BRA CUP FOR A BRASSIERE AND MANUFACTURING METHOD THEREOF

Description

FIELD OF THE PRESENT DISCLOSURE

The present disclosure generally relates to brassieres, and in particular to a bra cup for the brassiere having means to provide air permeability and allow for dissipating heat from the skin of the wearer when the brassiere is worn.

BACKGROUND

Typically, a bra cup for a brassiere includes a pad along with the fabric layer therein. The pad is located normally covering the entire breast cup regions of a bra. These pads are normally made from a foam material and is incorporated between interior and exterior most layers of the bra. Pads that are incorporated in bras can help support the breasts and also create uplift. The pad also provides the flexibility to adapt the bra cup to conform to shape of a breast of a wearer. Traditionally, such pads are manufactured by compression molding process, in which a preformed solid foam form is created into a bra cup shape. However, the use of compression molding process has some disadvantages. The pad formed by using such process may generally have inconsistent densities along various section; for example, thick sections may have generally higher densities and thin sections may have comparably lower densities. Also, the use of foam pad may reduce the air permeability of such bra cups and thus makes the brassiere uncomfortable to wear for a long duration of time. Moreover, the use of foam pads may result in large surface area of inner side of the bra cup to be disposed in contact with the skin of the wearer which negatively affect the heat dissipation therefrom. Furthermore, such compression molding process makes it difficult to define or form any structures or shapes in such pads, to provide certain characteristics to the brassiere.

Accordingly, there is a need of a bra cup with means which provide high air-permeability and allow for dissipating heat so as to provide comfortable experience for the wearer when the brassiere is worn.

SUMMARY

In one aspect, a bra cup for a brassiere to be worn by a wearer is disclosed. The bra cup comprises a core layer formed of a foam material and having a three-dimensional configuration so as to conform to a breast of the wearer when the brassiere is worn. The core layer has an inner side and an outer side. A plurality of apertures are formed in the core layer. In the bra cup, one or more of the plurality of apertures have a truncated conical cross-section with a relatively larger diameter towards the inner side and a relatively smaller diameter towards the outer side.

In one embodiment, the plurality of apertures comprises a plurality of circular apertures formed in a lateral area of the bra cup. One or more of the plurality of circular apertures in a lower portion of the lateral area have the truncated conical cross-section.

In one embodiment, the plurality of apertures comprises a plurality of elongated apertures formed in a frontal area of the bra cup. One or more of the plurality of elongated apertures have a dumbbell shape with a slit and two openings formed at two ends of the slits respectively.

In one embodiment, the bra cup further comprises a plurality of protrusions defined in the core layer towards the inner side thereof. The protrusions are arranged in a matrix form such that one or more of the plurality of apertures are surrounded by three or more protrusions at the inner side of the core layer.

Preferably, the plurality of protrusions comprises a first set of protrusions with substantially square shape and a second set of protrusions with substantially parallelogram. The first set of protrusions are located in a frontal area of the bra cup and the second set of protrusions are located in a lateral area of the bra cup.

Preferably, the core layer and the plurality of apertures are formed by an injection molding process.

Preferably, the bra cup further comprises a mesh joined with the core layer in the injection molding process.

Preferably, the bra cup further comprises an underwire embedded within the core layer.

Preferably, the underwire is made either of metallic material or plastic material.

In one or more embodiments, the bra cup further comprises an inner layer comprising at least a fabric sheet and optionally a foam sheet, and arranged with respect to the core layer such that the inner layer is disposed to be in contact with the breast of the wearer, when the brassiere is worn; and an outer layer comprising at least a fabric sheet and optionally a foam sheet, and arranged with respect to the core layer such that the outer layer is located at a distal end from the breast of the wearer, when the brassiere is worn.

In another aspect, a method of manufacturing a bra cup for a brassiere is disclosed, the method comprises providing a foam material in liquid form. The method further comprises providing a mold arrangement comprising a first mold and a second mold. At least one of the first mold and the second mold have a plurality of projections defined therein. The method further comprises injecting the foam material into the mold arrangement between the first mold and the second mold. The method further comprises curing the foam material to be contoured into a three-dimensional configuration to form a core layer of the bra cup with a plurality of apertures, complementary to the plurality of projections, formed therein.

Preferably, the plurality of apertures comprises a plurality of elongated apertures disposed in a frontal area of the bra cup and a plurality of circular apertures disposed in a lateral area of the bra cup.

Preferably, one or more of the plurality of elongated apertures have a dumbbell shape with a slit and two openings formed at two ends of the slits respectively.

Preferably, one or more of the plurality of circular apertures in a lower portion of the lateral area have a truncated conical cross-section with a relatively larger diameter towards an inner side of the core layer and a relatively smaller diameter towards an outer side of the core layer.

Preferably, the method further comprises providing a mesh; and supporting the mesh on one or more first anchors between the first mold and the second mold during the injection of the foam material, such that the mesh is joined with the core layer from at least one of an inner side and an outer side thereof when the foam material is cured.

Preferably, the method further comprises providing an underwire; and supporting the underwire on one or more second anchors between the first mold and the second mold during the injection of the foam material, such that the underwire is embedded within the core layer when the foam material is cured.

