Brassiere cup plastic strip support and manufacturing method therefor

Abstract

A brassiere cup support and method of manufacturing the support and cup therewith. The support comprises a plastic support in the shape of one or more of an underwire, an uplifting panel, a reinforcing pad, a sternum region, or an extended fish bone like pattern capable of providing desired “firmness” or “hardness” along its length and thereby providing desired degrees of support therealong. The plastic support comprises at least one layer of polymer and at least one layer of a second material, wherein the at least one layer of polymer and the at least one layer of the second material are in the form of a sandwich. Preferably, the plastic support comprises at least two layers of polymer and at least one layer of the second material, with an adhesive applied therebetween to secure the layers to one another.

1 . A brassiere cup plastic support comprising at least one layer of polymer and at least one layer of a second material; wherein the plastic support is in the shape of one or more of an underwire, an uplifting panel, a reinforcing pad, a sternum region, or an extended fish bone like pattern. 
     
     
         2 . The brassiere cup plastic support of  claim 1 , wherein the plastic support comprises at least two layers of the polymer and the at least one layer of the second material is formed sandwiched between the at least two layers of the polymer. 
     
     
         3 . The brassiere cup plastic support of  claim 1 , wherein the second material is selected from a group comprising a polymer, a fabric and a foam. 
     
     
         4 . The brassiere cup plastic support of  claim 1 , wherein the plastic support has a constant number of layers of the polymer and second material, so as to have a uniform crosswise dimension along its length. 
     
     
         5 . The brassiere cup plastic support of  claim 1 , wherein the plastic support has a variable number of layers of at least one of the polymer and second material along its length, so as to have a varied crosswise dimension along its length. 
     
     
         6 . The brassiere cup plastic support of  claim 5 , wherein the dimension graduates from a minimum at one end of the plastic support to a maximum at the other end of the plastic support. 
     
     
         7 . The brassiere cup plastic support of  claim 1 , wherein the polymer is selected from the group of an ethylene vinyl acetate (EVA), a resin, or a poly vinyl chloride (PVC). 
     
     
         8 . The brassiere cup plastic support of  claim 1 , wherein the plastic support is formed by cutting a desired shape from the plastic strip. 
     
     
         9 . The brassiere cup plastic support of  claim 1 , wherein the plastic support is formed by molding. 
     
     
         10 . The brassiere cup plastic support of  claim 1 , further including an adhesive material positioned at the interface between each layer of polymer and the at least one layer of the second material, for causing said layers to adhere to each other. 
     
     
         11 . The brassiere cup plastic support of  claim 1  located in an edge region of a brassiere cup. 
     
     
         12 . The brassiere cup plastic support of  claim 1  located between layers of material from which the brassiere cup is formed. 
     
     
         13 . A brassiere having a pair of the brassiere cups of  claim 1 . 
     
     
         14 . A method of manufacturing a brassiere part with a plastic support, comprising the steps of:
 (a) providing at least one layer of a polymer;   (b) providing at least one layer of a second material on top of the layer of polymer;   (c) applying an adhesive at the interface between the at least one layer of polymer and the at least one layer of the second material, for causing said layers to adhere to each other and form a layered plastic support;   (d) cutting the plastic support from the layered plastic support, where the size and shape of the plastic support cut from the layered plastic support corresponds to a desired size and shape for the plastic support of the brassiere part after application of heat as noted by Step (h);   (e) providing a mold for forming the brassiere part with a trough;   (f) laying down in the mold a brassiere part material from which the brassiere part is to be formed, such that some of the brassiere part material extends into the trough;   (g) positioning the plastic support cut from the layered plastic support upon the brassiere part material that extends into the trough; and   (h) applying heat to the mold sufficient to soften the plastic support so that it consolidates into a desired shape as defined by the shape of the trough, melts into a continuous strip and forms a whole piece of material together with the brassiere part material.   
     
     
         15 . The method of  claim 14  wherein step (b) provides the second material from a group comprising a foam, a fabric and a polymer. 
     
     
         16 . The method of  claim 14  wherein the brassiere part is a cup and the plastic support is an underwire, and where during step (h) the plastic material consolidates in the trough to form the underwire so as to have either a variable or uniform width and/or depth from one end of the underwire to the other. 
     
     
         17 . The method of  claim 14 , wherein step (a) provides multiple layers of polymer. 
     
     
         18 . The method of  claim 14 , wherein steps (a) and (b) each provide multiple layers of their respective polymer and second material, until a plastic material of desired shape and thickness is complete. 
     
     
         19 . The method of  claim 14 , wherein step (f) provides further layers of material for laying down, from which the brassiere cup is to be formed, so as to cover the plastic material in the trough before step (h). 
     
     
         20 . The method of  claim 14  wherein the brassiere part is a cup and the plastic support is in the shape of one or more of an uplifting panel, a reinforcing pad, a sternum region, or an extended fish bone like pattern.