Patent Application
20100056022
The present invention relates to improvements to brassieres.
Brassieres (hereinafter “bra”) are items of clothing that to many wearers are quite personal items. Their selection for purchase is primarily influenced by factors such as the comfort and support the bra provides the wearer. However many models of bras come in varying sizes to accommodate a range of such factors. Other factors that may influence the purchase of a bra are the aesthetic shape of the bra, the purpose for which it may be worn, and the bra color. The way a bra feels may also influence the purchase of a bra. Bra's come in many different materials. Lace, spandex, polyester are all materials that may be used in the construction of a bra. These materials all present a different tactile feel to the bra. Such is a superficial contact characteristic. It may be desirable for a bra to have other characteristics that can be felt, that are not superficial, in order to provide a user with a product that offers different or further factors that may appeal to them.
It is therefore an object of the present invention to provide a brassiere that has zones of different feel that will at least provide the public with a useful choice.
Accordingly in a first aspect the present invention consists bra that includes two breast cups that each include an outermost layer and an innermost layer, wherein at at least one breast cup, at least one intermediate panel is captured between the inner most layer and the outer most layer, and at least part of an edge of the intermediate panel is positioned at a location that is non-contiguous the perimeter of the cup to define within the cup perimeter at least two zones of different cross sectional composition.
Preferably at least the neckline perimeter of the at least one breast cup is defined at least by one of the outermost layer and innermost layer.
Preferably the innermost layer is laminated to a foam layer that is proximate more the outermost layer than the innermost layer.
Preferably the innermost layer and foam layer are coextensive.
Preferably the outermost layer is laminated to a foam layer that is proximate more the innermost layer than the outermost layer.
Preferably the outermost layer and second mentioned foam layer are coextensive.
Preferably the innermost layer is laminated to the outermost layer at regions save for where the intermediate panel is located.
Preferably the first mentioned foam layer is laminated to the outermost layer at regions save for where the intermediate panel is located.
Preferably the second mentioned foam layer is laminated to the innermost layer at regions save for where the intermediate panel is located.
Preferably the at least part of the edge of the intermediate panel extends or generally extends between (and preferably to and from) the neckline perimeter of the cup and the side perimeter of the cup.
Preferably the at least part of the edge of the intermediate layer extends or generally extends between (and preferably to and from) the neckline perimeter of the cup and the base perimeter of the cup.
Preferably the at least part of the edge of the intermediate layer extends or generally extends between (and preferably to and from) the side perimeter of the cup and the base perimeter of the cup.
Preferably at least one of the outermost and innermost layers comprises of at least two panels that correspond to or substantially align with the at least two zones of the at least one breast cup.
Preferably the at least two panels are at least in part joined to each other by ultrasonic welding.
Preferably at least one of the outermost and innermost layers comprises of at least two panels that define a boundary between said two panels that at least in part corresponds to or substantially aligns with at least part of the boundary of the at least two zones of the cup.
Preferably at least one of the outermost and innermost layers comprises of at least two panels that define a boundary between said two panels that corresponds to or substantially aligns with the boundary of the at least two zones of the cup.
Preferably both the innermost layer and the foam layer with which its laminated, each comprises of at least two panels that define a boundary between said two panels that at least in part corresponds to or substantially aligns with at least part of the boundary of the at least two zones of the cup.
Preferably both the outermost layer and the foam layer with which its laminated, each comprises of at least two panels that define a boundary between said two panels that at least in part corresponds to or substantially aligns with at least part of the boundary of the at least two zones of the cup.
Preferably the panels of the innermost layer and/or outermost layer and/or foam layers with which they are laminated are butt joined.
Preferably the panels of the innermost layer and/or outermost layer and/or foam layers with which they are laminated are joined in an overlapping manner.
Preferably the innermost layer and outermost layer are coextensive each other.
Preferably the inner most layer is a fabric layer.
Preferably the outer most layer is a fabric layer.
Preferably the intermediate panel is a panel of a material selected from one of foam, fabric and polyolefin.
Preferably there are at least two intermediate panels.
Preferably the at least two intermediate panels do not overlap each other.
Preferably each of the at least two intermediate panels are of a different characteristic (such as shape, thickness, material, composition, construction, color, texture, profile and/or density).
Preferably at least two of the panels defining the outermost layer are of a different characteristic (such as shape, thickness, material, composition, construction, color, texture, profile and/or density).
