CA1059721A - Method of making brassiere cup - Google Patents
Method of making brassiere cupInfo
- Publication number
- CA1059721A CA1059721A CA247,782A CA247782A CA1059721A CA 1059721 A CA1059721 A CA 1059721A CA 247782 A CA247782 A CA 247782A CA 1059721 A CA1059721 A CA 1059721A
- Authority
- CA
- Canada
- Prior art keywords
- dies
- pad
- contour
- resin
- thermoplastic resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41C—CORSETS; BRASSIERES
- A41C5/00—Machines, appliances, or methods for manufacturing corsets or brassieres
- A41C5/005—Machines, appliances, or methods for manufacturing corsets or brassieres by moulding
Abstract
Abstract of the Disclosure A brassiere cup of a resilient fibrous material intermixed with a resin formed by cooperating male and female die parts with the male die having a pad formed over the apex. The die parts are heated to a temperature above the softening temperature of the resin while said pad is maintained at a temperature below the softening temperature of the resin whereby the cup upon removal from the mold will have a thin peripheral portion and the material at the apex will expand to provide an apex of greater thickness.
Description
1~9t72~
This invention relates to an improved method of making brassiere cups. This method is especially useful in the manufacture of a brassiere cup from a soft fibre board material having a wall thickness which is sub-stantially greater at the outer or apex portion than at the peripheral portion adjoining the base.
A brassiere cup is required generally to be light and soft and have high air permeability and sufficient thickness. Prior brassiere cups made of sponge material such as of polyurethane resin or the like almost meet this requirement but have the disadvantage that it discolors and becomes yellow during use and gives a feeling of a physical disorder. This has resulted in the tendency to fabricate brassiere cups made of fibrous material. According to a prior art method, however, thc fibrous~brassiere cup is like a felt which is thin, hard and lacking in resiliency and it has been difficult to produce a thickJ lightJ soft and resilient cup. Moreover, it is almost impossible to produce a fibrous brassiere CUp having a wall thickness which is substantially greater at the apex portion than at the peripheral portion of the base.
Accordingly, an object of this invention is to provide an improved method of manufacturing a brassiere cup from a soft fibre board material, which can easily produce a brassiere cup having the variable thickness as described above, and without ~he addition of any special treatment step.
Known fibrous brassiere cups are press-formed from a soft fibre board material previously mixed with suitable thermo-plastic resin between male and female dies which are heated at least above the softening temperature of the thermoplastic resin and form a predetermined molding cavity there-between.
In accordance with this invention there is provided a method of making a brassiere cup having a wall thickness which is greater at the apex portion than at the peripheral portion, by press-shaping a soft fibre board intermixed with thermoplastic resin with a set of male and female dies which are heated to a temperature substantially higher than the softening tempera-ture of said thermoplastic resin and forming a predetermined mold cavity when ``~
'~ -1-" ~OS972~
closed, a pad o~ rounded configuration overlying the apex portion of said male die, whereby the gap between the top of said projection and the female die becomes significantly less than the wall thickness of the product at the corresponding portion when the dies are closed, and the temperature of said pad is maintained substantially lower than the softening temperature of said thermoplastic resin.
According to a feature of this invention, a rounded projection or pad is provided at the apex portion of the male die so that the gap between said projection and the female die in the engaged condition becomes signi-ficantly less than the wall thickness of the product at the corresponding -1~597Zl position, and the temperature of this projection is maintained substantially lower than the softening te~perature of the above thermo-plastic resin.
According to another feature of this invention, a horizon~al step portion having a contour which is substantially similar to bu~ greater than the contour of the aperture of the female die is provided around this aperture and the soft fibre board material is cut in a shape of this contour of the horizontal step portion and fit in said portion, whereby the peripheral portion of the material is not pressed between the horizontal planes of the dies in the engaged condition.
Other objects and features of this invention will be described in more detail hereinunder with reference to the accompanying drawings.
