The present disclosure relates to bras, and more specifically to unlined bras that do not have padding.
The following patent and patent applications are provided by way of background information and are hereby incorporated herein by reference in their entireties.
U.S. Pat. No. 11,312,808 discloses aqueous polyurethane dispersions, prepolymers for formation of these dispersions, methods for their use in shaping articles, as well as shaping articles produced thereby.
U.S. Publication No. 2021/0172114 discloses methods for improving localized shaping and/or support functionalities, shape retention, comfort and/or stay of apparel and other fabric articles by applying an aqueous polyurethane dispersion at a selected intensity and/or at one or more selected locations of the apparel or other fabric article. Apparel and other fabric articles with improved localized shaping and/or support functionalities, shape retention comfort and/or stay prepared in accordance with these methods are also provided.
International Application Publication No. WO 2021/178372 discloses fabrics and garments and methods for producing these fabrics and garments having a thin polymer layer which reduces degree of nipple protrusion.
This Summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
According to one aspect of the present disclosure, a bra cup for a bra includes an inner layer of material configured to face a wearer's breast when the bra is worn and an outer layer of material configured to face away from the wearer when the bra is worn. An outer face of the inner layer of material is adjacent an inner face of the outer layer of material. A thin polymer web is disposed on the outer face of the inner layer of material.
In one example, the thin polymer web comprises a plurality of line segments forming interconnected geometrical shapes. Optionally, a majority of the line segments in the plurality of line segments have a width of between 0.5 mm and 2.0 mm. In one particular example, a majority of the line segments in the plurality of line segments have a width of about 1.0 mm. Optionally, the geometrical shapes primarily comprise triangles.
In one example, the thin polymer web comprises an aqueous polyurethane dispersion. In one particular example, the aqueous polyurethane dispersion comprises a prepolymer comprising a glycol, an isocyanate, and a diol compound.
In one example, the thin polymer web extends over the entire outer face of the inner layer of material.
In one example, the thin polymer web extends over a first portion of the outer face of the inner layer of material that is configured to lie adjacent an underside of the wearer's breast when the bra is worn and over a second portion of the outer face of the inner layer of material that is configured to lie adjacent a laterally outer part of the wearer's breast when the bra is worn.
In one example, the inner layer of material comprises a mesh fabric and the outer layer of material comprises a lace fabric.
In one example, the inner and outer layers of material are coupled to each other only along an outer periphery of the bra cup.
According to another aspect of the present disclosure, a bra includes first and second bra cups, each of the first and second bra cups comprising a respective mesh layer configured to face a wearer's breast and a respective lace layer configured to face away from the wearer when the bra is worn. An outer face of the mesh layer is adjacent an inner face of the lace layer. A torso-encircling portion is coupled to at least one of the first bra cup and the second bra cup. A thin polymer web comprising an aqueous polyurethane dispersion is disposed on at least one of the outer face of the mesh layer and the inner face of the lace layer of each of the first and second bra cups. The thin polymer web comprises a plurality of line segments forming interconnected geometrical shapes. A majority of the line segments in the plurality of line segments have a width of between 0.5 mm and 2.0 mm.
In one example, the thin polymer web is disposed on the outer face of the mesh layer of each of the first and second bra cups, but not on the inner face of the lace layer of each of the first and second bra cups.
In one example, the thin polymer web extends over the entire outer face of the mesh layer of each of the first and second bra cups.
In one example, the thin polymer web extends over a first portion of the outer face of the mesh layer that is configured to lie adjacent an underside of the wearer's breast when the bra is worn and over a second portion of the outer face of the mesh layer that is configured to lie adjacent a laterally outer part of the wearer's breast when the bra is worn.
According to another aspect of the present disclosure, a method of manufacturing a bra cup for a bra includes: providing an inner layer of material configured to face a wearer's breast when the bra is worn; providing an outer layer of material configured to face away from the wearer when the bra is worn; disposing a thin polymer web on an outer face of the inner layer of material; and coupling the inner and outer layers of material together such that the outer face of the inner layer of material lies adjacent an inner face of the outer layer of material.