Preferably the at least one breast cup has lower region and an upper region, the lower region being having a harder hand feel than the upper region.
Preferably the lower region extends or generally extends from the base perimeter of the cup towards the neckline of the cup.
Preferably the upper region extends or generally extends from the neckline perimeter of the cup towards the base perimeter of the cup.
Preferably there is an intermediate region of the at least one breast cup having a hand feel that is intermediate that of the upper region and the lower region.
Preferably the intermediate region substantially separates the upper region and lower region.
Preferably the intermediate region extends or generally extends from the side perimeter region of the cup.
Preferably the intermediate panel is or comprises a ply of foam that has a thin perimeter region at at least part of the perimeter that is of a reduced thickness compared to other parts of the ply.
Preferably the intermediate panel is or comprises a non-stretch or substantially non-stretch fabric.
Preferably the bra is a molded bra.
Preferably the bra is a seamless bra.
In another aspect the present invention consists in a breast cup for a bra said breast cup comprising an outermost layer and an innermost layer and at least one intermediate panel that is captured between the innermost layer and the outermost layer, wherein at least part of an edge of the intermediate panel is positioned at a location that is non-contiguous the perimeter of the cup to define within the cup perimeter at least two zones of different cross sectional composition.
In another aspect the present invention consists in a method of producing a breast cup for a bra, the method comprising the steps of:
providing an outermost layer,
providing an innermost layer,
capturing an intermediate panel between the outermost layer and the innermost layer, the intermediate panel captured such that at least part of an edge of the intermediate panel is positioned at a location that is non-contiguous the perimeter of the breast cup so that at least two zones of different cross sectional compositions are defined within the cup perimeter.
Preferably prior to or at the time of capturing the intermediate panel the innermost layer is laminated to a foam layer that is to be positioned adjacent the intermediate panel.
Preferably the innermost layer and foam layer are coextensive.
Preferably prior to or at the time of capturing the intermediate panel the outermost layer is laminated to a second foam layer.
Preferably the outermost layer and innermost layer are shaped and positioned to be coextensive each other.
Preferably at least one of the outermost and innermost layers is formed from a plurality of panels joined together.
Preferably the joining of the plurality of panels is by ultrasonic welding.
Preferably the boundary between two of said panels joined together at least in part corresponds to at least part of the boundary of the two zones of the cup.
This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
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 some or all items of the bra that are more distal the body of the wearer. “Inner” does not necessarily mean “inner most” unless specified. This similarly applies to terms such as “outer” or “exterior”.
Where reference herein is made to “upper” or “lower” in relation to a bra or a bra cup, such is in relation to an orientation of the bra or bra cup where the bra or bra cup is in a state of being worn by a wearer in an upright position.
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).
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 may be of one ply or of more plies of the same or dissimilar characteristics (e.g. color, thickness, material, orientation, size) that are engaged to each other such as by lamination or other means in an at least partial overlapping and/or lapping configuration.
Where a seamless bra is mentioned, it is understood to mean that the bra is visibly substantially seamless, in that the edges of the bra are finished in a seamless way, for example by ultrasonic welding, or by folding the edge of an outer layer over and affixing it to an inner layer by a non-stitching means, or by some other means that is substantially without seams. Seams may however be found inside the bra structure where it is not externally visible, or is visibly less conspicuous externally at places such as the region where the shoulder strap is attached to a bra cup region, or the region where hook or eye tape is connected to the chest bands.
Where reference is made to soft or softer hand feel and hard or harder hand feel, this may primarily refer to but is not limited to the elasticity characteristics. Softer feel may mean but is not limited to more elasticity and harder feel may mean but is not limited to less elasticity.
The term “cross sectional composition” refers to the plies of material that may exist at any cross section taken through the cup of the bra. A non-homogenous cross sectional composition is for example one where at any given cross section, there may be different numbers of plies of material at different parts of the cross section. In addition or instead of a different number of plies, there may or may also be different materials, and/or the same materials having different characteristics.
As used herein the term “and/or” means “and” or “or”, or both.
As used herein “(s)” following a noun means the plural and/or singular forms of the noun.
The term “comprising” as used in this specification means “consisting at least in part of”. When interpreting statements in this specification which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as “comprise” and “comprised” are to be interpreted in the same manner.