In the drawings:
Figure 1 is a cross sectional side view representing an example of fibrous brassiere cup made in accordance with this invention;
Figure 2 is a cross sectional side view representing one step of process according to a prior art method;
Figure 3 is a cross sectional side view representing one step of process according to an embodiment of the method of this invention and corresponding to the step of Figure 2;
Pigure~ is a cross sectional side view representing the similar step of process according to another embodiment of the method of this invent ion; and Figure 5 is a cross sectional side view illustrating the dimensional relationships of the female die used in the embodiment of Figure 4.
Throughout the drawings, like reference numerals are used to denote corresponding components.
Figure 1 shows a vertical sectional contour of typical brassiere cup 1 which is conveniently made in accordance with the method of this invention from a soft fibre board material. As shown, the brassiere cup 1 has a wall thickness which is greatest at the outer or apex portion 11 and 1~59~Z~L
and least at the peripheral portion 12. According to a prior art method, the such brassiere cup 1 was made by hot press working of a flat fibre board 5 shown by dashed line in Figure 2 and impregnated or intermixed with thermoplastic resin. Molding was accomplished by a set of heated stamping dies 2 and 3 having a mold cavity 4 having substa~tially the same geometry as the product, as shown in Figure 2. The stamping dies were heated at a temperature higher than the softening temperature of the thermoplastic resin but much lower than that of the fibre board material and, therefore, the fibres filling the cavity 4 would be fixed in shape as it was with the fused thermoplastîc resin when cooled.
In practice, however, when the soft fibre board 5 is pressed by the male die 2, the fibre board 5 encounters the greatest horizontal tension and resultant high compression at the apex 21 of the male di~ 2 and reduces its thickness to leave a crevice at the bottom 31 of the female die 3 as shown in Figure 2, Thus, a brassieTe cup having variable wall thickness as shown in Figure l could no$ be made satisfactorily in accordance with the prior art method.
Figure 3 shows an embodiment of the stamping dies used in the method of this invention. In this embodiment, the metallic dies 2 and 3 are somewhat similar to those of the prior art as shown in Figure 2, but the male die 2 is provided with a central projection 6 at the apex 21. The projection 6 has a rounded shape with the outer surface approaching the bottom 31 of the female die 3 to reduce the mold cavi~y signficantly. In this embodiment, the projection 6 is made of fluorine resin and adhered to the die 2 by a refractory adhesive.
As an example, when the fibre board 5 is made of polyester fibres having a softening temperature above 200C and impregna~ed with latex resin having softening temperature of 130 to 140C, the male die 2 is heated to about 185C and the female die 3 is heated to about 150C by conventional heating means such as electric heating elements or a heated fluid flowing ~L~597~21 through the dies. Under this conditionJ the surface temperature of the projection 6 made of fluorin0 resin is maintained at 100 to 120C throughout the operation. Accordingly, the la~ex resin existing in the polyester fibre layer 1 which is pressed by the projection 6 is not heated up to its softening temperature, while that existing in the layer 1 which is pinched between the both die surfaces is heated up ~o its softening temperature and fusPd to fix the shape of the fibre layer in the compressed condition. When the product is discharged from the dies and cooled, therefore the central porti~n 11 of the fibre layer 1 expands due to its resiliency, while the peripheral portion 12 main~ains its molded shape. This results in a variable wall thickness of the brassiere cup as shown in Figure 1.
While a fluorine resin has been given as an example~ any material having relstivel~ low thermal conductivity can be used as the material of the projection 6. Wood and paper board are suitable for this purpose but have relatively short lifetimes due to carbonization. Also, the projection 6 can be made of thermally conductiYe material such as metal, which may be integral with the die 2, and cooled with a suitable coolant flowing there-through, Figure~4 and 5 show another feature of this invention proposed to further impro~e the effect of the projection 6, In this embodiment, the female die 3 has a flat step portion 32 around the aperture edge. The contour of ~his step portion 32 is similar to the con~our of the aperture edge and the depth of the step is a little less than the thickness of the fibre board 5 to be used. The object of this step portion is to prevent the peripheral portion of the fibre board 5 from bcing pinched between the both dies 2 and 3 and block its free movement therebetween. This results in reduction of horizontal tension of the fibre layer 1 in the central portion 11 during the molding operations and consequently increases the expansion of the layer 1.