Preferably, the method further comprises providing a fabric sheet which is to be part of an inner layer of the bra cup; and providing a fabric sheet which is to be part of an outer layer of the bra cup, such that the foam material is injected between the fabric sheet of the inner layer and the fabric sheet of the outer layer such that the formed core layer is joined therewith when the foam material is cured.

In yet another aspect, a bra cup for a brassiere to be worn by a wearer is disclosed. The bra cup comprises a core layer formed of a foam material and having a three-dimensional configuration so as to conform to a breast of the wearer when the brassiere is worn. The bra cup further comprises a plurality of apertures formed in the core layer. The plurality of apertures comprises a plurality of elongated apertures formed in a frontal area of the bra cup and a plurality of circular apertures formed in a lateral area of the bra cup.

Preferably, one or more of the plurality of elongated apertures have a dumbbell shape with a slit and two openings formed at two ends of the slits respectively, such that each of the one or more of the plurality of elongated apertures allows for expansion of the core layer along a direction substantially orthogonal to a direction of extension of the corresponding slit therein.

In still another aspect, a bra cup for a brassiere to be worn by a wearer is disclosed. The bra cup comprises a core layer formed of a foam material and having a three-dimensional configuration so as to conform to a breast of the wearer when the brassiere is worn. The core layer has an inner side and an outer side. The bra cup further comprises a plurality of apertures formed in the core layer. The plurality of apertures are extending between the inner side and the outer side of the core layer. The bra cup further comprises a plurality of protrusions defined in the core layer towards the inner side thereof. The protrusions are arranged in a matrix form such that one or more of the plurality of apertures are surrounded by three or more protrusions at the inner side of the core layer.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of example embodiments of the present disclosure, reference is now made to the following descriptions taken in connection with the accompanying drawings in which:

FIG. 1 illustrates a diagrammatic perspective view of a brassiere incorporating a bra cup, in accordance with one or more embodiments of the present disclosure;

FIG. 2A illustrates a diagrammatic perspective view of the bra cup, in accordance with one or more embodiments of the present disclosure;

FIG. 2B illustrates a partial side view of the bra cup along with a zoomed-in portion thereof, in accordance with one or more embodiments of the present disclosure;

FIG. 3A illustrates a front view of a core layer of a bra cup region of the brassiere, in accordance with a first embodiment of the present disclosure;

FIG. 3B illustrates a back view of the core layer of the bra cup region of the brassiere, in accordance with the first embodiment of the present disclosure;

FIG. 3C illustrates a cross-section view of the core layer taken along a line A-A′ of FIG. 3A, in accordance with the first embodiment of the present disclosure;

FIG. 4A illustrates a front view of the core layer of the bra cup region of the brassiere, in accordance with a second embodiment of the present disclosure;

FIG. 4B illustrates a back view of the core layer of the bra cup region of the brassiere, in accordance with the second embodiment of the present disclosure;

FIG. 5A illustrates a front view of the core layer of the bra cup region of the brassiere, in accordance with a third embodiment of the present disclosure;

FIG. 5B illustrates a back view of the core layer of the bra cup region of the brassiere, in accordance with the third embodiment of the present disclosure;

FIG. 6A illustrates a front view of the core layer of the bra cup region of the brassiere, in accordance with a fourth embodiment of the present disclosure;

FIG. 6B illustrates a back view of the core layer of the bra cup region of the brassiere, in accordance with the fourth embodiment of the present disclosure;

FIG. 6C illustrates a cross-section view of the core layer taken along a line B-B′ of FIG. 6A along with a zoomed-in portion thereof, in accordance with the first embodiment of the present disclosure; and

FIG. 7 illustrates a diagrammatic view depicting a molding arrangement for manufacturing the core layer with a shape of the bra cup defined therein, in accordance with one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one skilled in the art that the present disclosure can be practiced without these specific details. In other instances, apparatuses and methods are shown in block diagram form only in order to avoid obscuring the present disclosure.

Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments.

The embodiments are described herein for illustrative purposes and are subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but are intended to cover the application or implementation without departing from the spirit or the scope of the present disclosure. Further, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. Any heading utilized within this description is for convenience only and has no legal or limiting effect.

Where reference herein is made to interior and exterior or similar terminology in relation to component parts or items of the bra or part of the bra, it is meant to be understood to be in relation to the body of the wearer of the bra. For example, the “interior” or “inner side” or “inner region” is a relative term to denote that an item is more proximate the face side of the bra that is more proximate to the body of the wearer than items of the bra that are more distal the body of the wearer. “Inner” does not mean “inner most” unless specified. This similarly applies to terms such as “outer” or “exterior”.

Where there is reference to the word “layer” it is to be understood that it may have its common definition and, but not limited to that the layer could consist of one panel or may have regions that are defined by two or more panels that are joined and that may each be of a different characteristic (e.g. color, thickness, material, orientation, size).

