Breast form with underwire and method of manufacturing thereof

Abstract

A method of manufacturing a breast form includes forming an underwire subassembly by placing a housing strip disposed on a support wire, positioning the underwire subassembly on a bag filled with a liquid silicone composition, and permanently affixing the underwire subassembly to the bag.

What is claimed is: 
     
         1 . A method of manufacturing a breast form, the method comprising:
 forming an underwire subassembly by placing a housing strip disposed on a support wire;   positioning the underwire subassembly on a bag filled with a liquid silicone composition; and   permanently affixing the underwire subassembly to the bag.   
     
     
         2 . The method of  claim 1 , wherein the permanent affixing comprises:
 compressing the bag and the underwire subassembly between a floating member and a bottom mold; and   heating the floating member and the bottom mold.   
     
     
         3 . The method of  claim 1 , wherein the positioning comprises:
 applying an adhesive to a bottom surface of the housing strip; and   placing the housing strip on the bag.   
     
     
         4 . The method of  claim 1 , further comprising applying a permanent adhesive to an interior surface of the breast form. 
     
     
         5 . The method of  claim 1 , wherein the underwire subassembly is located at a lower part of the breast form. 
     
     
         6 . The method of  claim 5 , wherein the underwire subassembly forms a crescent shape along the lower part of the breast form. 
     
     
         7 . The method of  claim 1 , wherein ends of the support wire are wrapped with tape. 
     
     
         8 . The method of  claim 1 , wherein the support wire is round. 
     
     
         9 . The method of  claim 1 , wherein the support wire is flat. 
     
     
         10 . The method of  claim 1 , wherein the support wire comprises steel. 
     
     
         11 . The method of  claim 10 , wherein the support wire is coated with plastic. 
     
     
         12 . The method of  claim 1 , wherein the housing strip comprises a thermoplastic material. 
     
     
         13 . The method of  claim 12 , wherein the housing strip comprises polyurethane. 
     
     
         14 . A breast form comprising:
 two thermoplastic films coupled to each other along edges of each of the two thermoplastic films;   a silicone gel sealed within the two thermoplastic films; and   an underwire subassembly attached to one of the two thermoplastic films, wherein the underwire subassembly comprises a housing strip disposed on a support wire.   
     
     
         15 . The breast form according to  claim 14 , wherein the housing strip has a thickness in a range from about 10 millimeters to about 50 millimeters. 
     
     
         16 . The breast form according to  claim 14 , wherein the underwire subassembly is located at a lower part of the breast form. 
     
     
         17 . The breast form according to  claim 16 , wherein the underwire subassembly forms a crescent shape along the lower part of the breast form. 
     
     
         18 . The breast form according to  claim 14 , wherein ends of the wire are wrapped with tape. 
     
     
         19 . The breast form according to  claim 14 , wherein the wire is round. 
     
     
         20 . The breast form according to  claim 14 , wherein the wire is flat. 
     
     
         21 . The breast form according to  claim 14 , wherein the wire comprises steel. 
     
     
         22 . The breast form according to  claim 21 , wherein the wire is coated with plastic. 
     
     
         23 . The breast form according to  claim 14 , wherein the housing strip comprises a thermoplastic material. 
     
     
         24 . The breast form according to  claim 23 , wherein the housing strip comprises polyurethane. 
     
     
         25 . The breast form according to  claim 14 , wherein an interior surface of the breast form is coated with a permanent adhesive.