It has been found preferable to select the width of the step ~5~72~L
portion 32 so tha~ it is substantially inversely proporti~nal to the horizontal distance to the corresponding aperture edge ~rom the extreme bottom 31 of the female die 3. This rela~ion is expressed as follows in accordance with Figure 5.
A/B = b/a The fibre board 5 is previously cut in a contour which is substantially same as the contour of the step portion 32 and fits therein as shown in Figure 5.
As described above, in the brassiere cup made by the method of this invention, the fibre layer 1 does not encounter the thermal-setting effect of the thermoplastic resin at the central portion 11 and is very soft as compared with the prior cups. Thus, a brassiere cup which is light and soft, having high air permeability, and gives no feelîng of physical disorder can be manufactured easily in accordance with this invention.
While ~he fibre material and the thermoplastic resin referred to ~bove have the desired tempera~ure characteristics, any other similar materials having similar ~emperature characteristics can be used in this method. For example, fibre boards of poly~nide, polyuTethane, polyethylene, polypropylene and like synthetic resin fibres, natural cotton and like natural fihres and mixtures thereof, impregnated or intermixed with variDus thermoplastic resin adhesives can be used. Moreover, instead of impregnating the fibre board with adhesive resin, a fibre board intermixed with ~hermo-plastic resin fibres may be used conveniently.
This invention relates to an improved method of making brassiere cups. This method is especially useful in the manufacture of a brassiere cup from a soft fibre board material having a wall thickness which is sub-stantially greater at the outer or apex portion than at the peripheral portion adjoining the base.
A brassiere cup is required generally to be light and soft and have high air permeability and sufficient thickness. Prior brassiere cups made of sponge material such as of polyurethane resin or the like almost meet this requirement but have the disadvantage that it discolors and becomes yellow during use and gives a feeling of a physical disorder. This has resulted in the tendency to fabricate brassiere cups made of fibrous material. According to a prior art method, however, thc fibrous~brassiere cup is like a felt which is thin, hard and lacking in resiliency and it has been difficult to produce a thickJ lightJ soft and resilient cup. Moreover, it is almost impossible to produce a fibrous brassiere CUp having a wall thickness which is substantially greater at the apex portion than at the peripheral portion of the base.
Accordingly, an object of this invention is to provide an improved method of manufacturing a brassiere cup from a soft fibre board material, which can easily produce a brassiere cup having the variable thickness as described above, and without ~he addition of any special treatment step.
Known fibrous brassiere cups are press-formed from a soft fibre board material previously mixed with suitable thermo-plastic resin between male and female dies which are heated at least above the softening temperature of the thermoplastic resin and form a predetermined molding cavity there-between.
In accordance with this invention there is provided a method of making a brassiere cup having a wall thickness which is greater at the apex portion than at the peripheral portion, by press-shaping a soft fibre board intermixed with thermoplastic resin with a set of male and female dies which are heated to a temperature substantially higher than the softening tempera-ture of said thermoplastic resin and forming a predetermined mold cavity when ``~
'~ -1-" ~OS972~
closed, a pad o~ rounded configuration overlying the apex portion of said male die, whereby the gap between the top of said projection and the female die becomes significantly less than the wall thickness of the product at the corresponding portion when the dies are closed, and the temperature of said pad is maintained substantially lower than the softening temperature of said thermoplastic resin.
According to a feature of this invention, a rounded projection or pad is provided at the apex portion of the male die so that the gap between said projection and the female die in the engaged condition becomes signi-ficantly less than the wall thickness of the product at the corresponding -1~597Zl position, and the temperature of this projection is maintained substantially lower than the softening te~perature of the above thermo-plastic resin.
According to another feature of this invention, a horizon~al step portion having a contour which is substantially similar to bu~ greater than the contour of the aperture of the female die is provided around this aperture and the soft fibre board material is cut in a shape of this contour of the horizontal step portion and fit in said portion, whereby the peripheral portion of the material is not pressed between the horizontal planes of the dies in the engaged condition.
Other objects and features of this invention will be described in more detail hereinunder with reference to the accompanying drawings.