Referring to the drawings, FIG. 1 illustrates a diagrammatic view of a brassiere 100 (also, sometimes simply referred to as “bra 100”), in accordance with an embodiment of the present disclosure. In particular, FIG. 1 illustrates a bra cup region 102 of the brassiere 100. As illustrated, the bra cup region 102 preferably defines two bra cups (both of which are referred by a common numeral 104) that are generally identical to each other and are positioned adjacent to each other. As shown in FIG. 1, the bra cup region 102 may generally be divided into three areas; a frontal area 102a of the bra cup 104 (which spans around an apex center ‘C’ of the bra cup 104), a lateral area 102b (which spans the sides and undersides of the bra cup 104) of the bra cup 104 and a peripheral area 102c (which spans outside of the bra cups 104). An intermediate bridge region 106 may extend between the two bra cups 104. In the preferred form, at least one of the material components of the bra cup region 102 is continuous throughout therein and preferably also over the bridge region 106. However, in alternative forms each of the bra cups 104 may be separately predefined and may be affixed together at the bridge region 106 to define, once assembled, a bra cup region 102. In some examples, the bra cup region 102 may be seamless and made from materials at least some of which are molded and that are engaged to each other preferably at least in part by lamination. The brassiere 100 may further include elements, such as shoulder straps 108, chest bands 110, etc. for supporting the brassiere 100 against the body of the wearer, when worn.

In one embodiment of the present disclosure, the bra cup 104 is a multi-layer structure. FIG. 2A illustrates a diagrammatic view of the bra cup 104 and FIG. 2B illustrates a partial side edge view of the bra cup 104, of FIG. 1. As illustrated more clearly in FIG. 2B, the bra cup 104 includes three layers; a core layer 112, an inner layer 114 and an outer layer 116. As may be seen, the core layer 112 is disposed between the inner layer 114 and the outer layer 116, in the bra cup 104. The three layers 112, 114, 116 are arranged such that the inner layer 114 is disposed to be in contact with a breast of a wearer and the outer layer 116 is located at a distal end from the breast of the wearer, when the brassiere 100 is worn. The core layer 112 have an inner side 112a (as illustrated more clearly in FIG. 3B) which is disposed in contact with the inner layer 114 and an outer side 112b (as illustrated in more clearly FIG. 3A) which is disposed in contact with the outer layer 116, when the brassiere 100 is in its completed form. In general, as illustrated in the associated drawings, the core layer 112 has a three-dimensional configuration, such that the bra cup 104 has a generally concave shape when viewed with respect to the inner layer 114 in front and a generally convex shape when viewed with respect to the outer layer 116 in front.

In the brassiere 100, the core layer 112 is made of foam material. The foam material provides the flexibility to the core layer 112, and thereby the bra cup 104 which is required for conforming to the breast of the wearer, when the brassiere 100 is worn. In one or more embodiments, the foam material includes one of polyurethane-based material, silicone-based material, latex-based material and rubber-based material. Preferably, the foam material includes one of thermoplastic rubber (TPR), thermoplastic polyurethane (TPU), silicone, ethylene vinyl acetate (EVA), polyvinyl chloride (PVC) and polypropylene (PP). Further, in one embodiment, both of the inner layer 114 and the outer layer 116 includes a fabric sheet (not shown). In other embodiments, both of the inner layer 114 and the outer layer 116 includes a fabric sheet (not shown) and a foam sheet (not shown). In such case, the fabric sheet and the foam sheet may be laminated and co-extensive with each other. The inner layer 114 and the outer layer 116 are arranged with respect to the core layer 112 such that the foam sheets thereof are in contact with the inner side 112a and the outer side 112b of the core layer 112 and thereby the fabric sheets thereof form the exterior surfaces of the bra cup 104, when the brassiere 100 is in its completed form.

In one example, the fabric sheets may be a product known by model number CMF-7440MU of Friendly Foundate Ltd. and having a make-up of approximately 80% Tactel and 20% Lycra, and of a weight of, for example, about 190 g/sqm. Further, the foam sheets are preferably of a polyurethane foam such as, for example, EL58-4S of Inoac Corporation which is a memory foam. In some examples, the fabric sheet and the foam sheet of the corresponding layer may be laminated together using an adhesive, such as glue HM-1 of Forbo Swift Adhesives SA. The adhesive may be sprayed onto at least one of the opposing facing surfaces of the fabric sheet and the foam sheet. The adhesive may stick the fabric sheet and the foam sheet together when dry without heating, to form the corresponding panels for the inner layer 114 and the outer layer 116.

Further, as illustrated in FIGS. 2A-2B, the bra cup 104 includes a mesh 118, such as a mesh fabric, joined with the core layer 112. In some examples, the mesh 118 is formed with the core layer 112 in the injection molding process (as will be discussed later). The mesh 118 provides support to the core layer 112 and prevent breaking of the core layer 112 during the said injection molding process. In the illustrated example, the mesh 118 is shown to be provided between the core layer 112 and the outer layer 116; however, in other examples, the mesh 118 may be provided between the core layer 112 and the inner layer 114 without affecting the scope of the present disclosure. In some other examples, the bra cup 104 may have two meshes 118 provided between the core layer 112 and the outer layer 116, as well as between the core layer 112 and the inner layer 114. Furthermore, as illustrated in FIGS. 2A-2B, the bra cup 104 also includes an underwire 120 embedded within the core layer 112. In one or more examples, the underwire 120 may generally be a U-shaped wire. The underwire 120, in each bra cup 104, may help to shape and support lower periphery of the corresponding bra cup 104, in the core layer 112. The underwire 120 is made either of metallic material or plastic material, like a rigid plastic material.

