Production of a brassiere and brassiere produced thereby

Abstract

A method of manufacture of a brassiere comprising the steps of providing a first substrate layer; providing thermoplastic polyurethane (hereinafter “TPU”) base material; heating the TPU base material to a molten state; providing a printing roller having recesses on its outer surface; transferring molten TPU material into a recess on a printing roller; transferring the molten TPU onto the first substrate layer by rolling the printing roller over at least part of a surface of the substrate layer; providing a second substrate layer; compressing the first substrate layer and second substrate layer together with the transferred TPU in between the first substrate layer and second substrate layer; heating the compressed first substrate layer and second substrate layer to melt the transferred TPU between the substrate layers, thereby bonding at least part of the first substrate layer and at least part of second substrate layer together to form a laminate; cutting the laminate to form a shape suitable for use in a brassiere; and merging the cut laminate to other components to form a brassiere.

1 . A method of manufacture of a brassiere comprising the steps of:
 providing a first substrate layer;   providing thermoplastic polyurethane (hereinafter “TPU”) base material;   heating said TPU base material to a molten state;   providing a printing roller having recesses on its outer surface;   transferring molten TPU material into a recess on a printing roller;   transferring the molten TPU onto said first substrate layer by rolling the printing roller over at least part of a surface of the substrate layer;   providing a second substrate layer;   compressing the first substrate layer and second substrate layer together with the transferred TPU in between the first substrate layer and second substrate layer;   heating the compressed first substrate layer and second substrate layer to melt the transferred TPU between the substrate layers, thereby bonding at least part of said first substrate layer and at least part of second substrate layer together to form a laminate;   cutting the laminate to form a shape suitable for use in a brassiere; and   merging the cut laminate to other components to form a brassiere.   
   
   
       2 . A method as claimed in  claim 1 , including the step of moulding the cut laminate to form at least part of a breast cup shape suitable for use in a brassiere. 
   
   
       3 . A method as claimed in  claim 1 , including the step of simultaneously moulding at least part of the substrate layers to an at least partial breast cup shape while laminating the first substrate layer and second substrate layer. 
   
   
       4 . A method as claimed in  claim 1 , wherein the step of moulding the cut laminate is performed by the application of any or both elements selected from pressure and/or heat. 
   
   
       5 . A method as claimed in  claim 1 , including the step of providing one or both of strengthening and/or padding members disposed between the first and the second substrate layers. 
   
   
       6 . A method as claimed in  claim 1 , including, the step of transferring molten TPU material into a recess on a roller may be by extrusion. 
   
   
       7 . A method as claimed in  claim 5 , including the step of layering the first substrate layer, the second substrate layer and the strengthening and/or padding members in a configuration suitable for use in a brassiere before laminating the first substrate layer and the second substrate layer. 
   
   
       8 . A method as claimed in  claim 5 , wherein the strengthening and/or padding members is laminated together with the first substrate layer and the second substrate layer as at least one intermediate layer. 
   
   
       9 . A method as claimed in  claim 1 , wherein the TPU is solvent free. 
   
   
       10 . A method as claimed in  claim 1 , wherein the TPU base material is in granular form. 
   
   
       11 . A method as claimed in  claim 1 , wherein the first substrate layer is fabric. 
   
   
       12 . A method as claimed in  claim 1 , wherein the second substrate layer is fabric. 
   
   
       13 . A method as claimed in  claim 1 , wherein the recesses on the outer surface of the printing roller are engraved. 
   
   
       14 . A method as claimed in  claim 1 , wherein the recesses on the outer surface of the printing roller are machined. 
   
   
       15 . A method as claimed in  claim 1 , wherein the recesses on the outer surface of the printing roller are apertures into a central compartment. 
   
   
       16 . A laminate adapted for use in the manufacture of a brassiere comprising
 a first substrate layer; and   a second substrate layer;   wherein the first substrate layer and second substrate layer have been laminated by means of a solvent-free heated thermoplastic polyurethane printing process, and the laminate has been shaped for application as a component of a brassiere.   
   
   
       17 . A laminate as claimed in  claim 16 , wherein the laminate is shaped to define a pair of breast cups with an intermediate bridge member between them. 
   
   
       18 . A laminate as claimed in  claim 17 , wherein the laminate is shaped to at least partially define fastening straps. 
   
   
       19 . A brassiere comprising
 a laminate including
 a first substrate; and 
 a second substrate; 
   wherein the first substrate and second substrate have been laminated by means of a solvent-free heated thermoplastic polyurethane printing process.   
   
   
       20 . A brassiere as claimed in  claim 19 , wherein the laminate is shaped for application in a brassiere. 
   
   
       21 . A brassiere as claimed in  claim 19 , wherein the laminate is shaped to define a pair of breast cups connected by a bridge member. 
   
   
       22 . A brassiere as claimed in  claim 19 , wherein the shape of the laminate further at least partially defines fastening straps. 
   
   
       23 . A brassiere formed at least in part by the method according to  claim 1 . 
   
   
       24 . A brassiere that includes a laminate according to  claim 16 .