Note: Descriptions are shown in the official language in which they were submitted.
CA 02722333 2010-11-17
TITLE OF INVENTION
APPARATUS AND METHOD FOR FORMING
LAMINATED AND MOLDED GARMENTS
[0001] This application is a divisional of Canadian patent application
Serial No.
2,522,777 filed internationally on June 28, 2004 and entered nationally on
October 17,
2005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to an apparatus and method for
forming
garments. More particularly, the present invention relates to an apparatus and
method for
forming laminated and molded garments.
2. Description of the Related Art
[0003] Various methods and/or mechanisms for making garments have been
developed and are known. For example, U.S. Patent No. 3,058,154 is directed to
an
apparatus and method for making breast fronts without the use of any sewing or
seams.
However, notwithstanding that which is known, there remains a constant need
for
improved methods and/or devices for providing simple, efficient, and
economical garment
manufacturing.
BRIEF DESCRIPTION OF THE INVENTION
[0004] It is an object of the present invention to provide an apparatus
and method
for forming a laminated and molded garment.
[0005] It is another object of the present invention to provide an
apparatus and
method for simultaneously laminating and molding a garment simply,
efficiently, and
economically.
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[0006] It is still another object of the present invention to provide an
apparatus and
method that employs at least one first element, at least one second element,
and at least
one third element that interact to facilitate the simultaneous laminating and
molding of
garments.
[0007] It is yet another object of the present invention to provide an
apparatus and
method for forming a garment that offers improved durability and longevity.
[0008] These and other objects and advantages of the present invention are
achieved by a method for forming a molded garment. The method includes
positioning an
assembly of material between a first heated mold element and a second heated
mold
element, moving the first and second heated mold elements in relation to one
another to
laminate the assembly of material into a laminated assembly; moving a third
heated mold
element through the first heated mold element into contact with the laminated
assembly so
that the third heated mold element shapes a portion of the laminated assembly;
and
causing the first and second heated mold elements to trim fabric from the
laminated to
define the molded garment.
[0009] These and other objects and advantages of the present invention are
achieved by a method including positioning an assembly of material between a
first heated
mold element and a second heated mold element; holding the assembly of
material in a
desired location on the second heated mold element; moving the first and
second heated
mold elements in relation to one another to laminate the assembly of material
into a
laminated assembly while the second heated mold element shapes a portion of
the
laminated assembly; and causing the first and second heated mold elements to
trim fabric
from the laminated to define the molded garment.
100101 Still further objects and advantages of the present invention are
achieved by
an apparatus having three heatable mold portions. The first heatable mold
portion has a
pair of breast cup cavities defined therein. The second heatable mold portion
has a pair of
openings defined therein. The openings correspond in position to the cavities.
The third
heatable mold portion has a pair of breast cup molds defined thereon. The
breast cup
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molds are reciprocatively positioned in the openings so that the breast cup
molds are
moveable into and out of the breast cup cavities.
[0011] In one embodiment of the present invention there is provided, a
method for
forming a molded breast covering garment, comprising: positioning an assembly
of
material between a first heated mold element and a second heated mold element,
the first
heated mold element having a pair of spaced openings formed through a
substantially
planar lower surface, the second heated mold element having a pair of female
cavities
formed therein a substantially planar upper surface and corresponding to the
openings
formed through the first heated mold element; moving the first and second
heated mold
elements in relation to one another to laminate the assembly of material into
a
substantially planar laminated assembly; moving a third heated mold element
having a
pair of male molds through the pair of spaced openings in the first heated
mold element
into contact with the laminated assembly and into the pair of female cavities
of the second
heated mold element so that said third heated mold elements forms a pair of
breast cups in
the laminated assembly; and causing the first and second heated mold elements
to trim the
laminated assembly to define the molded breast covering garment.
[0012] In another embodiment of the present invention there is provided,
a method
for forming a molded breast covering garment, comprising: positioning an
assembly of
material between a first heated mold element and a second heated mold element,
the first
heated mold element having a pair of male molds projecting from a
substantially planar
lower surface, the second heated element having a pair of female cavities
formed therein a
substantially planar upper surface; holding the assembly of material in a
desired location
on the second heated mold element; moving the first and second heated mold
elements in
relation to one another to laminate the assembly of material between the
substantially
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,
planar lower and upper surfaces into a laminated assembly while the first
heated mold
element forms a pair of breast cups in the laminated assembly; and causing the
first and
second heated mold elements to trim the laminated assembly to define the
molded breast
covering garment.