FIGS. 3A-3B illustrate front and back views of the core layer 112, respectively, spanning the entire bra cup region 102, according to a first embodiment of the present disclosure. It may be contemplated that although the core layer 112 is shown spanning the entire bra cup region 102; in other examples, the core layer 112 may be spanning only one of the bra cup 104, and the two such core layers for respective two bra cups 104 may be joined together later to define the bra cup region 102, without any limitations. As illustrated in FIGS. 3A-3B, each of the bra cups 104 includes a plurality of apertures (generally designated by the numeral 122) formed in the core layer 112. In one or more examples, the plurality of apertures 122 are circular apertures in the form of circular holes formed in the core layer 112. In other examples, the apertures 122 may have different shapes, such as but not limited to, elliptical, triangular, hexagonal, square, rectangular, or the like without any limitations. Further, in one or more examples, one or more of the apertures 132 have a truncated cross-section, similar to the apertures 122 in the lower portion 102d of the lateral area 102b of the bra cup 104, as discussed in reference to FIGS. 3A-3C. As may be seen, the plurality of apertures 122 may be disposed radially outwards from the center ‘C’ of the bra cup 104 (which is also an apex thereof). As illustrated in FIGS. 3A-3B, the plurality of apertures 122 are formed both in the frontal area 102a and the lateral area 102b of the bra cup 104. In one or more embodiments, the bra cup 104 have a denser concentration of the apertures 122 around the center ‘C’, and the concentration of the apertures 122 may start decreasing in a regular or irregular manner moving radially away from the center ‘C’. As may be seen, the bra cup 104 may generally have a relatively larger concentration of the apertures 122 in the frontal area 102a as compared to the lateral area 102b. In one or more examples, the peripheral area 102c also has apertures 122 formed therein.

In the present embodiment, the apertures 122 formed in the lateral area 102b of the bra cup 104 in the core layer 112 have a truncated conical cross-section, while the apertures 122 formed in the frontal area 102a of the bra cup 104 in the core layer 112 have a substantially cylindrical cross-section. In other words, the apertures 122 formed in the lateral area 102b have a relatively larger diameter towards the inner side 112a of the core layer 112 and a relatively smaller diameter towards the outer side 112b of the core layer 112. In one or more embodiments, only the apertures 122 formed in a lower portion (generally shown with numeral 102d in FIGS. 3A-3C) of the lateral area 102b of the bra cup 104 have the truncated conical cross-section. That is, at least one of the apertures 122 in the lower portion 102d of the lateral area 102b has a larger diameter at the inner side 112a as compared to the same aperture 122 at the outer side 112b. This implies that the apertures 122 in the lower portion 102d of the lateral area 102b at the inner side 112a being generally larger than the apertures 122 in the frontal area 102a at the inner side 112a; whereas the apertures 122 at the outer side 112b are generally even-sized. This is done because larger diameter apertures are not desirable on the outer side 112b, as it is preferable to have a smooth outlook of the bra cup 104 from the outside, and thus even-sized apertures 122 are provided therein. Further, it may be contemplated that in case the apertures 122 have larger diameter at the outer side 112b, it may possibly render the bra cup 104 as see-through, which is again not desirable.

FIG. 3C illustrates a cross-section view of the bra cup 104 of FIGS. 3A-3B taken along a line A-A′ of the core layer 112 of FIG. 3A. As may further be seen from the section view of FIG. 3C, the apertures 122 in the lower portion 102d of the lateral area 102b have the truncated conical shape between the inner side 112a and the outer side 112b. It may be appreciated by a person skilled in the art that the lower portion 102d of the lateral area 102b of the bra cup 104 is generally tightly fit to the breast of the wearer, and thus may possibly develop and accumulate more sweat from the breast of the wearer, when the brassiere 100 is worn. The larger diameter of the apertures 122 at the inner side 112a of the core layer 112 aids with improving ventilation around the lower portion 102d of the lateral area 102b of the bra cup 104 to mitigate such issues to some extent. As a result, the truncated conical cross-section of the apertures 122 may help with providing some relief to the wearer by improving ventilation and thus enhances the comfort to the wearer, when the brassiere 100 is worn. Furthermore, the truncated conical cross-section of the apertures 122 in the core layer 112 reduces the amount of the foam material that may be required for forming the core layer 112, and may thus reduce the cost of manufacturing the core layer 112 for the present brassiere 100.

FIGS. 4A-4B illustrate front and back views of the core layer 112, respectively, spanning the entire bra cup region 102, according to a second embodiment of the present disclosure. It may be contemplated that although the core layer 112 is shown spanning the entire bra cup region 102; in other examples, the core layer 112 may be spanning only one of the bra cup 104, and the two such core layers for respective two bra cups 104 may be joined together later to define the bra cup region 102, without any limitations. In the present embodiment, the plurality of apertures 122 formed in the core layer 112 of the bra cup 104 includes a plurality of circular apertures 124 and a plurality of elongated apertures 126. In some examples, the circular apertures 124 may generally be in the form of holes formed in the core layer 112 and the elongated apertures 126 may generally be in the form of slits formed in the core layer 112. In one or more examples, the circular apertures 124 are formed generally in the lateral area 102b of the bra cup 104 and the elongated apertures 126 are formed generally in the frontal area 102a of the bra cup 104.

