Patent Application
20050023718
1. Field of the Invention
The present invention relates to an apparatus and method for molding garments or the like. More particularly, the present invention relates to an apparatus and method for molding a spacer fabric or lofted material to provide such fabric or material with a three dimensional shape.
2. Description of the Prior Art
Various methods and mechanisms for molding different types and assemblies of material have been developed and are known. For example, U.S. Pat. No. 3,464,418 provides an apparatus and method for making brassiere pads from bonded non-woven fibrous batting material, U.S. Pat. No. 4,025,597 provides a method of making a brassiere cup from a soft fibrous board material, U.S. Pat. No. 4,080,416 provides a method for making multi-layered seamless brassiere pads, and U.S. Pat. No. 4,250,137, which provides a process for preparing breast pads or fronts such that the pads are centrally soft and peripherally firmer.
Notwithstanding that which is known, there remains a continuing need for improved methods and/or devices for molding a spacer fabric or lofted material to provide a three dimensional shape thereto without compromising the loft characteristics associated with such material. Problems heretofore associated with various processes of molding a lofted material include at least the following: (1) thinning of material at points of increased pressure or applied heat, or both, such as for example, the apex of a bra cup or pad, (2) requiring relatively complicated or additional structural elements, or both to facilitate a desired result, for example, spacer devices or vacuum systems, and (3) requiring that heat, pressure or both be avoided at relatively substantial portions of the material being molded, which can complicate the molding process.
It is an object of the present invention to provide an improved apparatus and method for molding a spacer fabric or lofted material.
It is another object of the present invention to provide an improved apparatus for molding a lofted material that can be adjusted to accommodate the loft of different materials.
It is a further object of the present invention to provide an improved apparatus for molding a lofted material that can be adjusted to provide different lofts to a variety of materials.
It is still another object of the present invention to provide an improved apparatus and method for molding a lofted material to provide a balance of comfort, support and durability.
These and other objects and advantages of the present invention are achieved by a molding apparatus with at least a first die or mold with a projecting element and a first level portion, and a second die or mold with a recessed element and a second level portion. The projecting element and the recessed element are formed such that when the first level portion of the first mold and the second level portion of the second mold are brought into relatively close relation, a uniform preset distance or gap is created between the projecting element and the recessed element. The gap is preferably adjustable to accommodate the loft of different materials. The first mold and second mold each are preferably selectively and/or independently heatable and configured as appropriate to facilitate the following material molding method.
The method for molding the lofted material essentially comprises the steps of first, positioning a lofted material or an assembly of lofted material in the molding apparatus. Then, closing the first mold in relation to the second mold, or vice-versa, sandwiching the lofted material therebetween such that the portion of the lofted material situated between the first and second level portions is compressed and the portion of the lofted material situated between the projecting element and recessed element is compressed only to the extent desired or not at all. The extent of compression being adjustable. Following this closing step is a step of opening the first mold in relation to the second mold after a period of selectively providing pressure and/or heat as appropriate for the desired molding result. The resulting molded lofted material preferably providing a balance of comfort, support and durability.
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.
Referring to the drawings and, in particular to
Preferably, first mold 10 and second mold 20 cooperate to mold or form a lofted material 30 positioned therebetween into a three-dimensional shape, such as, for example, that required by molded brassiere pads. Preferably, lofted material 30 can be any of a variety of materials or combination of materials (i.e., batting, foam, etc.) and can be fashioned into a variety of forms, such as for example, a garment or an upholstery item. The three-dimensional shape
First mold 10 preferably has at least one first contact surface 40 with at least one projecting element 50 in the form of a dome. First contact surface 40 preferably also has a first level portion 42 about projecting element 50. First contact surface 40 may also have any of a variety of other surface elements 43 associated therewith, such as for example, nodes, dimples, and/or teeth as shown in
Preferably, first mold 10, first contact surface 40, projecting element 50, and/or first level portion 42 can be heatable. This heating can be accomplished in any of a variety of ways, such as for example, via electric heating wires or rods associated with first mold 10. These heating wires or rods could preferably conduct or transmit heat, via first mold 10, as appropriate to provide any and/or all of the aforementioned elements thereof with sufficient heat for effective molding under a variety of different molding parameters. First mold 10 can preferably have any shape, size, and/or configuration suitable for accomplishing one or more different molding operations. See, for example,
It is also noted, with regard to surface elements 43 discussed above, that surface elements 43 are preferably suitable for achieving a variety of different molding effects. For example, surface elements 43 can be disposed on either and/or both projecting element 50 and first level portion 42 to interact with lofted material 30 during a molding process. Surface elements 43 can be, for example, one or more piercing elements, heating or cooling elements, cushioning or insulating elements, or any combination of the same. Other similar types of elements may also be used and are within the scope of the present invention.
Referring again to
Preferably, second mold 20, second contact surface 60, recessed element 70, and/or second level portion 62 can be heatable. Such heating can be accomplished in any of a variety of ways, such as, for example, by electric heating wires or rods associated with second mold 20. These heating wires or rods could preferably conduct or transmit heat, via second mold 20, as appropriate to provide any and/or all of the aforementioned elements thereof with sufficient heat for effective molding under a variety of different molding parameters. Second mold 20 can preferably have any shape, size, and/or configuration suitable for accomplishing one or more different molding operations in cooperation with mold 10. See, for example,
As with the first mold 10, surface elements 43 for providing a variety of different molding effects that can be disposed on either and/or both recessed element 70 and second level portion 62 to interact with lofted material 30 during the molding process.
Referring to
The process of molding lofted material 30 preferably includes at least the following steps. Referring to
The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined herein.