[0013] In another embodiment of the present invention there is provided, an
apparatus for forming a garment, comprising: a first heated mold element; a
second heated
mold element, the first heated mold element the second heated mold element
being
movable relative to one another; and a third heated mold element for
cooperating with the
first and second heated mold elements to form the garment from an assembly of
material.
[0014] In another embodiment of the present invention there is provided, an
apparatus for forming a molded garment, comprising: a first heatable mold
portion having
a pair of breast cup cavities defined therein; a second heatable mold portion
having a pair
of openings defined therein, the pair of openings corresponding in position to
the pair of
breast cup cavities; and a third heatable mold portion having a pair of breast
cup molds
defined thereon, the pair of breast cup molds being reciprocatively positioned
in the pair of
openings so that the pair of breast cup molds are moveable into and out of the
pair of
breast cup cavities.
[0014a1 In another aspect of the invention there is provided a method for
forming a
molded brassiere. The method comprises positioning a multi-layer assembly of
material
comprising an outer layer, an inner layer and an intermediate support layer,
between a first
heated mold element and a second heated mold element. The first heated mold
element
has a pair of male molds projecting from a substantially planar inner surface
and the
second heated element has a pair of female cavities formed therein a
substantially planar
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inner surface. The method further comprises holding the assembly of material
in a desired
location on the second heated mold element and moving the first and second
heated mold
elements in relation to one another to laminate the assembly of material
between said
substantially planar inner surfaces into a laminated assembly while the first
heated mold
element forms a pair of breast cups in the laminated assembly. The method
further
comprises cutting excess material from the laminated assembly to define a
laminated
brassiere assembly having a pair of spaced apart and interconnected breast
cups, an
integrally formed torso band portion extending outwardly from each breast cup,
and
finished edges, without any additional sewing steps. The first and second
heated mold
elements are engaged to move and laminate, cut and mold the brassiere
simultaneously.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
100151 Other and further objects, advantages and features of the present
invention
will be understood by reference to the following specification in conjunction
with the
accompanying drawings, in which like reference characters denote like elements
of
structure.
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[0016] Fig. 1 is a front perspective view of an apparatus for
forming a laminated
and molded garment in accordance with an illustrative embodiment of the
present
invention;
[0017] Fig. 2 is an exploded perspective view of an assembly of
material in
accordance with an illustrative embodiment of the present invention;
[0018] Fig. 3 is an exploded perspective view of an assembly of
material in
accordance with another illustrative embodiment of the present invention;
[0019] Fig. 4 is a side sectional view of the apparatus of Fig. 1,
reflecting a
forming step in accordance with an illustrative embodiment of the present
invention;
[0020] Fig. 5 is a side sectional view of the apparatus of Fig. 1,
reflecting another
forming step in accordance with an illustrative embodiment of the present
invention;
[0021] Fig. 6 is a side sectional view of the apparatus of Fig. 1,
reflecting still
another forming step in accordance with an illustrative embodiment of the
present
invention;
[0022] Fig. 7 is a front perspective view of an apparatus for
forming a laminated
and molded garment in accordance with another illustrative embodiment of the
present
invention;
[0023] Fig. 8 is a side sectional view of the apparatus of Fig. 7,
reflecting a
forming step in accordance with an illustrative embodiment of the present
invention;
[0024] Fig. 9 is a side sectional view of the apparatus of Fig. 7,
reflecting another
forming step in accordance with an illustrative embodiment of the present
invention;
[0025] Fig. 10 is a plan view of a laminated and molded garment in
accordance
with an illustrative embodiment of the present invention; and
[0026] Fig. 11 is a perspective view of the integral laminated and
molded garment
of Fig. 10.
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DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring to the drawings and, in particular to Fig. 1, there is shown
an
illustrative embodiment of an apparatus for forming a laminated and molded
garment,
generally represented by reference numeral 10. The apparatus 10 essentially
has at least
one first element 20, at least one second element 30, and at least one third
element 40 that
cooperate to form the integral laminated and molded garment from an assembly
of
material 50 shown in Fig. 2.
[0028] First element 20 is preferably a surface heated retention plate that
cooperates with second element 30 and/or third element 40 to form a garment
70, such as
that shown in Figs. 1 and 11, from an assembly of material 50 such as that
shown in Figs.
2 and 3. First element 20 is preferably heated via any suitable method
sufficient to
accomplish the intended purposes thereof. For example, first element 20 can be
heated via
electric heating wires or rods (not shown), which transmit heat to a
contacting surface 22
of the first element. First element 20 preferably has one or more through
holes 24.