As may be seen in FIGS. 4A-4B, the elongated apertures 126 are disposed substantially in a circular fashion around the center ‘C’ of each of the bra cup 104. In particular, the elongated apertures 126 may be arranged along one or more circular tracks of different diameters around the center ‘C’ of each of the bra cup 104. Specifically, the elongated apertures 126 may be so arranged such that the slits formed in the core layer 112 are generally extending along a longitudinal direction ‘X’ of the bra cup 104 and thereby allow for expansion of the bra cup 104 along a lateral axis ‘Y’ thereof. Such lateral expansion of the bra cup 104 allows the bra cup 104 to expand (if needed) and conform to the shape of the breast of the wearer with relatively much ease, when the brassiere 100 is worn. Further, in one or more examples, one or more of the circular apertures 124 have a truncated cross-section, similar to the apertures 122 in the lower portion 102d of the lateral area 102b of the bra cup 104, as discussed in reference to FIGS. 3A-3C.

FIGS. 5A-5B illustrate front and back views of the core layer 112, respectively, spanning the entire bra cup region 102, according to a third embodiment of the present disclosure. It may be contemplated that although the core layer 112 is shown spanning the entire bra cup region 102; in other examples, the core layer 112 may be spanning only one of the bra cup 104, and the two such core layers for respective two bra cups 104 may be joined together later to define the bra cup region 102, without any limitations. In the present embodiment, the plurality of apertures 122 formed in the core layer 112 of the bra cup 104 includes a plurality of circular apertures 128 and a plurality of elongated apertures 130. In some examples, the circular apertures 128 may generally be in the form of holes formed in the core layer 112. In the present embodiment, as illustrated in FIGS. 5A-5B, one or more of the elongated apertures 130 have a dumbbell shape with a slit 130a, and two openings 130b formed at two ends of the slits 130a respectively. In one or more examples, the circular apertures 128 are formed in the lateral area 102b of the bra cup 104 and the elongated apertures 130 are formed in the frontal area 102a of the bra cup 104.

As may be seen in FIGS. 5A-5B, the elongated apertures 130 are disposed substantially in a circular fashion around the center ‘C’ of each of the bra cup 104. In particular, the elongated apertures 130 may be arranged along one or more circular tracks of different diameters around the center ‘C’ of each of the bra cup 104, such that each of the one or more of the plurality of elongated apertures 130 allows for expansion of the core layer 112 along a direction substantially orthogonal to a direction of extension of the corresponding slit 130a in the core layer 112. Specifically, the elongated apertures 130 may be so arranged such that the slits 130a formed in the core layer 112 are generally extending along the longitudinal direction ‘X’ of the bra cup 104 and thereby allow for expansion of the bra cup 104 generally along the lateral axis ‘Y’ thereof. Such lateral expansion of the bra cup 104 allows the bra cup 104 to expand (if needed) and conform to the shape of the breast of the wearer with relatively much ease, when the brassiere 100 is worn. Furthermore, the openings 130b in the elongated apertures 130 allows for enhanced ventilation from the elongated apertures 130 around the frontal area 102a in comparison to the elongated apertures 126 of the bra cup 104 of FIGS. 4A-4B. As may be understood, this improved ventilation may result in enhanced comfort to the wearer, when the brassiere 100 is worn. Further, in one or more examples, one or more of the circular apertures 128 have a truncated cross-section, similar to the apertures 122 in the lower portion 102d of the lateral area 102b of the bra cup 104, as discussed in reference to FIGS. 3A-3C.

FIGS. 6A-6B illustrate front and back views of the core layer 112, respectively, spanning the entire bra cup region 102, according to a fourth embodiment of the present disclosure. It may be contemplated that although the core layer 112 is shown spanning the entire bra cup region 102; in other examples, the core layer 112 may be spanning only one of the bra cup 104, and the two such core layers for respective two bra cups 104 may be joined together later to define the bra cup region 102, without any limitations. Further, it may be contemplated that although the outline of the bra cup region 102 is shown different in FIGS. 6A-6B as compared to FIGS. 3A-5B; in other examples, it may have similar outline without affecting the scope of the present disclosure in any manner. As illustrated in FIGS. 6A-6B, each of the bra cups 104 includes a plurality of apertures 132 formed in the core layer 112. In one or more examples, the plurality of apertures 132 are circular apertures in the form of holes formed in the core layer 112. The apertures 132 extend between the inner side 112a and the outer side 112b of the core layer 112. Further, as illustrated better in FIG. 6B, the bra cup 104 includes a plurality of protrusions 134 defined in the core layer 112 towards the inner side 112a thereof. As may be seen from FIG. 6B, the apertures 132 and the protrusions 134 are arranged individualistically at the inner side 112a of the core layer 112.