In one example, disposing the thin polymer web on the outer face of the inner layer of material comprises screen printing an aqueous polyurethane dispersion onto the outer face of the inner layer of material. Optionally, disposing the thin polymer web on the outer face of the inner layer of material comprises allowing the aqueous polyurethane dispersion to air dry for at least 30 minutes after the aqueous polyurethane dispersion has been screen printed onto the outer face of the inner layer of material and subsequently heat pressing or oven curing the inner layer of material with the dried aqueous polyurethane dispersion forming the thin polymer web disposed thereon.
In one example, the method further comprises layering the heat-pressed or oven-cured inner layer of material with the thin polymer web disposed thereon with the outer layer of material such that the outer face of the inner layer of material is adjacent the inner face of the outer layer of material; placing the layered inner and outer layers of material in a mold such that the outer layer of material is adjacent a female side of the mold and the inner layer of material is adjacent a male side of the mold; and molding the layered inner and outer layers of material together in the mold.
In one example, the thin polymer web comprises a plurality of line segments forming interconnected geometrical shapes. Optionally, a majority of the line segments in the plurality of line segments have a width of between 0.5 mm and 2.0 mm.
Various other features, objects, and advantages of the invention will be made apparent from the following description taken together with the drawings.
The present disclosure is described with reference to the following Figures. The same numbers are used throughout the Figures to reference like features and like components.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
Unless otherwise specified or limited, the phrases “at least one of A, B, and C,” “one or more of A, B, and C,” and the like, are meant to indicate A, or B, or C, or any combination of A. B, and/or C, including combinations with multiple instances of A, B, and/or C. Likewise, unless otherwise specified or limited, the terms “mounted,” “connected,” “linked,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.
As used herein, unless otherwise limited or defined, discussion of particular directions is provided by example only, with regard to particular embodiments or relevant illustrations. For example, discussion of “top,” “bottom,” “front,” “back,” “left,” “right,” “lateral” or “longitudinal” features is generally intended as a description only of the orientation of such features relative to a reference frame of a particular example or illustration. Correspondingly, for example, a “top” feature may sometimes be disposed below a “bottom” feature (and so on), in some arrangements or embodiments. Additionally, use of the words “first,” “second”, “third,” etc. is not intended to connote priority or importance, but merely to distinguish one of several similar elements from another. Unless otherwise specified or limited, the word “about” means±10%. The phrase “at least about” means greater than or equal to the value recited±10%. Unless otherwise specified or limited, the word “majority” means more than 50%.
Reference will be made herein to the “inner face” of a layer of material or a bra cup or to the “outer face” of a layer of material or a bra cup. The inner face is the surface that faces toward a wearer's skin when the bra is worn as intended. The outer face is the surface that faces outwardly away from the wearer when then bra is worn as intended.
As used herein, the term “dispersion” refers to a system in which the disperse phase consists of finely divided particles and the continuous phase can be a liquid, solid, or gas.
As used herein, the term “aqueous polyurethane dispersion” refers to a composition containing at least a polyurethane or polyurethane urea polymer or prepolymer (such as the polyurethane prepolymer described herein) that has been dispersed in an aqueous medium, such as water, including de-ionized water.
In the example of
According to the present disclosure, the thin polymer web 126 is disposed on at least one of the outer face 124 of the mesh layer 122 and the inner face 121 of the lace layer 120 of each of the first and second bra cups 102. As shown in
The thin polymer web 126 is shown in isolation in
According to the present disclosure, a majority of the line segments 130 in the plurality of line segments have a width (i.e., the lateral dimension of a line segment 130 when viewed in plan) of between 0.5 mm and 2.0 mm. More particularly, in one example, a majority of the line segments 130 in the plurality of line segments have a width of between 0.8 mm and 1.2 mm. Preferably, a majority of the line segments 130 in the plurality of line segments have a width of about 1.0 mm. In one particular example, more than 90% of the line segments 130 have a width of about 1.0 mm, which may prevent clogging of the holes in the mesh with polymer and which ensures that the inner layer of material 122 with the thin polymer web 126 is lightweight and breathable while still providing a desired level of support. A width greater than 1.0 mm can increase the stiffness of the inner layer of material 122, which may be undesirable or desirable depending on the application. In one example, the thickness (i.e., the dimension of a line segment 130 when viewed in elevation, as projecting from the face of the material onto which it is applied) of each line segment is 100 micron to 1500 micron, preferably 200 micron to 500 micron. In one example, each line segment 130 has a length (i.e., the longitudinal dimension of a line segment 130 when viewed in plan) of between 0.3 mm to 1.5 mm, more particularly between 0.5 mm and 1.2 mm.
