Patent Application
20150111466
The present disclosure relates to the field of garments and materials that can be used to construct garments.
intimate Wear, active Wear, and shape wear grip to a Wearer's body at focused pressure points, such as waistbands or other apertures for a wearer's torso and/or limbs. For example, strapless garments such as bras or tube tops usually grip to a wearer's body at several pressure points: along, a bra wing in the underarm region at both the top and bottom edge of the bra wing band. These pressure points and the pressure level are the focus for maintaining the strapless garment in place on the wearer's torso.
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 potentially claimed subject matter, nor is it intended to be used as an aid in limiting the scope of potentially claimed subject matter.
The present disclosure relates to a garment comprising a fabric that is knit so as to purposefully cling and grip to a wearer's body. Yarns made from, for example, thermoplastic polyurethane polymers, spandex, and/or latex may be used for such purposes. The yarns are knit into fabric such that they contact a wearer's skin, thereby providing an all-over clinging/gripping effect to the garment. Other features may be incorporated into bands, straps, and/or around apertures for a wearer's limbs, such as printing with silicone to enhance a clinging/gripping, effect at these areas. Glue bonding may be used to apply elastic to these areas, or wherever elastic is desired on a garment. Overall, a garment with such features dings to a wearer's body over the entire surface of the garment that is in contact with the wearer's body, rather than at the above-mentioned (or other) pressure points. The garment therefore stays in place and provides a tight-to-skin feel, while remaining lightweight and breathable.
The present disclosure therefore applies to any garment for which this tight-to-skin feel is desired, and is not limited to the exemplary strapless bra disclosed herein.
In one example of the present disclosure, a bra comprises a pair of bra cups, each bra cup in the pair having an inner edge and an outer edge, the inner edges configured to be coupled to one another. The bra includes a pair of bra wings, each bra wing in the pair having a first end and a second end, each first end being coupled to an outer edge of each bra. cup, respectively, and the second ends configured to be coupled to one another. At least one of the pair of bra cups and the pair of bra wings comprises a layer of fabric having intrinsically sticky fibers. The layer of fabric having intrinsically sticky fibers comprises an inner layer of the at least one of the pair of bra cups and the pair of bra wings and contacts a wearer's skin while the bra is being worn, so as to cause the bra to cling to the wearer's skin.
According to another example of the present disclosure, a method of manufacturing a bra comprises providing a first fabric having intrinsically sticky fibers and providing a second fabric, having intrinsically sticky fibers. The first fabric having intrinsically sticky fibers is fashioned into a pair of bra cups, each bra cup in the pair has an inner edge and an outer edge, and the inner edges are configured to be coupled to one another. The second fabric having intrinsically sticky fibers is fashioned into a pair of bra wings, each bra wing in the pair has a first end and a second end, each first end is coupled to a respective one of the outer edges of the bra cups, and the second ends are configured to be coupled to one another. The method includes situating the pair of bra cups and the pair of bra wings such that the first fabric having intrinsically sticky fibers and the second fabric having intrinsically sticky fibers both contact a wearer's skin while the bra is being worn, so as to cause the bra to cling to the wearer's skin.
Examples of articles of manufacture and methods for manufacturing garments and materials that can be used to construct garments are described with reference to the following figures. These same numbers are used throughout the figures to reference like features and like components.
The garment of the present disclosure is knitted using specific fibers, such as but not limited to polyester spandex, monopolyester, spandex, thermoplastic elastomers such as thermoplastic polyurethane (TPU) polymers, nylon, and latex. Specifically, in some examples, TPU polymers, spandex, and latex are used for their gripping abilities in order to cause the garment to cling, to the wearer's skin. These three fibers will hereinafter be referred to as “sticky fibers”. These sticky fibers are used not only for their performance properties such as stretch characteristics and modulus levels, but for their intrinsic surface nature as well, because when they are knitted in certain combinations and according to certain patterns, the resulting fabric exhibits properties that causes it to cling to a wearer's body, providing a “tight-to-skin” feel. Fabric knitted according to the herein described patterns using the herein described fibers can be incorporated into not only a strapless bra as described below, but into any other category of garments, such as but not limited to sports bras, panties, shapewear, and active wear. Fabrics such as those described herein provide improvement in comfort and wearability. The fabrics have a clinging (or gripping) effect on the skin of the wearer.
In the knitted fabrics described herein, each intrinsically sticky fiber that is in contact with the skin absorbs a portion of the force applied by a wearer's body to a garment as it is worn. The different tensions around the body while the garment is worn will be spread over all the surfaces where the wearer's skin and the garment are in contact, thereby eliminating any localized pressure points. When the fabric is used in a bra, this spreading of tension further eliminates localized pressure points where the top and bottom of the bra wing dig and cut into the wearer's skin, where the tip of the underwire digs in, and where an optional strap on the top of the shoulder carries the weight of the wearer's breast. Specifically, the compression properties of the TPU polymer yarn emphasizes these benefits as well.