Preferably one or more through holes 24 are sized, shaped and/or configured to
accommodate third element 40 such that the third element can cooperate with
first element
20 and second element 30, and can interact with the assembly of material 50
preferably
during the garment forming process to provide a three dimensional shape to the
assembly
of material. Preferably, first element 20 can facilitate the controlled
placement and/or
lamination or bonding of material 50. First element 20 can move relative to
second
element 30 and/or third element 40. First element 20 can also be rigid and
relatively
stationary with respect to second element 30 and/or third element 40. Further,
the
contacting surface 22 of first element 20 can have any of a variety of
textures, patterns
and/or configurations sufficient to provide any of a variety of different
effects on the
assembly of material 50.
[0029] Second element 30 is preferably a surface heated support plate. As
discussed above, second element 30 cooperates with first element 20 and/or
third element
40 to form a garment 70, such as that shown in Fig. 11, from the assembly of
material 50.
Second element 30 is preferably heated via any suitable method sufficient to
accomplish
the intended purposes thereof. For example, second element 30 can be heated
via electric
heating wires or rods (not shown), which transmit heat to a contacting surface
32 the
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second element. Second element 30 preferably has one or more cavities or
female mold
sections 34. Preferably, one or more female mold sections 34 are sized,
shaped, and/or
configured to accommodate third element(s) 40 such that third element(s) 40
can interact
with material 50 preferably during the garment forming process to provide a
three
dimensional shape to the assembly of the material. Second element 30 can move
relative
to first element 20 and/or third element 40. Second element 30 can also be
rigid and
relatively stationary with respect to first element 20 and/or third element
40. The
contacting surface 32 of second element 30 can have any of a variety of
textures, patterns
and/or configurations sufficient to provide any of a variety of different
effects on the
assembly of material 50. For example, contacting surface 32 of second element
30 can
have a plurality of nodes, dimples or grooves 36, such as is shown in Fig. 1,
for
cooperating with a plurality of complementary nodes, dimples or grooves
provided on first
element 20 and/or third element 40.
[0030] Third element 40 is preferably one or more surface heatable male molds.
As discussed above, third element 50 cooperates with first element 20 and/or
second
element 30 to form a garment 70 from the assembly of material 50. Third
element 40 is
preferably heated via any suitable method sufficient to accomplish the
intended purposes
of the third element. For example, the third element can be heated via
electric heating
wires or rods (not shown), which transmit heat to a contacting surface 42
thereof.
Preferably, one or more male molds 40 are sized, shaped and/or configured to
interact with
first element 20 and to engage second element 30 such that the third
element(s) can
interact with material 50 preferably during the garment forming process to
provide a three
dimensional shape to the assembly of the material. Third element 40 can move
relative to
first element 20 and/or second element 30. Third element 40 can also be
configured to be
rigid and relatively stationary with respect to first element 20 and/or second
element 30. It
is noted that the contacting surface 42 of third element 40 can have any of a
variety of
textures, patterns and/or configurations sufficient to provide any of a
variety of different
effects on the assembly of material 50. For example, contacting surface 42 of
third
element 40 can have a plurality of nodes, dimples or grooves 36, such as is
shown in
Fig. 1, for cooperating with a plurality of complementary nodes, dimples or
grooves
provided on first element 20 and/or second element 30.
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[0031] Referring to Figs. 2 and 3, the assembly of material 50 preferably has
at
least an outer layer 52, an intermediate layer 54, and an inner layer 58.
Preferably outer
layer 52 is decorative and appealing to the eye, intermediate layer 54 is
preferably a
supportive type layer. Intermediate layer 54 preferably provides durability as
appropriate
for the type of garment being formed. Inner layer 58 is preferably soft to
provide comfort
during wear of the garment. Preferably, the various layers of material
assembly 50 can be
formed from natural and/or man-made fiber. Additional layers may also be
incorporated as
part of the assembly of material 50. For example, a separate adhesive or
bonding layer can
be used to facilitate fusing or bonding the various layers of the assembly
together. The
adhesive layer can have elastic properties sufficient to compliment those
properties
associated with the fibers or materials used in the various layers of the
assembly of
material 50. Adhesive layer may be suitable for use with a variety of fibers
and fabric
forming techniques, including microfibers and specialized nonwovens. Foam type
materials may also be used or incorporated as part of material assembly 50.
Preferably,
apparatus 10 is suitable to accommodate the loft material characteristics of
various types
of foam such that the loft characteristics remain relatively unchanged after
having been
formed and/or molded in accordance with any of the illustrative embodiments of
present
invention.
[0032] Outer layer 52 preferably has an inner surface 51 and outer surface 53.