In the example of
In some examples, the bra 100 comprises only one layer of material and the thin polymer web 126 is provided on the outer face of that single layer of material. For instance, the bra 100 may comprise only a layer of lace, with the thin polymer web 126 disposed on the outer face of the lace. However, providing the mesh layer 122 may enhance the comfort of the bra 100, as mesh may be more comfortable against the wearer's skin than lace. The mesh layer 122 can be brushed on the inner face thereof that touches the wearer's skin, further enhancing the comfort against the wearer's skin in comparison to a mesh layer that is not brushed. Further, disposing the thin polymer web 126 on the mesh layer 122 instead of the lace layer 120 allows for easier manufacturing, as the same manufacturing process can be used on the same mesh layer 122 for every bra. The lace layer 120 can then be varied to provide a different aesthetic to each bra, and the manufacturing process does not need to be redeveloped to provide the thin polymer web 126 on each different type of lace that may be desired to be used in the bra 100.
In the example of
According to the present disclosure, the thin polymer web 226 is disposed on at least one of the outer face 224 of the mesh layer 222 and the inner face of the lace layer 220 of each of the first and second bra cups 202. As shown in
The thin polymer web 226 is shown in isolation in
According to the present disclosure, a majority of the line segments 230 in the plurality of line segments have a width of between 0.5 mm and 1.5 mm. More particularly, in one example, a majority of the line segments 230 in the plurality of line segments have a width of about 1.0 mm. In one example, the thickness of each line segment is 100 micron to 1500 micron, preferably 200 micron to 500 micron. In one example, each line segment 230 has a length of between 0.3 mm to 1.5 mm, more particularly between 0.5 mm and 1.2 mm.
In the example of
In some examples, the bra 200 comprises only one layer of material and the thin polymer web 226 is provided on the outer face of that single layer of material. For instance, the bra 200 may comprise only a layer of lace, with the thin polymer web 226 disposed on the outer face of the lace. However, providing the mesh layer 222 may enhance the comfort of the bra 200, as mesh may be more comfortable against the wearer's skin than lace. Further, disposing the thin polymer web 226 on the mesh layer 222 instead of the lace layer 220 allows for easier manufacturing as noted hereinabove.
The above examples of
In the example of
As shown in
According to the present disclosure, the thin polymer web 326 is disposed on at least one of the outer face 324 of the inner layer of material 322 and the inner face of the outer layer of material 320 of each of the first and second bra cups 302. As shown in
The thin polymer web 326 is shown in isolation in
According to the present disclosure, a majority of the line segments 330 in the plurality of line segments have a width of between 0.5 mm and 1.5 mm. More particularly, in one example, a majority of the line segments 330 in the plurality of line segments have a width of about 1.0 mm. In one example, the thickness of each line segment is 100 micron to 1500 micron, preferably 200 micron to 500 micron. In one example, each line segment 330 has a length of between 0.3 mm to 1.5 mm, more particularly between 0.5 mm and 1.2 mm.
In the example of
In some examples, the bra 300 comprises only one layer of material and the thin polymer web 326 is provided on the outer face of that single layer of material. However, providing a second layer of material over the layer of material bearing the thin polymer web 326 may enhance the aesthetics of the bra 300 from the outside.