There are four specific areas of the exemplary bra described herein below, each of which has been modified so as to provide a strapless garment which can move with the wearer's body and stay in place for a longer period of time than prior art bras. With reference to
The bra 9 of the present disclosure comprises a pair of bra cups 12, each bra cup 12 in the pair having an inner edge 13 and an outer edge 15, the inner edges 13 configured to be coupled to one another. In the example shown, the inner edges 13 are coupled to one another by a center gore 17. However, the cups 12 of the bra 9 could he connected directly to one another or the bra 9 could instead comprise a bandeau bra having two cup areas for each of the wearer's breasts.
The bra further comprises a pair of bra wings 10, each bra wing 10 in the pair having a first end 19 and a second end 21. Each first end 19 is coupled to the outer edge 15 of each bra cup 12, respectively, and the second ends 21 are configured to be coupled to one another. In the example shown, the second ends 21 are configured to be coupled to one another by a hook and eye closure 23. In alterative embodiments, the wings 10 of the bra 9 are continuous and extend across the entirety of the wearer's back. In this instance, the center gore 17 may comprise a front closure or clasp for the bra 9.
At least one of the pair of bra cups 12 and the pair of bra wings 10 comprises a layer of fabric having intrinsically sticky fibers. The layer of fabric having intrinsically sticky fibers comprises an inner layer of the at least one of the pair of bra cups 12 and the pair of bra wings 10 and contacts a wearer's skin while the bra is being worn, so as to cause the bra 9 to cling, to the wearer's skin. As mentioned above, the intrinsically sticky fibers comprise one or more of thermoplastic polyurethane polymers, spandex, and latex, as will be further described herein below as well.
Bra Wing
The fabric of the bra wing 10 may be knitted in any fashion, so long as the sticky fiber is knitted on one side of the garment such that it can be placed in contact with the wearer's skin in the fashioned form of the garment. For example, the fabric can be a traditional single or double knit fabric, such as for example jersey knit, or a single knit plated jersey fabric. The fabric may be made with spandex, TPU polymer, or latex yarns. Alternatively, the fabric is lace or mesh.
In one example as shown in
In the knitting pattern of
In one example, the TPU polymer yarn may be an elastic fiber that has a relatively flat modulus curve at between 100% and 200% elongation. The elastic fiber is made from thermoplastic polyurethane polymers and is made by a melt-spinning process where the fiber is wound onto bobbins at a speed just slightly higher than the melt velocity of the polymer exiting the spinneret. The TPU polymer yarn is strong due to its high molecular weight for a given denier. The TPU polymer yarn therefore provides a good elastic, modulus, which is needed during wearing. The TPU polymer yarn is thin and breathable. The TPU polymer yarn has high stretch because of its thermoplastic nature. Also at higher (body) temperature, its elongation will be increased by about 10% to 20% over that at room temperature. Its stretchiness can react to the body's temperature to provide more comfort during wearing. In one example, the TPU polymer yarn is created according to the processes described in U.S. Patent Publication No. 2010/0325782 and/or U.S. Pat. Nos. 7,763,351 and 7,799,255, all assigned to Lubrizol Advanced Materials, Inc., of Cleveland, Ohio. Lubrizol sells an exemplary TPU polymer yarn under the trademark X4ZOL™-J. Other TPU polymers or even other types of thermoplastic elastomers could be used for the fibers as well.
Fabric knitted from the TPU polymer yarn controls compression in 360° and in three dimensions (x-y-z), thereby providing comfort, shape, and support while allowing more freedom of movement. This three-dimensional nature allows fabric knitted from the TPU polymer yarn to balance stresses in order to allow freedom of movement. Fabric knitted from the TPU polymer yarn is easy to stretch in the x-y direction, so a garment made from the fabric is easy to put on and take off. Further, fabric made from the TPU polymer yarn provides compression in the z direction. This can help to hold the garment to the body more tightly.
When the TPU polymer yarn is exposed to the wearer's skin, its gripping surface helps the garment to stay up. A fabric, knitted with TPU polymer yarn generally has higher gripping effect than other fabrics without TPU polymer yarn. For example, the three-layer fabric knitted with TPU polymer yarn as disclosed herein (
In another example, the knitted three-layer fabric of the bra wing it) comprises a spandex layer in the back (layer 303) and middle (layer 302), and a nylon layer in the front (layer 301). This fabric is knitted according to the pattern shown in
In another example, the knitted three-layer fabric of the bra wing may 10 also comprise various combinations of yarn made from nylon, TPU polymers, and spandex, in any of the front, middle, or back layers.