Preferably, inner surface 51 has an adhesive or bonding substance integrated
therein
and/or dispersed thereon for facilitating the fusing or laminating of outer
layer 52 with
intermediate layer 54 and/or inner layer 58. Outer layer 52 can preferably be
shaped, sized
and/or configured to provide any of a variety of aesthetic impressions as
appropriate or
intended for a garment type. Intermediate layer 54 can preferably be secured
or positioned
only where essential for support.
[0033] Intermediate layer 54 is preferably at least somewhat less flexible
than
either outer layer 52 or inner layer 58. Like outer layer 52, intermediate
layer 54
preferably has an inner surface 55 and an outer surface 56. Both inner and
outer surfaces
55, 56, respectively, of intermediate layer 54 can have an adhesive or bonding
substance
integrated therein and/or dispersed thereon for facilitating the fusing or
laminating of the
intermediate layer with outer layer 52 and/or inner layer 58. Intermediate
layer 54 can be
shaped, sized and/or configured to comfortably conform against the body of a
wearer of
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the garment to provide support and/or augmentation as appropriate or intended
for a
garment type. Intermediate layer 54 can preferably be secured or positioned
only where
essential for support. For example, intermediate layer 54 can be one or more
stays or wires
54 positioned as shown in Fig. 2, which stays or wires 54 can preferably be
made from any
of a variety of different materials and/or combination of materials.
[0034] Inner layer 58 can preferably be formed from any material suitable for
improving the comfort to the wearer. Also, preferably, inner layer 58 has an
inner surface
57 and an outer surface 59. Preferably, outer surface 59 of inner layer 58 has
an adhesive
or bonding substance integrated therein and/or dispersed thereon for
facilitating the fusing
or laminating of outer layer 52 with intermediate layer 54 and/or outer layer
52.
Preferably, inner layer 58 can be shaped, sized and/or configured to
comfortably conform
against the body of a wearer of the garment to provide comfort and/or reduce
irritation as
appropriate or intended for a particular garment type. Inner layer 58 can, if
desirable, be
secured or positioned only where essential for providing comfort and/or
reducing
irritation.
[0035] Having described some of the preferred characteristics of the
illustrative
embodiment, the process or method for forming a garment 70, preferably
includes at least
the following steps. Referring to Fig. 4, an assembly of material 50 is first
positioned in a
heat molding apparatus having at least one first element 20, at least one
second element
30, and at least one third element 40. Then, as shown in Fig. 5, first element
20 is moved
into a closed relation with second element 30, or vice-versa, sandwiching the
assembly of
material 50 therebetween. Thereafter, third element 40 is engaged to cooperate
with first
element 20 and second element 30 such that the third element interacts with
the assembly
of material 50. Now, referring to Fig. 6, third element 40 is disengaged,
then, first element
20 is opened in relation to second element 30, or vice-versa, to provide the
integral
laminated and molded assembly of material 50, such as that shown in Fig. 10.
Thereafter,
as shown in Fig. 11, any excess material is eliminated as appropriate, leaving
the integral
laminated and molded garment. For example, first and second elements 20, 30
can trim
excess material during the molding process such that when the elements are
opened,
garment 70 is completed.
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[0036] It is noted that the step of engaging third element 40 can be
accomplished
simultaneously with the step of closing first element 20 in relation to second
element 30.
Further, the step of disengaging third element 40 is preferably performed
after a period of
about 10 seconds to about 60 seconds and more preferably about 35 seconds,
from the
time third element 40 is engaged. Still further, the step of opening first
element 20 in
relation to second element 30 is preferably performed after an additional
period of about 5
seconds to about 30 seconds and more preferably about 15 seconds from the time
that third
element 40 is disengaged.
[0037] Referring to Fig. 7, there is shown another illustrative embodiment of
an
apparatus for forming a laminated and molded garment, generally represented by
reference
numeral 100. Apparatus 100 preferably has at least one first element 120, a
second
element 130, and alternatively a third element 140, all of which cooperate to
form the
integral laminated and molded garment from an assembly of material 50.
[0038] First element 120 preferably has a surface heated retention plate 120
that
can cooperate with second element 130 and/or third element 140 to form a
garment 70,
such as that shown in Fig. 11, from an assembly of material 50 such as that
shown in
Figs. 2 and 3. First element 120 is preferably heated via any suitable method
sufficient to
accomplish the intended purposes thereof. For example, first element 120 can
be heated
via electric heating wires or rods (not shown), which transmit heat to a
contacting surface
122 thereof.
[0039] First element 120 preferably has one or more male molds 124 and one or
more elongated relatively planar portions 126 about the one or more male
molds.
