Pads having a central summit for bras and the like
View Patent ↗A method of manufacturing a bra pad having a thicker summit area, as well as the pad itself, includes holding a sheet of resilient and formable material of uniform thickness, such as thermoplastic foam, and forming the sheet to have a graduated thicker summit area corresponding to each summit of a bra or bra-like garment for including the pad, and a surrounding thinner area. Each pad thus has a thicker summit area for extending over the summits of the breasts.
1. A method of manufacturing a bra pad, comprising:
holding a first sheet of resilient and formable material having a uniform thickness in a first mold with at least some of the material in at least one graduated recess of the first mold;
removing some of the material from the first sheet by shaving or cutting to leave a graduated sheet of the material having at least one graduated thicker summit area of the graduated sheet corresponding to the graduated recess of the first mold and a surrounding thinner area of the graduated sheet;
adhering to the graduated sheet, a further sheet of resilient and formable material using adhesive; and
then forming the graduated sheet with the adhered further sheet of material to form a bra pad.
2. A method according to claim 1 , wherein the material of the first sheet is thermo-formable material.
3. A method according to claim 1 , including cutting a bra pad out of the graduated sheet by cutting the surrounding thinner area around the summit area.
4. A method according to claim 1 , wherein the graduated sheet has a pair of spaced apart summit areas.
5. A bra pad made by the process comprising:
holding a first sheet of resilient and formable material having a uniform thickness in a first mold with at least some of the material of the first sheet being in at least one graduated recess of the first mold;
removing some of the material of the first sheet by shaving or cutting to leave a graduated sheet of the material having at least one graduated thicker summit area of the graduated sheet corresponding to the graduated recess of the first mold, and a surrounding thinner area of the graduated sheet; and
a further sheet of resilient and formable material adhered by adhesive to the graduated sheet of resilient and formable material.
6. A pad according to claim 5 , where each of the graduated and further sheets of resilient and formable material are made of thermoplastic foam and have one laminated surface and an opposite surface adhered to the other sheet of material.
7. A pad according to claim 6 , wherein the sheets of resilient and formable material each comprise thermoplastic material.
8. A pad according to claim 7 , wherein the thermoplastic material is polyurethane foam.
9. A bra pad made by the process comprising:
holding a first sheet of resilient and formable material having a uniform thickness in a first mold with at least some of the material of the first sheet in at least one graduated recess of the first mold;
removing some of the material of the first sheet by shaving or cutting to leave a graduated sheet of the material having at least one graduated thicker summit area of the graduated sheet corresponding to the graduated recess of the first mold, and a surrounding thinner area of the graduated sheet; and
providing a further sheet of resilient and formable material adhered by adhesive to the graduated sheet of resilient and formable material with a fabric laminate on outer surfaces of each sheet of material which is opposite from a surface at which the sheets of material are adhered to each other.
10. A pad according to claim 9 , including forming the graduated sheet with the adhered further sheet of material to form a bra pad.
11. A pad according to claim 9 , wherein the material of the first sheet is thermo-formable material.
12. A pad according to claim 9 , including cutting the bra pad out of the graduated sheet by cutting the surrounding thinner area around the summit area.
13. A pad according to claim 9 , wherein the graduated sheet has a pair of spaced apart summit areas.