The present disclosure is therefore more generally related to a bra cup 102, 202, 302 for a bra 100, 200, 300. The bra cup 102, 202, 302 comprises an inner layer of material 122, 222, 322 configured to face a wearer's breast when the bra 100, 200, 300 is worn. The bra cup 102, 202, 302 also comprises an outer layer of material 120, 220, 320 configured to face away from the wearer when the bra 100, 200, 300 is worn. An outer face 124, 224, 324 of the inner layer of material 122, 222, 322 is adjacent an inner face of the outer layer of material 120, 220, 320. A thin polymer web 126, 226, 326 is disposed on the outer face 124, 224, 324 of the inner layer of material 122, 222, 322. In a nonlimiting example, the thin polymer web 126, 226, 326 comprises a plurality of line segments 130, 230, 330 forming interconnected geometrical shapes. Through research and development, the present inventors have discovered that the varying orientations and sizes of the primarily triangular geometrical shapes formed by the plurality of line segments 130, 230, 330 in the above-noted bras 100, 200, 300 are particularly advantageous for providing breathable support that does not render the bra cups 102, 202, 302 too stiff. However, the thin polymer web 126, 226, 326 may have different forms than the examples shown in
For example,
While
In the example of
According to the present disclosure, the thin polymer web 426 is disposed on at least one of the outer face 424 of the inner mesh layer 422 and the inner face of the outer lace layer of each of the first and second bra cups 402a, 402b. In this example, the thin polymer web 426 is disposed on the outer face 424 of the inner mesh layer 422 of each of the first and second bra cups 402a, 402b, but not on the inner face of the outer lace layer of each of the first and second bra cups 402a, 402b. However, in other examples it may be advantageous to dispose the thin polymer web 426 on the inner face of the outer layer of material only or on both the inner face of the outer layer of material and on the outer face 424 of the inner layer of material 422.
As shown in
According to the present disclosure, a majority of the line segments 430 in the plurality of line segments have a width of between 0.5 mm and 1.5 mm. More particularly, in one example, a majority of the line segments 430 in the plurality of line segments have a width of about 1.0 mm. In one example, the thickness of each line segment is 100 micron to 1500 micron, preferably 200 micron to 500 micron. In one example, each line segment 330 has a length of between 0.3 mm to 1.5 mm, more particularly between 0.5 mm and 1.2 mm.
The method 1700 includes providing an inner layer of material 122 configured to face a wearer's breast when the bra 100 is worn, as shown at 1702. The inner layer of material 122 may be mesh or a more closely knit fabric as noted hereinabove. The method also includes providing an outer layer of material 120 configured to face away from the wearer when the bra 100 is worn, as shown at 1704. The outer layer of material 120 may be mesh, lace, or a more closely knit fabric as noted hereinabove. After the inner layer of material 122 is provided, the method includes disposing a thin polymer web 126 on an outer face 124 of the inner layer of material 122, as shown at 1706. The thin polymer web 126 can be applied to selected locations of the inner layer of material 122 by methods such as, but not limited to, padding, coating, printing, painting, brushing, bonding, laminating, and spraying and combinations thereof. In one nonlimiting example, the polymer layer is printed onto the inner layer of material 122. In one particular example, disposing the thin polymer web 126 on the outer face 124 of the inner layer of material 122 comprises screen printing an aqueous polyurethane dispersion onto the outer face 124 of the inner layer of material 122.
In a nonlimiting example, to prepare for screen printing, the inner layer of material 122 may be placed on a lower frame that is situated on a plate, with the surface that will become the outer face 124 facing up. An upper frame can be aligned with the lower frame and placed on top of the inner layer of material 122 to hold the inner layer of material 122 in place. The plate holding the frames and inner layer of material is moved to the screen printing area. The screen printer is provided with a screen having apertures in the desired arrangement for printing and the plate is located under the screen such that the polymer will be printed on the desired locations on the inner layer of material 122. As noted above, the thin polymer web 126 comprises a plurality of line segments 130 forming interconnected geometrical shapes, and thus the apertures in the screen match the arrangement of the desired plurality of line segments 130 forming interconnected geometrical shapes. Also as noted above, a majority of the line segments in the plurality of line segments 130 have a width of between 0.5 mm and 1.5 mm, and thus the apertures cut in the screen accordingly have a width between 0.5 mm and 1.5 mm. In one example, the width of the apertures is 1.0 mm. The viscous aqueous polyurethane dispersion is disposed on the screen, after which the squeegees make at least one full pass (back and forth) across the screen to apply the aqueous polyurethane dispersion to the outer face 124 of the inner layer of material 122. Through research and development, the present inventors have determined that one back-and-forth pass and another single pass of printing deposits the preferable thickness (e.g., 100 micron to 1500 micron, preferably 200 micron to 500 micron) of aqueous polyurethane dispersion onto the outer face 124 of the inner layer of material 122. Less than a second may elapse between each pass of the squeegee so that the aqueous polyurethane dispersion does not dry during printing. Further, the screen and inner layer of material 122 may be kept moist with water vapor during printing so that the aqueous polyurethane dispersion does not dry during printing. After printing is complete, the plate, with the inner layer of material 122 still in the frame, can be removed from the printing area.