Preferably one or more male molds 124 and one or more planar portions 126 are
sized,
shaped and/or configured to cooperate with one or more complementary female
molds 134
and one or more planar portions 136 of second element 130.
[0040] Preferably, third element 140 can cooperate with first element 120 and
second element 130 such that third element 140 can interact with the assembly
of material
50 preferably during the garment forming process to retain or secure the
assembly of
material 50 during the garment forming process and/or to provide a texture,
pattern or
other type of shape or configuration to the assembly of material 50.
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[0041] First element 120 can move relative to second element 130 and/or third
element 140. First element 120 can be rigid and relatively stationary with
respect to
second element 130 and/or third element 140. Further, the contacting surface
122 of first
element 120 can have any of a variety of textures, patterns and/or
configurations sufficient
to provide any of a variety of different effects on the assembly of material
50.
[0042] Second element 130 is preferably a surface heated support plate 130
fashioned to cooperate with first element 120 and/or third element 140. Second
element
130 is preferably heated via any suitable method sufficient to accomplish the
intended
purposes thereof. For example, second element 130 can be heated via electric
heating
wires or rods (not shown), which transmit heat to a contacting surface 132
thereof.
Preferably, one or more female molds 134 and one or more planar portions 136
of second
element 130 are sized, shaped and/or configured to accommodate the one or more
male
molds 124 and one or more planar portions 126 of first element 120.
Accordingly, first
element 120 can interact with the assembly of material 50 during the garment
forming
process to provide a three dimensional shape to the assembly of material 50.
Second
element 130 can be rigid and/or move relative to first element 120 and/or
third element
140. Contacting surface 132 of second element 130 can have any of a variety of
textures,
patterns and/or configurations sufficient to provide any of a variety of
different effects on
the assembly of material 50. For example, contacting surface 132 of second
element 130
can have one or more holes, nodes, dimples or grooves 138 for cooperating with
one or
more complementary holes, nodes, dimples or grooves 128, 148 provided on first
element
120 and/or third element 140, respectively.
[0043] Third element 140 is preferably a retention plate that can cooperate
with
first element 120 and/or second element 130 to form integral garment 70. Third
element
140 can be heated, for example, by electric heating wires or rods (not shown),
which
transmit heat to a contacting surface 142 thereof Third element 140 is
preferably
positioned between first element 120 and second element 130. Third element 140
can be
sized, shaped and/or configured to facilitate or enable first element 120 to
directly interact
with second element 130 and/or the assembly of material 50 during the garment
forming
process. Preferably, third element 140 facilitates the controlled placement
and/or
lamination or bonding of the various layers of material assembly 50. Third
element 140
can be rigid and/or move relative to first element 120 and/or second element
130.
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Contacting surface 142 of third element 140 can, as with the first and second
elements
120, 130, have any of a variety of textures, patterns and/or configurations
sufficient to
provide any of a variety of different effects on the assembly of material 50.
For example,
contacting surface 142 can have one or more holes, nodes, dimples or grooves
148 for
cooperating with one or more complementary holes, nodes, dimples or grooves
128, 138
provided on first element 120 and/or second element 130, respectively.
[0044] Having described some of the preferred characteristics of another
illustrative embodiment, the process or method for forming a garment 70 using
apparatus
100, preferably includes at least the following steps. First, referring to
Fig. 8, assembly of
material 50 is positioned between first element 120 and second element 130 of
apparatus
100. Referring to Fig. 9, first element 120 is then closed in relation to
second element 130,
or vice-versa, thereby sandwiching the assembly of material 50 therebetween.
Then, first
element 120 is opened in relation to second element 130, or vice-versa, after
a period of
about 20 seconds to about 80 seconds and more preferably about 50 seconds, to
leave a
laminated and molded assembly 60 like that shown in Fig. 10, and then,
eliminating any
excess material as appropriate, leaving a laminated and molded garment 70 like
that
shown in Fig. 11.
[0045] It is noted that third element 140, if used, may be engaged in relation
to
second element 130 either before, after or simultaneously with the step of
closing first
element 120 in relation to second element 130. Further, the step of
disengaging third
element 140 is preferably performed after the step of opening first element
120 in relation
to second element 130.
[0046] It is also noted that various other steps and/or features well known in
the art
may also be incorporated into the present invention as appropriate for forming
a desired
garment type. Thus, for example, various alternative techniques for connecting
fabrics/materials can used, various different cutting and/or finishing
techniques can be
used, or various material types may also be used as appropriate.
[0047] The present invention having been thus described with particular
reference
to the preferred forms thereof, it will be obvious that various changes and
modifications
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may be made therein without departing from the broadest interpretation
consistent with the
description as a whole.
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