FIG. 6C illustrates a cross-section view of the bra cup 104 taken along a line B-B′ of FIG. 6A. As may be seen more clearly from FIG. 6C, the protrusions 134 may be defined by forming multiple grooves 136 in the inner side 112a of the core layer 112. The apertures 132 are generally disposed within the grooves 136 at the inner side 112a of the core layer 112. In one or more embodiments, the protrusions 134 are arranged in a matrix form such that one or more of the plurality of apertures 132 are surrounded by three or more protrusions 134 at the inner side 112a of the core layer 112. In the illustrated examples, the apertures 132 are disposed between two protrusions 134 in one direction, and between two other protrusions 134 in another direction. For this purpose, the protrusions 134 may be defined by forming two groups such that the grooves 136 in the same group are disposed parallel to each other and the grooves 136 in different groups are running in orthogonal directions with respect to each other, in the inner side 112a of the core layer 112. In other examples, the protrusions 134 may be arranged in a circular manner around the center ‘C’ or in a radial manner from the center ‘C’, without any limitations.

In one or more embodiments, the plurality of protrusions 134 includes a first set of protrusions 134a with substantially square shape and a second set of protrusions 134b with substantially parallelogram or rhombus shape, such that the first set of protrusions 134a are disposed proximal to the bridge region 106 of the bra cup 104 in the core layer 112 (i.e. towards a middle of the bra cup region 102) and the second set of protrusions 134b are disposed away from the bridge region 106 of the bra cup 104 in the core layer 112 (i.e. towards edges of the bra cup region 102). It may be understood that the change in shape of the protrusions 134 as moving away from the bridge region 106 of the bra cup 104 provides better fit of the bra cup 104 (with the three-dimensional configuration of the core layer 112) over the breast of the wearer, when the brassiere 100 is worn. In other examples, the protrusions 134 may have different shapes, such as but not limited to, circular, elliptical, triangular, hexagonal, or the like without any limitations. Further, in one or more examples, one or more of the apertures 132 have a truncated cross-section, similar to the apertures 122 in the lower portion 102d of the lateral area 102b of the bra cup 104, as discussed in reference to FIGS. 3A-3C.

It may be understood that a top of the protrusion 134 is in contact with the inner layer 114, when the brassiere 100 is in its completed form. Further, the ventilation space is created where protrusions 134 are absent; that is, in the grooves 136 at the inner side 112a of the core layer 112. The protrusions 134 in the core layer 112 further result in less material being used for the core layer 112 (due to the grooves 136 formed therein), which results in reduced weight of the core layer 112 and hence of the bra cup 104, without compromising the support provided to the breasts of the wearer, when the brassiere 100 is worn. As better illustrated in FIG. 6B, the peripheral area 102c of the bra cup region 102 may not have the protrusions 134 defined therein. In some examples, the peripheral area 102c flushes with the top of the protrusions 134 at the inner side 112a to provide a substantially smooth profile on the inner side 112a of the core layer 112.

In one or more embodiments of the present disclosure, the three layers 112, 114, 116 are either loose with respect to each other or affixed to each other. Preferably, the three layers 112, 114, 116 are molded together using known heat molding techniques involving the application of heat and pressure to form the bra cup 104. The core layer 112, the inner layer 114 and the outer layer 116 may be separately pre-molded and later joined together to form the bra cup 104. In one or more examples, the three layers 112, 114, 116 may be bonded or laminated during the molding process simply by the application of heat and pressure, or may additionally involve the use of an adhesive to facilitate bonding of the layers. The employed bonding techniques may depend largely on the nature of the various layers. In one example, the adhesive may be a glue such as RM-30 of Ultra Energy Adhesive Trading Co., Ltd. The adhesive may be sprayed on the inner side 112a and the outer side 112b of the core layer 112 and the corresponding facing surfaces of the inner layer 114 and the outer layer 116. The molding process may involve use of heat and pressure for joining together the three layers 112, 114, 116 together, and further aid with drying of the adhesive glue. For example, this adhesive may not get dry and sticky until heated, but then stick to join the three layers 112, 114, 116 when heated during the molding process. Further, the three layers 112, 114, 116 may be joined together by ultrasonic welding or the like. The following paragraphs explain in detail the molding setup and process for forming the core layer 112 (in accordance with the said third embodiment of FIGS. 5A-5C) with the shape of the bra cup 104 defined therein.

FIG. 7 illustrates a molding arrangement 700 for forming the core layer 112 of the bra cup 104. As illustrated, the molding arrangement 700 includes a first mold 702 and a second mold 704. As discussed, the core layer 112 is formed of the foam material, such as, for example, a polyurethane foam. In an embodiment, the core layer 112 is formed by injection molding process. For this purpose, the foam material in liquid form, and in appropriate quantity, is injected into a cavity between the first mold 702 and the second mold 704. The injection molding process of foam materials and the required parameters thereof are well known in the art and thus have not been described herein for the brevity of the present disclosure. The injection molding of the foam material forms a panel (not shown) with the core layer 112 having the desired three-dimensional configuration being a part thereof. Therefrom, the core layer 112 may be obtained by trimming the edges of such formed panel. As illustrated in FIG. 7, the first mold 702 and the second mold 704 may have projections 706 defined therein. These projections 706 may include one or more of cylindrical projections 706a and elongated projections 706b. In some examples, the elongated projections 706b may have a dumbbell shape. It may be contemplated by a person skilled in the art that the cylindrical projections 706a may define the complementary circular apertures, such as the circular apertures 128, and the elongated projections 706b may define the complementary elongated apertures, such as the elongated apertures 130, in the molded core layer 112.

