Method for fabricating bra structure

Abstract

A method for fabricating a bra structure includes forming an integral 3D knitted-fabric substrate, and compression-molding the integral 3D knitted-fabric substrate to form the bra structure. The bra structure includes two cups connected to each other, each having an apex area and a peripheral area, wherein each the apex is proximate centrally middle area of an associated cup of the two cups and each the peripheral is proximate laterally outer area of the associated cup, and two wings respectively extending from the peripheral areas of the two cups, wherein ends of the wings, which are far away from the cups, are configured to be fastened together. The two cups and two wings are made of the integral 3D knitted-fabric substrate, and the integral 3D knitted-fabric substrate is compressed to have a larger thickness in the apex areas than in the peripheral areas and the wings.

What is claimed is: 
     
         1 . A method for fabricating a bra structure, comprising the following steps of:
 forming an integral 3D knitted-fabric substrate; and   compression-molding said integral 3D knitted-fabric substrate to form said bra structure;   wherein said bra structure comprises:   
       two cups connected to each other, each having an apex area and a peripheral area, wherein each said apex is proximate centrally middle area of an associated cup of the two cups and each said peripheral is proximate laterally outer area of said associated cup; and 
       two wings respectively extending from said peripheral areas of said two cups, wherein ends of said wings, which are far away from said cups, are configured to be fastened together;
 wherein said two cups and two wings are made of said integral 3D knitted-fabric substrate, and wherein said integral 3D knitted-fabric substrate is compressed to have a larger thickness in said apex areas than in said peripheral areas and said wings. 
 
     
     
         2 . The method according to  claim 1 , wherein after compression-molding, said 3D knitted-fabric substrate is gradually thinned from said apex areas to said peripheral areas. 
     
     
         3 . The method according to  claim 1 , wherein after compression-molding, a thickness of said 3D knitted-fabric substrate in each said peripheral area is equal to or smaller than a thickness of said 3D fabric substrate in said associated wing. 
     
     
         4 . The method according to  claim 1 , wherein after compression-molding, said 3D knitted-fabric substrate in each said wing is gradually thinned from one end of said associated wing, which is near said associated cup, to another end of said associated wing, which is far away from said associated cup. 
     
     
         5 . The method according to  claim 1 , wherein each said apex area is at a center of said associated cup and occupies 30-50% area of said cups. 
     
     
         6 . The method according to  claim 1 , wherein said 3D knitted-fabric substrate is 2 mm-10 mm thick in each said apex area, and wherein said 3D knitted-fabric substrate is 0.1 mm-5 mm thick in each said peripheral area and each said wing. 
     
     
         7 . The method according to  claim 1 , wherein said two cups are connected by a central member, and wherein said two cups, said central member and said two wings are integrally fabricated via compression-molding a single piece of said 3D knitted-fabric substrate. 
     
     
         8 . The method according to  claim 1 , wherein said 3D knitted-fabric substrate is a sandwich fabric or a spacer fabric. 
     
     
         9 . The method according to  claim 1 , wherein said 3D knitted-fabric substrate includes an upper fabric layer, a lower fabric layer, and a middle fabric layer between said upper fabric layer and said lower fabric layer, and wherein said middle fabric layer is formed by several pieces of waved yarn, and wherein crests of said waved yarn are connected with said upper fabric layer, and wherein troughs of said waved yarn are connected with said lower fabric layer. 
     
     
         10 . The method according to  claim 1 , wherein said waved yarn of said middle fabric layer is formed by monofilaments. 
     
     
         11 . The method according to  claim 9  wherein either said upper fabric layer or said lower fabric layer is knitted with shrinkable core-spun yarn. 
     
     
         12 . The method according to  claim 9 , wherein either said upper fabric layer or said lower fabric layer is knitted with polyester yarn, elastic yarn, nylon yarn, cotton yarn, rayon yarn, or a combination thereof. 
     
     
         13 . The method according to  claim 1  further comprising the step of forming an outer covering layer stuck to an outer surface of said 3D knitted-fabric substrate, wherein said 3D knitted-fabric substrate and said outer covering layer are jointly compression-molded to integrally form said two cups connected to each other and said two wings extended from said cups. 
     
     
         14 . The method according to  claim 13 , wherein said outer covering layer is a knitted fabric, a woven fabric, a woolen fabric, a nylon fabric, a rayon fabric, a polyester fabric, or a cotton fabric. 
     
     
         15 . The method according to  claim 1 , wherein jacquard, embossing, printing or a combination thereof is formed on at least one surface of said 3D knitted-fabric substrate. 
     
     
         16 . The method according to  claim 1 , wherein bordering elements are sewed on a portion of edges of said cups and said wings, and wherein steel wires are disposed in lower edges of inner sides of said cups. 
     
     
         17 . The method according to  claim 1  further comprising the step of forming two shoulder straps, wherein one end of each said shoulder strap is connected with an upper edge of said associated cup, and wherein another end of said shoulder strap is connected with an upper edge of said associated wing connected with said associated cup. 
     
     
         18 . The method according to  claim 1 , wherein ends of said two wings, which are far away from said cups, are fastened together with a hook and eye fastening mechanism, a hook and loop fastening mechanism, or an elastic ribbon.