A preferred form of the present invention will now be described with reference to the accompanying drawings in which:
With reference to
Such over the shoulder straps may however be optional as it is envisaged that the bra may also be of a strapless version. Indeed whilst reference is herein made to a bra, it is envisaged that the assembly of panels, component, parts and items to define such, may alternatively be incorporated into other garments such as, for example, evening dresses or bathing suits or similar.
At the ends of each of the chest bands may be fasteners 6 that are mutually cooperative to allow for the bra 4 to be fastened about the chest of a wearer.
The bra may be seamless and made from materials at least some of which are molded or moldable and that are engaged to each other preferably at least in part by lamination. Heat and pressure and/or adhesives are generally applied during such lamination. In one preferred form, the bra is a one-piece bra, so that at least the outermost layer and the innermost layer of the bra are each a continuous piece of, for example, fabric layer or layer of any other suitable material.
As can be seen with reference to
The breast cup region 1 preferably defines two breast cups 2 and 3 that are adjacent to each other and between which may extend an intermediate bridge region 8. At least some of the material components defining the breast cups 2 and 3 may be continuous over the entire breast cup region 1, including across the bridge region 8. Alternatively some or all of the material components may only be present at at least part of the breast cups 2 and 3.
In the preferred form, at least one of the layers of the breast cup region 1 is preferably continuous over the breast cup region 1 and preferably also over the bridge region 8. However in alternative forms each of the breast cups 2 and 3 may be separately predefined and may be affixed or joined together at the bridging region 8 to define, once assembled, a breast cup region 1.
The bra includes a neckline perimeter 9 at each of the breast cups 2 and 3. The neckline perimeter 9 may be continuous over the two breast cups or may be discretely defined for each breast cup. The neckline perimeter generally extends from an upper region of each breast cup preferably at where the shoulder straps 7 are engaged to the breast cup, to or towards the bridge region 8. The neckline perimeter 9 as shown in the bra in
Additional components, layers or plies of material may be provided with the materials defining the breast cup region and/or the bra, to those herein defined.
Variations to the bra shown in
The bra of the present invention has cups 2 and 3 that comprise zones of different cross sectional compositions and thus may have different tactile and/or elastic characteristics.
In the preferred embodiment of the invention there are panels 12, 13, 14, 15 and 16 which are joined together. The joints between adjacent panels may be abutting joints or overlapping joints that are preferably ultrasonically welded together. Ultrasonically-welded abutting joints are most preferred since the resultant fabric surface will have the joints visible but still remain smooth. An adhesive may also be used. Sewing may also be an alternative method of joining adjacent panels.
Alternatively, any number of panels may be used to form the outer most layer 11. Preferably at least two panels are used.
The panels of the inner most layer and/or outermost layer can be of different types, colors, texture, etc. Note that description herein in relation to the outermost layer may be applied instead, or in addition, to the innermost layer.
Each of the panels of
As an alternative to the preferred embodiment of the invention, the foam layer 10 may be unitary (not provided in panels) across the outer most layer 11. In such a configuration, the foam layer 10 is laminated to the outer most layer 11 after the panels of the outer most layer 11 are joined together.
The substantially non-stretch layers may preferably be selected from a non-stretchable or substantially non stretchable fabric. Their purpose is to increase the “hardness” of the regions where they are present.
The foam layer 20 may be of any suitable thickness and bonded to the substantially non-stretch layers 19 (and the foam layer 10, or fabric layer 11 underneath the substantially non-stretch layers) by any suitable means such as adhesive, possibly with heat and pressure applied. Whilst the foam layer 20 is present in the preferred embodiment of the invention, it is optional.
As an alternative to using the non-stretch or substantially non-stretch fabric layer 19, a foam layer may be used instead. This foam layer is generally harder than the foam layer 10 that is laminated to the outermost layer 11. Still alternatively, the increased hardness of a particular zone as compared with other zone(s) may be achieved by an increased thickness of the foam layer 10 or the second foam layer 20 at the place where increased hardness is desired.
As shown in
The inner most layer 21 is preferably a fabric layer, but may be any other suitable material. Preferably the inner most fabric layer is of the same material as the outer most fabric layer.