In the drawings:
Figure 1 is a cross sectional side view representing an example of fibrous brassiere cup made in accordance with this invention;
Figure 2 is a cross sectional side view representing one step of process according to a prior art method;
Figure 3 is a cross sectional side view representing one step of process according to an embodiment of the method of this invention and corresponding to the step of Figure 2;
Pigure~ is a cross sectional side view representing the similar step of process according to another embodiment of the method of this invent ion; and Figure 5 is a cross sectional side view illustrating the dimensional relationships of the female die used in the embodiment of Figure 4.
Throughout the drawings, like reference numerals are used to denote corresponding components.
Figure 1 shows a vertical sectional contour of typical brassiere cup 1 which is conveniently made in accordance with the method of this invention from a soft fibre board material. As shown, the brassiere cup 1 has a wall thickness which is greatest at the outer or apex portion 11 and 1~59~Z~L
and least at the peripheral portion 12. According to a prior art method, the such brassiere cup 1 was made by hot press working of a flat fibre board 5 shown by dashed line in Figure 2 and impregnated or intermixed with thermoplastic resin. Molding was accomplished by a set of heated stamping dies 2 and 3 having a mold cavity 4 having substa~tially the same geometry as the product, as shown in Figure 2. The stamping dies were heated at a temperature higher than the softening temperature of the thermoplastic resin but much lower than that of the fibre board material and, therefore, the fibres filling the cavity 4 would be fixed in shape as it was with the fused thermoplastîc resin when cooled.
In practice, however, when the soft fibre board 5 is pressed by the male die 2, the fibre board 5 encounters the greatest horizontal tension and resultant high compression at the apex 21 of the male di~ 2 and reduces its thickness to leave a crevice at the bottom 31 of the female die 3 as shown in Figure 2, Thus, a brassieTe cup having variable wall thickness as shown in Figure l could no$ be made satisfactorily in accordance with the prior art method.
Figure 3 shows an embodiment of the stamping dies used in the method of this invention. In this embodiment, the metallic dies 2 and 3 are somewhat similar to those of the prior art as shown in Figure 2, but the male die 2 is provided with a central projection 6 at the apex 21. The projection 6 has a rounded shape with the outer surface approaching the bottom 31 of the female die 3 to reduce the mold cavi~y signficantly. In this embodiment, the projection 6 is made of fluorine resin and adhered to the die 2 by a refractory adhesive.
As an example, when the fibre board 5 is made of polyester fibres having a softening temperature above 200C and impregna~ed with latex resin having softening temperature of 130 to 140C, the male die 2 is heated to about 185C and the female die 3 is heated to about 150C by conventional heating means such as electric heating elements or a heated fluid flowing ~L~597~21 through the dies. Under this conditionJ the surface temperature of the projection 6 made of fluorin0 resin is maintained at 100 to 120C throughout the operation. Accordingly, the la~ex resin existing in the polyester fibre layer 1 which is pressed by the projection 6 is not heated up to its softening temperature, while that existing in the layer 1 which is pinched between the both die surfaces is heated up ~o its softening temperature and fusPd to fix the shape of the fibre layer in the compressed condition. When the product is discharged from the dies and cooled, therefore the central porti~n 11 of the fibre layer 1 expands due to its resiliency, while the peripheral portion 12 main~ains its molded shape. This results in a variable wall thickness of the brassiere cup as shown in Figure 1.
While a fluorine resin has been given as an example~ any material having relstivel~ low thermal conductivity can be used as the material of the projection 6. Wood and paper board are suitable for this purpose but have relatively short lifetimes due to carbonization. Also, the projection 6 can be made of thermally conductiYe material such as metal, which may be integral with the die 2, and cooled with a suitable coolant flowing there-through, Figure~4 and 5 show another feature of this invention proposed to further impro~e the effect of the projection 6, In this embodiment, the female die 3 has a flat step portion 32 around the aperture edge. The contour of ~his step portion 32 is similar to the con~our of the aperture edge and the depth of the step is a little less than the thickness of the fibre board 5 to be used. The object of this step portion is to prevent the peripheral portion of the fibre board 5 from bcing pinched between the both dies 2 and 3 and block its free movement therebetween. This results in reduction of horizontal tension of the fibre layer 1 in the central portion 11 during the molding operations and consequently increases the expansion of the layer 1.