In some embodiments, as illustrated, the mesh 118 may be placed between the first mold 702 and the second mold 704 so that the mesh 118 may be integrally formed with the core layer 112. For this purpose, the mesh 118 may be supported in a frame 708 to be kept stretched during the molding process. Further, one or more first anchors 710 may be provided with one or more of the first mold 702 and the second mold 704 to maintain a gap (generally equivalent to a thickness of the core layer 112) with one of the first mold 702 and the second mold 704, such that the mesh 118 is formed with one of the inner side 112a and the outer side 112b (as desired), when the foam material is cured. It may be understood that the mesh 118 helps with curing of the foam material into the shape of the core layer 112 without breaking. In some embodiments, as illustrated, the underwire 120 is supported on one or more second anchors 712 provided with either the first mold 702 or the second mold 704 (shown with the second mold 704 in the illustrated example) at a height (generally equivalent to half of a thickness of the core layer 112) so that the underwire 120 is embedded within the core layer 112, when the foam material is cured.

It may be contemplated by a person skilled in the art that the core layer 112 as provided in other above-mentioned embodiments (such as, for example, in reference to FIGS. 3A-3B, 4A-4B and 6A-6B) may be manufactured using slightly different molding arrangements (as compared to the molding arrangement 700); in particular, by having different types of projections 706 defined therein. For example, the core layer of FIGS. 6A-6C may be formed by using a molding arrangement with projections in the form of ridges to define the protrusions 134 therein. In one or more examples, the thickness of the formed core layer 112 is generally equal to the sum of the thicknesses of a base of the core layer 112, the protrusion 134 and the mesh 118. Exemplarily, the base of the core layer 112 has a thickness of 0.2 mm, the protrusion 134 has a thickness of 0.6 mm and the mesh 118 has a thickness of 0.2 mm, and therefore the thickness of the core layer 112 is about 1 mm. Additional components, layers or plies of material may be provided with the materials defining the bra cup region 102 and/or the bra cup 104, to those herein defined.

In the present brassiere 100, the bra cup 104 with apertures and protrusions formed in the core layer 112 thereof enhances the ventilation and air permeability of the bra cup 104. In addition, the bra cup 104 of the present disclosure with multi-layer structure provides higher deformability to conform to varying sized and shaped breasts, as compared to bra cup with a single thin foam layer as conventionally known in the art. The bra cup 104 being primarily formed from the foam material and generally light fabric sheets may be light-weight, and thus make the present brassiere 100 light in comparison to conventional brassieres. Therefore, the present brassiere 100 may provide enhanced comfort to the wearer, when worn. The present bra cup 104 further evenly distributes pressure caused by the weight of the brassiere 100 to the breasts of the wearer, thereby further enhancing comfort during long use.

Molding of the bra cup 104 may substantially simplify the otherwise complicated process of stitching various layers together. The bra cup 104 may be manufactured substantially without or with no significant stitching. This may result in significant savings in labor cost which may otherwise be needed for manual stitching of the various layers together. The implementation of injection molding for forming the core layer 112 results in even distribution of the foam material in the core layer 112 between thin and thick sections of the bra cup 104. This even density distribution of the foam material in the core layer 112 may enhance the stability of the overall brassiere 100, when worn. This further enhances the ability of the bra cup 104 to absorb impacts, including torsional and compressive forces. The fabric sheets of the inner layer 114 and the outer layer 116, which form the exterior surface of the bra cup 104, may provide breathable material in contact with the skin of the wearer, when the brassiere 100 is worn. This may help to absorb and disperse moisture from the skin to some extent, thereby further enhancing comfort for the wearer. Such fabric sheets may further be formulated with anti-microbial chemicals, which may improve hygiene conditions.

The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present disclosure and its practical application, to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated.