The laminate of
With reference to
For example, in the preferred embodiment of the invention as illustrated in
With reference to the embodiment as shown in
With reference to
The different characteristics (i.e. due to elasticity, hardness of materials etc) of the zones 30, 31 and 32 is created as a result of the layer or assembly of layers of material captured between the outermost fabric layer 11 and the innermost fabric layer 21 of the bra cup (or of the breast cup region of a molded bra as the case may be). The captured assembly of layers of material may consist only of foam layer(s) or may consist of a combination of foam layer(s) and (for example) non-stretch or substantially non-stretch fabric layer.
The “lines” defining the zones 30, 31, and 32 are optional. If they are present, they preferably correspond roughly to the dividing lines or boundaries between adjacent zones of different characteristics, so that one can merely by looking at the bra cup know, by the presence of those lines, where the three different characterizing regions are located. If the “lines” are absent, the outermost and/or innermost fabric layer can for example be one continuous piece of fabric.
There are preferably three zones or regions of different characteristics, but there can be more or less than three zones, yet there will always be more than one zone.
The harder characteristic of a particular zone (as compared with the characteristic of a softer zone) is implemented through a harder foam layer or assembly of layers captured between the inner and outer most layers at that zone. For example, the harder characteristic of a particular zone could be the result of a harder foam layer (for example, the second foam layer 20 may be such a harder foam layer), or the result of a thicker foam layer being molded to the same or substantially the same resultant thickness as the foam layer of the other zones(s) (for example, the second foam layer 20 may be such a thicker foam layer), or the result of a non-stretch or substantially non-stretch fabric layer (for example 100% nylon or polyester) being captured within the assembly of layers (the substantially non-stretch layer 19 described herein is an example of this), or a combination of any of these. Preferably there is at least one foam layer in the captured assembly of layers.
The different zones can take any shapes, and can be located anywhere over the bra cup. As to possible locations of the different hand feel regions, it depends on the preference of the individual as to which location is softer and which other location(s) is/are harder. It should be appreciated that the shapes and locations of the zones as shown in the Figures are exemplary only and many other configurations are possible without departing from the scope of the invention.
The zones can be produced by a number of ways. For example, the boundaries between the panels on the inner fabric layer or on the outer fabric or on both the inner and outer fabric layers can define the zones. Additionally, the layering of substantially non-stretch layers 19, and foam layer 20 can define the different zones.
With reference to the preferred embodiment shown in
On the other hand, zone 30 should essentially be (though not absolutely) rigid and not elastic in order to provide the necessary support to the breast.
The three-zone embodiment is the most preferred embodiment. In such an embodiment, the intermediate zone 31 may act as a “buffer or transitional zone” between the hard zone 30 and the softer zone 32. If the buffer zone is absent, the substantial difference in elasticity and hardness characteristics between the hard and soft zones could cause an abrupt splitting of the breast shape into two portions, one being substantially following the shape of the substantially rigid and non-elastic hard zone while the other portion is to a certain extent enlarged through the other substantially softer and more elastic zone.
The fabric material or some of the fabric material used may be of a material known by model number CMF-7440MU of Friendly Foundate Ltd. This fabric is made of 80% Tactel and 20% lycra. The fabric layers 11 and 21 may have a make-up of approximately 80% Tactel 40d/34f and 20% lycra 40d and of a weight of, for example, 190 g/m2.
The foam used is preferably a polyurethane foam of a precursor density of, for example, 30-40 kg/m3.
Adhesive used may be of a kind such as RM-30 of Ultra Energy Adhesive Trading Co., Ltd.
The non-stretch layer 19 may be 7118 of Goldspring Co. Ltd. It is preferably a piece of gauze which is 100% nylon or polyester.
One or all the molding processes occur preferably at an upper mold temperature of 180° C. to 200° C. and the lower mold is preferably of 180° C. to 200° C. The dwell time holding the mold portions together is for example 120 seconds.
More specifically, the foam hardness and density for a foam layer implementing varying degrees of hardness may be as follows:
Preferred foam thickness for a polyurethane foam layer for implementing varying degrees of hardness may be as follows:
The thickness after molding here refers to the thickness over the major portion of a zone excluding the portion (if any) at or close to the edge of the bra cup, since at or close to the edge of the bra cup the molded thickness will be reduced.
While the present invention has been described with reference to particular embodiments thereof, it will be understood that such embodiments are susceptible of modifications and variations without departing from the scope of the present invention and that the invention will include all embodiments falling within the scope of the appended claims.