In one example, a double pallet, single head, automatic flat screen-printing machine may be used to carry out the screen printing. The printing may occur in a room having a temperature of 26.9° C. to 27.2° C. and a humidity between 67% to 70%.
In some instances in which the inner layer of material 122 is a mesh, the aqueous polyurethane dispersion may fill some of the holes in the mesh during the printing process. If this happens, the mesh may be blown with air to remove the aqueous polyurethane dispersion from the holes. To do so, the printed mesh may be placed between two screens and air may be vacuumed or blown at high pressure through the screens and the mesh. The polymer will remain on the fibers of the mesh, but the holes will no longer be filled with the polymer.
As shown at 1708, the method next includes allowing the aqueous polyurethane dispersion to air dry for at least 30 minutes after the aqueous polyurethane dispersion has been screen printed onto the outer face 124 of the inner layer of material 122. The present inventors have determined that allowing the aqueous polyurethane dispersion to dry for at least 30 minutes before heat pressing or oven curing allows the aqueous polyurethane dispersion to be printed onto materials such as lace or mesh, which have large openings between yarns/threads, with success. As shown at 1710, the method comprises subsequently heat pressing or oven curing the inner layer of material 122 with the dried aqueous polyurethane dispersion forming the thin polymer web 126 disposed thereon. The inner layer of material 122 may be placed between two release papers within the heat press and pressed at 120-140° ° C. for 30-60 seconds. In one particular example, the inner layer of material 122 with the thin polymer web 126 disposed thereon is heat pressed at 130° C. for 45 seconds, which may prevent a lightweight fabric from curling at higher temperatures. If the inner layer of material 122 is oven-cured, the time and temperature may be the same as those noted herein for heat pressing. The heat-pressed or oven-cured inner layer of material 122 may then be allowed to rest for at least 8 hours.
It should be understood that if the outer layer of material 120 is alternatively or additionally provided with the thin polymer web 126, the aqueous polyurethane dispersion may be disposed onto the desired face of the outer layer of material 120 in the same manner as that described hereinabove.
Next, the method 1700 comprises layering the heat-pressed or oven-cured inner layer of material 122 with the thin polymer web 126 disposed thereon with the outer layer of material 120 such that the outer face 124 of the inner layer of material 122 is adjacent the inner face 121 (
Finally, as shown at 1718, the method includes coupling the inner and outer layers of material 122, 120 together such that the outer face 124 of the inner layer of material 122 lies adjacent the inner face 121 of the outer layer of material 120 to form the bra cups 102a, 102b. In a nonlimiting example, the inner and outer layers of material 122, 120 are coupled to each other only along an outer periphery (103a, 103b,
Although the present bras 100, 200, 300 are all constructed in a similar manner and have traditional full coverage with underwires, the present disclosure is equally applicable to strapless bras as shown in
In the present description, certain terms have been used for brevity, clarity, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The different assemblies described herein may be used alone or in combination with other systems. Various equivalents, alternatives, and modifications are possible within the scope of the appended claims.
The present application is a continuation of U.S. application Ser. No. 18/155,375, filed Jan. 17, 2023, now U.S. Pat. No. 11,771,144, issued Oct. 3, 2023, which is hereby incorporated by reference in its entirety.
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Child | 18365329 | US |