Brassiere

Abstract

A molded brassiere, a core assembly of a first layer of molded foam material laminated with a second layer of molded foam material, defining two breast cup regions and an intermediate bridge region. At least one layer of flexible material having non-stretch properties adjacent one of or intermediate of and laminated with the layers of molded foam material at the bridge region, and oriented so that across the bridge region parallel to the cup to cup direction the material is non-stretchable. A first and second layer of the fabric is laminated with the core assembly on the respective interior and exterior side and preferably encases the core assembly. A third layer joined at least to the first layer at or near the lowermost perimeter of the core assembly is wrapped over that perimeter and extends towards the remaining perimeter thereof.

1 . A moulded brassiere, including a core assembly of at least a first layer of moulded foam material preferably laminated with a second layer of moulded foam material, said core assembly defining two breast cup regions and
 an intermediate bridge region extending there between, and   wherein at least one layer of flexible material having non-stretch properties is provided adjacent one of or intermediate of and laminated with said first and second layer of moulded foam material at said bridge region, said flexible material having non-stretch properties oriented so that across the bridge region parallel to the cup to cup direction said core assembly is non-stretchable; and   a first and second layer, each of at least a fabric material, is disposed outside of and each laminated with said core assembly on a respective interior and exterior side of said core assembly to preferably encase said core assembly, and   a third layer joined at least to said first layer at or near the lower most perimeter of said core assembly, said third layer wrapped over the lower most perimeter and extending to or towards the remaining perimeter of said core assembly.   
   
   
       2 . A moulded brassiere including,
 a core assembly of at least a first layer of moulded foam material preferably laminated with a second layer of moulded foam material, said core assembly defining two breast cup regions and an intermediate bridge region extending there between and wherein at least one layer of flexible material having non-stretch properties is provided adjacent one of or intermediate of and laminated with said first and second layer of moulded foam material at said bridge region, said flexible material having non-stretch properties oriented so that across the bridge region parallel to the cup to cup direction said core assembly is non-stretchable, and   a first and second layer, each of at least a fabric material, disposed outside of said core assembly on the respective interior and exterior sides of said core assembly, said first layer laminated to the interior side of said core assembly,   said second layer joined at its lower edge at the lower perimeter of the core assembly, to said first layer and folded over to wrap around said core assembly to the exterior side of said core assembly,   the join between said first and second exterior layers located toward the bottom periphery of said moulded brassiere, having no raw edges or sewing presenting exteriorly.   
   
   
       3 . A moulded brassiere according to  claim 1 , wherein there is an intermediate fabric layer between said core assembly and at least one of said first and second layers of fabric that is/are laminated with said core assembly. 
   
   
       4 . A moulded brassiere according to  claim 1 , wherein said flexible material having non stretch properties is a woven fabric material with bi-directional non-stretch properties and is oriented such that the non stretch orientation extends across said bridge region parallel to the cup to cup direction of said core assembly. 
   
   
       5 . A moulded brassiere according to  claim 1 , wherein said layer of flexible material having non stretch properties is captured intermediate of said first and second layer of moulded foam material. 
   
   
       6 . A moulded brassiere according to  claim 1 , wherein said first and second layers of foam are coextensive with each other and both define the perimeter of the said core assembly. 
   
   
       7 . A moulded brassiere according to  claim 1 , wherein said core assembly is of a shape defining only the breast cups, said bridge and preferably at least in part said shoulder straps, but not chest strap(s). 
   
   
       8 . A moulded brassiere according to  claim 7 , wherein said chest straps extend outwardly from each side of said core assembly provided region of said moulded brassiere. 
   
   
       9 . A moulded brassiere according to  claim 1 , wherein two underwire structures are provided intermediate of said first layer and said second layers of foam, one each adjacent the breast cup regions. 
   
   
       10 . A moulded brassiere according to  claim 1 , wherein said first layer and said second layer of foam are laminated directly to each other save for said flexible material having non-stretch properties and said two underwire structures. 
   
   
       11 . A moulded brassiere according to  claim 9 , wherein said underwire structure comprises a rigid elongate member and a flexible material casing about at least part of said rigid elongate member. 
   
   
       12 . A moulded brassiere according to  claim 11 , wherein said casing is a fabric material. 
   
   
       13 . A moulded brassiere according to  claim 11 , wherein said casing is adhered to one or each of the facing surfaces of said first and second layers of foam by an adhesive material. 
   
   
       14 . A moulded brassiere according to  claim 1 , wherein said casing is a tubular sock within which said rigid elongate member is located, the sock having closed distal ends. 
   
   
       15 . A moulded brassiere according to  claim 1 , wherein said first layer and said foam layer or the foam layers are coextensive each other. 
   
   
       16 . A moulded brassiere according to  claim 1 , wherein said second layer and said foam layer or the foam layers are coextensive each other. 
   