Claims

1. A bra cup for a brassiere to be worn by a wearer, the bra cup comprising: a core layer formed of a foam material and having a three-dimensional configuration so as to conform to a breast of the wearer when the brassiere is worn, the core layer having an inner side and an outer side; anda plurality of apertures formed in the core layer, wherein the plurality of apertures comprises a plurality of circular holes and a plurality of elongated apertures;wherein one or more of the plurality of circular holes have a truncated conical cross-section with a relatively larger diameter towards the inner side and a relatively smaller diameter towards the outer side, of the core layer;wherein the plurality of circular holes are formed in a lateral area of the bra cup, and the plurality of elongated apertures are formed in a frontal area of the bra cup; andwherein one or more of the plurality of circular holes in a lower portion of the lateral area have the truncated conical cross-section.
2. (canceled)
3. The bra cup as claimed in claim 1, wherein one or more of the plurality of elongated apertures have a dumbbell shape with a slit and two openings formed at two ends of the slits respectively.
4. The bra cup as claimed in claim 1 further comprising a plurality of protrusions defined in the core layer towards the inner side thereof, wherein the protrusions are arranged in a matrix form such that one or more of the plurality of apertures are surrounded by three or more protrusions at the inner side of the core layer.
5. The bra cup as claimed in claim 4, wherein the plurality of protrusions comprises a first set of protrusions with substantially square shape and a second set of protrusions with substantially parallelogram shape, and wherein the first set of protrusions are located in a frontal area of the bra cup and the second set of protrusions are located in a lateral area of the bra cup.
6. The bra cup as claimed in claim 1, wherein the core layer and the plurality of apertures therein are formed by an injection molding process.
7. The bra cup as claimed in claim 6 further comprising a mesh joined with the core layer in the injection molding process.
8. The bra cup as claimed in claim 1 further comprising an underwire embedded within the core layer.
9. The bra cup as claimed in claim 8, wherein the underwire is made either of metallic material or plastic material.
10. The bra cup as claimed in claim 1 further comprising: an inner layer comprising at least a fabric sheet and optionally a foam sheet, and arranged with respect to the core layer such that the inner layer is disposed to be in contact with the breast of the wearer, when the brassiere is worn; andan outer layer comprising at least a fabric sheet and optionally a foam sheet, and arranged with respect to the core layer such that the outer layer is located at a distal end from the breast of the wearer, when the brassiere is worn.
11. A method of manufacturing a bra cup for a brassiere, the method comprising: providing a foam material in liquid form;providing a mold arrangement comprising a first mold and a second mold, at least one of the first mold and the second mold having a plurality of projections defined therein;injecting the foam material into the mold arrangement between the first mold and the second mold; andcuring the foam material to be contoured into a three-dimensional configuration to form a core layer of the bra cup with a plurality of apertures, complementary to the plurality of projections, formed therein, wherein one or more of the plurality of apertures have a truncated conical cross-section with a relatively larger diameter towards the inner side and a relatively smaller diameter towards the outer side, of the core layer;wherein the plurality of apertures comprises: a plurality of elongated apertures disposed in a frontal area of the bra cup; anda plurality of circular holes disposed in a lateral area of the bra cup, wherein one or more of the plurality of circular holes in a lower portion of the lateral area have the truncated conical cross-section.
12. (canceled)
13. The method as claimed in claim 11, wherein one or more of the plurality of elongated apertures have a dumbbell shape with a slit and two openings formed at two ends of the slits respectively.
14. (canceled)
15. The method as claimed in claim 11 further comprising: providing a mesh; andsupporting the mesh on one or more first anchors between the first mold and the second mold during the injection of the foam material, such that the mesh is joined with the core layer from at least one of an inner side and an outer side thereof when the foam material is cured.
16. The method as claimed in claim 11 further comprising: providing an underwire; andsupporting the underwire on one or more second anchors between the first mold and the second mold during the injection of the foam material, such that the underwire is embedded within the core layer when the foam material is cured.
17. The method as claimed in claim 11, further comprising: providing a fabric sheet which is to be part of an inner layer of the bra cup; andproviding a fabric sheet which is to be part of an outer layer of the bra cup;wherein the foam material is injected between the fabric sheet of the inner layer and the fabric sheet of the outer layer such that the formed core layer is joined therewith when the foam material is cured.
18. A bra cup for a brassiere to be worn by a wearer, the bra cup comprising: a core layer formed of a foam material and having a three-dimensional configuration so as to conform to a breast of the wearer when the brassiere is worn, the core layer having an inner side and an outer side;a plurality of apertures formed in the core layer, the plurality of apertures extending between the inner side and the outer side of the core layer; anda plurality of protrusions defined in the core layer towards the inner side thereof, wherein the protrusions are arranged in a matrix form such that one or more of the plurality of apertures are surrounded by three or more protrusions at the inner side of the core layer;wherein the plurality of apertures comprises: a plurality of elongated apertures formed in a frontal area of the bra cup; anda plurality of circular holes formed in a lateral area of the bra cupwherein one or more of the plurality of elongated apertures have a dumbbell shape with a slit and two openings formed at two ends of the slits respectively, such that each of the one or more of the plurality of elongated apertures allows for expansion of the core layer along a direction substantially orthogonal to a direction of extension of the corresponding slit therein; andwherein one or more of the plurality of circular holes in a lower portion of the lateral area have a truncated conical cross-section with a relatively larger diameter towards the inner side of the core layer and a relatively smaller diameter towards the outer side of the core layer.
19-21. (canceled)
22. The bra cup as claimed in claim 18, wherein the plurality of protrusions comprises a first set of protrusions with substantially square shape and a second set of protrusions with substantially parallelogram shape, and wherein the first set of protrusions are located in a frontal area of the bra cup and the second set of protrusions are located in a lateral area of the bra cup.

PCT Information

Filing Document	Filing Date	Country	Kind
PCT/CN2018/076973	2/22/2018	WO	00

BRA CUP FOR A BRASSIERE AND MANUFACTURING METHOD THEREOF

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PCT Information