It has been found preferable to select the width of the step ~5~72~L
portion 32 so tha~ it is substantially inversely proporti~nal to the horizontal distance to the corresponding aperture edge ~rom the extreme bottom 31 of the female die 3. This rela~ion is expressed as follows in accordance with Figure 5.
A/B = b/a The fibre board 5 is previously cut in a contour which is substantially same as the contour of the step portion 32 and fits therein as shown in Figure 5.
As described above, in the brassiere cup made by the method of this invention, the fibre layer 1 does not encounter the thermal-setting effect of the thermoplastic resin at the central portion 11 and is very soft as compared with the prior cups. Thus, a brassiere cup which is light and soft, having high air permeability, and gives no feelîng of physical disorder can be manufactured easily in accordance with this invention.
While ~he fibre material and the thermoplastic resin referred to ~bove have the desired tempera~ure characteristics, any other similar materials having similar ~emperature characteristics can be used in this method. For example, fibre boards of poly~nide, polyuTethane, polyethylene, polypropylene and like synthetic resin fibres, natural cotton and like natural fihres and mixtures thereof, impregnated or intermixed with variDus thermoplastic resin adhesives can be used. Moreover, instead of impregnating the fibre board with adhesive resin, a fibre board intermixed with ~hermo-plastic resin fibres may be used conveniently.
Claims (5)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method of making a brassiere cup having a wall thickness which is greater at the apex portion than at the peripheral portion, by press-shaping a soft fibre board intermixed with thermoplastic resin with a set of male and female dies which are heated to a temperature substantially higher than the softening temperature of said thermoplastic resin and forming a predetermined mold cavity when closed, a pad of rounded configur-ation overlying the apex portion of said male die, whereby the gap between the top of said projection and the female die becomes significantly less than the wall thickness of the product at the corresponding portion when the dies are closed, and the temperature of said pad is maintained substanti-ally lower than the softening temperature of said thermoplastic resin.
2. The method according to Claim 1, wherein said pad is made of a material having thermal conductivity which is significantly lower than that of the material of said dies.
3. The method according to Claim 2, wherein said material having low thermal conductivity is a fluorine resin.
4. The method according to Claim 1, wherein a horizontal step portion having a contour which is similar to but greater than the contour of the aperture edge of said female die is formed around said aperture edge, said fibre board material is cut in coincidence with contour of said step portion and fit in said step portion, thereby preventing the peripheral portion of the material from being pressed between the horizontal surfaces of said dies when the dies are closed.
5. The method according to Claim 4, wherein the width of said horizon-tal step portion is substantially inversely proportional to the horizontal distance to the corresponding aperture edge from the extreme bottom of said female die.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3165075A JPS51106548A (en) | 1975-03-14 | 1975-03-14 | CHICHIBANDOKATSUPUNO SEISAKUHOHO |
| JP3165175A JPS51106549A (en) | 1975-03-14 | 1975-03-14 | CHICHIBANDOKATSUPUNO SEISAKUSOCHI |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1059721A true CA1059721A (en) | 1979-08-07 |
Family
ID=26370154
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA247,782A Expired CA1059721A (en) | 1975-03-14 | 1976-03-12 | Method of making brassiere cup |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US4025597A (en) |
| CA (1) | CA1059721A (en) |