   
       17 . A moulded brassiere including,
 a core assembly of at least a first layer of moulded foam material said core assembly defining at least one breast cup region   and a first and second layer, each of at least a fabric material, disposed outside of said core assembly on the respective interior and exterior sides of said core assembly, said first layer laminated to the interior side of said core assembly,   said second layer joined at the interior side of core assembly at its lower edge at the lower perimeter of the core assembly to said core assembly (and preferably to the first layer) and folded over to wrap around said core assembly to the exterior side of core assembly.   
   
   
       18 . A method of manufacturing a moulded component assembly for a brassiere comprising or including:
 affixing to a core of at least a first layer of moulded foam material (and preferably a second layer of foam material) and preferably with which and/or between which there is sandwiched a layer of flexible material having non stretch properties, a layer of fabric material at the inner side of the core and adjacent the lower perimeter of the core,   wrapping the layer of fabric material around at least part of the lower perimeter to the exterior of the core and affixing the layer to at least part of other perimeter regions of the core.   
   
   
       19 . A moulded brassiere, including
 a core assembly having a proximal face and an opposed distal face, said core assembly comprising
 a core layer defining two breast cup regions, and at least one upper edge and at least 
 one lower edge, and 
 a bridge region extending between the breast cup regions; 
   a distal fabric layer, defining an upper edge and a lower edge, said distal fabric layer extending from the distal face of the core assembly around at least part of the lower edge of the core assembly to the proximal face of the core assembly, said distal fabric layer being folded over distally along its lower edge to form a distal flap, said distal flap being secured to the proximal face of the core assembly.   
   
   
       20 . A moulded brassiere according to  claim 19 , wherein distal fabric layer is comprised of at least one layer of moulded foam and at least one layer of fabric. 
   
   
       21 . A moulded brassiere according to  claim 19 , wherein the core layer is composed of at least one layer of moulded foam and at least one layer of fabric. 
   
   
       22 . A moulded brassiere according to  claim 19 , wherein the distal fabric layer extends from the distal flap, around the lower edge of the core assembly, across at least part of the distal face of the core assembly, and around the upper edge of the core assembly, to the proximal face of the core assembly. 
   
   
       23 . A moulded brassiere according to  claim 19 , wherein the distal fabric layer is secured along its upper edge towards the upper edge of the proximal face of the core assembly. 
   
   
       24 . A moulded brassiere according to  claim 19 , wherein the distal flap is secured to the proximal face of the core assembly towards the lower edge of the core assembly. 
   
   
       25 . A moulded brassiere according to  claim 24 , wherein the distal flap is secured to the proximal face of the core assembly towards the lower edge of the core assembly by means of ultrasonic welding. 
   
   
       26 . A moulded brassiere according to  claim 23 , wherein the distal fabric layer is secured to the proximal face of the core assembly towards the upper edge of the core assembly by adhesive bonding. 
   
   
       27 . A moulded brassiere according to  claim 23 , wherein the distal fabric layer is secured to the proximal face of the core assembly towards the upper edge of the core assembly by ultrasonic welding. 
   
   
       28 . A moulded brassiere according to  claim 19 , wherein the core assembly includes an underwire structure comprising at least one resiliently rigid arcuate elongate member. 
   
   
       29 . A moulded brassiere according to  claim 28 , wherein the underwire structure is secured to the distal face of the core layer. 
   
   
       30 . A moulded brassiere according to  claim 28 , wherein the underwire structure further comprises a sock surrounding the elongate member. 
   
   
       31 . A moulded brassiere according to  claim 19 , wherein the core assembly includes a chest strap member secured to the core layer outwardly of each breast cup region. 
   
   
       32 . A moulded brassiere according to  claim 31 , wherein the chest strap member is secured to the core layer at a securing zone. 
   
   
       33 . A moulded brassiere according to  claim 31 , wherein each of the chest strap members is secured to the core layer by sewing. 
   
   
       34 . A moulded brassiere according to  claim 31 , wherein each of the chest strap members is secured to the core layer by ultrasonic bonding. 
   
   
       35 . A moulded brassiere according to  claim 31 , wherein each chest strap comprises at least a pair of ultrasonically bonded fabric layers each having an upper and lower edge. 
   
   
       36 . A moulded brassiere according to  claim 35 , wherein the fabric layers of the chest strap are coextensive of each other and are bonded to each other towards their lower edges. 
   
   
       37 . A moulded brassiere according to  claim 36 , wherein the lower edge of each of the pair of fabric layers of the chest strap are folded in towards each other and bonded at their adjacent faces. 
   
   
       38 . A moulded brassiere according to  claim 31 , wherein each chest strap includes a resilient elongate strap. 
   
   
       39 . A moulded brassiere according to  claim 38 , wherein the resilient elongate strap is composed of natural or synthetic rubber. 
   
   
       40 . A moulded brassiere according to  claim 19 , wherein the core assembly includes a shoulder strap secured to the core layer towards its upper edge above each breast cup region. 
   
   
       41 . A moulded brassiere according to  claim 19 , wherein the distal fabric layer overlaps at least one of the securing zones where it extends from the proximal face of the core layer to the distal face of the core layer.