded into the settable material.