| GB (1) | GB1484114A (en) |
| HK (1) | HK32479A (en) |
| PH (1) | PH16027A (en) |
Families Citing this family (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4202853A (en) * | 1977-09-06 | 1980-05-13 | Hanes Corporation | Method for constructing breast cups |
| JP2875278B2 (en) * | 1989-04-14 | 1999-03-31 | 本田技研工業株式会社 | Molding method of fiber reinforced resin |
| DE4423194A1 (en) * | 1994-07-01 | 1996-01-04 | Triumph International Ag | Process for the production of formations in fabrics made from aromatic polyamides |
| WO1997010375A1 (en) * | 1995-09-11 | 1997-03-20 | Du Pont-Toray Company, Ltd. | Heat-set garments and a method of boarding garments |
| USH2062H1 (en) | 1998-09-03 | 2003-04-01 | Kimberly-Clark Worldwide | Nursing pad |
| SE520783C2 (en) * | 2001-06-28 | 2003-08-26 | Pergo Europ Ab | Method of making decorative surface elements |
| JP4628642B2 (en) * | 2002-07-29 | 2011-02-09 | 株式会社Ｍｉｃ | Clothes such as foundation and method for producing the same |
| US7722432B2 (en) * | 2003-07-31 | 2010-05-25 | Hbi Branded Apparel Enterprises, Llc | Method for molding lofted material with decorative support panel and garment made |
| US7556553B2 (en) * | 2003-07-31 | 2009-07-07 | Hbi Branded Apparel Enterprises, Llc | Method for molding lofted material with laminated support layer and decorative panel and garment made |
| US7666059B2 (en) * | 2003-07-31 | 2010-02-23 | Hbi Branded Apparel Enterprises, Llc | Method for molding lofted material with laminated support layer and garment made |
| US20050023718A1 (en) * | 2003-07-31 | 2005-02-03 | Sara Lee Corporation | Apparatus and method for molding spacer fabric or lofted material |
| US7052360B2 (en) * | 2004-03-19 | 2006-05-30 | Victoria's Secret Stores Brand Management, Inc. | Brassiere and related breast cup construction |
| US20060043636A1 (en) * | 2004-08-25 | 2006-03-02 | Pan-Ting Hsueh | Method for preparing brassiere cup |
| US7044829B1 (en) | 2005-02-17 | 2006-05-16 | Victoria's Secret Stores Brand Management, Inc. | Pad with rigid and stretchable foam |
| US20070298680A1 (en) * | 2006-06-21 | 2007-12-27 | Nathalie Martinet | Bra structures with variable rigidity fabrics |
| US11134734B2 (en) * | 2017-09-10 | 2021-10-05 | Rounderbum Llc | Garments having muscle enhancement device and method of the making the same |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2190807A (en) * | 1935-05-29 | 1940-02-20 | Celanese Corp | Method of making wearing apparel |
| US2378642A (en) * | 1941-09-02 | 1945-06-19 | Burkart Mfg Company F | Process of making fiber-body articles |
| US2963744A (en) * | 1956-06-13 | 1960-12-13 | Mcintire Company | Filter element and machine for making same |
| US3164655A (en) * | 1964-05-01 | 1965-01-05 | United Cellular Products Corp | Method of making breast pads, cups and fronts |
| US3348549A (en) * | 1964-07-06 | 1967-10-24 | Du Pont | Brassiere pad and process |
| GB1285032A (en) * | 1968-10-02 | 1972-08-09 | British Bata Shoe Co Ltd | Improvements in or relating to the manufacture of footwear |
| US3534128A (en) * | 1968-11-06 | 1970-10-13 | Alexander G Makowski | Method of forming a foamed plastic article having portions of varying thickness and density |
| US3502083A (en) * | 1969-02-19 | 1970-03-24 | United Cellular Products Corp | Breast pads and method of making the same |
| US3597800A (en) * | 1969-03-20 | 1971-08-10 | Silveco Products Inc | Apparatus for making brassiere pads |
-
1976
- 1976-02-19 PH PH18122A patent/PH16027A/en unknown
- 1976-02-23 US US05/660,362 patent/US4025597A/en not_active Expired - Lifetime
- 1976-02-24 GB GB7285/76A patent/GB1484114A/en not_active Expired
- 1976-03-12 CA CA247,782A patent/CA1059721A/en not_active Expired
-
1979
- 1979-05-17 HK HK324/79A patent/HK32479A/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| PH16027A (en) | 1983-06-02 |
| US4025597A (en) | 1977-05-24 |
| HK32479A (en) | 1979-05-25 |
| GB1484114A (en) | 1977-08-24 |
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