In another example, the bra wing 10 comprises one or more layers of single knit or double knit fabric, such as for example jersey knit fabric, and is knit from nylon, polyester, nylon-polyester blend, or other yarn, laminated to a 100% spandex layer of fabric. The bra wing 10 could alternatively be lace or mesh knit from any of the above-mentioned types of yarns laminated to 100% spandex or with spandex as the back yarn. The 100% spandex layer of fabric rests against the wearer's skin to provide a gripping effect. In another example, a single knit or double knit fabric is knitted with spandex at the back. In yet other examples, the bra wing 10 is knitted as a spacer fabric, such as, for example, shown in
Bra Cup
The fabric of the bra cup 12 may be knitted in any fashion, so long as the sticky fiber is knitted on one side of the garment such that it can be placed in contact with the wearer's skin in the fashioned form of the garment. For example, the fabric can be a traditional single or double knit fabric, such as a single knit plated jersey fabric, mesh, or lace. The fabric can be made with spandex, TPU polymers, or latex yarns.
In one example as shown in
The 100% spandex back/inner face layer (yarn 401) clings/grips onto the skin, and replaces the typical silicone elastic used to hold a strapless bra up, which has a high modulus and often causes discomfort and irritation to the wearer at the above-mentioned pressure points.
In another example, yarn 401 is polyester spandex, yarn 402 is monopolyester, and yarn 403 is polyester spandex.
In another example, as shown in
As another alternative, a single knit or double knit fabric is knitted with spandex at the back, such that the spandex contacts the wearer's skin. As another alternative, a single knit, double knit, or spacer fabric knitted from nylon and/or polyester may be laminated to a 100% spandex fabric. If this 100% spandex fabric is provided on the back of the bra cup 12, it has a similar gripping effect to the spacer fabric with spandex knitted into the inner face layer, described herein above with reference to
As another alternative, a spacer fabric knitted from nylon and/or polyester may be knitted with TPU polymer yarn as the back layer.
As another alternative, a spacer fabric knitted from nylon and/or polyester may be knitted with multifilament yarn as the middle layer, rather than monofilament yarn.
Underwire Casing
Referring to
The silicone stripes 18 create resistance in opposition to the force of gravity, which tends to pull the cup down along the wearer's torso. This can help to better anchor the bra cup 12 to the body. Silicone stripes 18 provide a surface for contact with the skin 44 (see
Silicone stripes 18 can be printed or painted on to the underwire casing 16 in many different ways, one of which is provided by Stretchline USA Inc. of Rocky Mount, N.C. Some types of silicone that may be used, and processes associated therewith, are provided in U.S. Patent Publication Nos. 2006/0154053 and 2009/0053441, as well as GB 2305870 A.
In one example, as shown in
In one example, the silicone stripes 18 are horizontal with respect to the wearer's torso. (
In another example, the silicone stripes are perpendicular to the edge 22 of the underwire casing 16. (
In another example, a rib 20 can be woven into the underwire casing 16, instead of or in addition to providing silicone stripes. See
Elastic Bands
With reference to
The top and bottom elastic bands 14 provided on the bra wing 10 may be glue bonded with glue 24 to the bra wing 10 using a low temperature one-step bonding process, This provides stretch and a body-matching effect, as the elastic bands 14 move with the wearer.
Glue bonding gives high stretch, and requires only low temperature bonding. Because TPU polymer yarn is heat-sensitive, there is a possibility of shrinkage if the TPU polymer yarn is heated to high temperatures while the bra wing 10 is bonded to the elastic bands 14. As both the elastic bands 14 and the bra wing 10 may comprise TPU polymer yarn, if temperatures can be kept low, this runs less risk of heat-shrinking the TPU polymer yarn. A glue bonding machine is set to around 120-130 degrees Celsius, which is a low temperature that will not cause shrinkage attic TPU polymer yarn.
Glue bonding allows application of glue in different thicknesses on different parts of the garment as it is applied. Thickness can also be varied at finer levels (microns). Glue bonding such as that described herein can be done with glue provided by MAS Holdings of Colombo, Sri Lanka or MAS Intimates of Kandawala Estate, Ratmalana, Sri Lanka. In one example, the glue includes NCO-terminated urethane prepolymers and 4,4-methylenediphenyl diisocyanate.
Alternatively, the elastic bands 14 may be held to the bra wing 10 by heat-attached (“hot-melt”) adhesive tape, such as, for example, that provided by BemisTape of Minneapolis, Minn. Alternatively, the elastic bands 14 may be ultrasonically bonded to the bra wings 10. Alternatively, the elastic bands 14 may be sewn to the bra wings 10.
Alternatively, the elastic bands 14 may be made of spandex or latex instead of TPU polymers.
Add-One-Size
As shown in
Method
The present disclosure also contemplates a method of constructing the bra 9 shown in
In one example, the method comprises providing a first fabric, having intrinsically sticky fibers, as shown at 1401. The method also comprises providing a second fabric having intrinsically sticky fibers, as shown at 1403. The method next comprises fashioning the first fabric having intrinsically sticky fibers into a pair bra cups 12, each bra cup 12 in the pair having an inner edge 13 and an outer edge 15, and configuring the inner edges 13 to be coupled to one another, as shown at 1405, in one example, the inner edges 13 are coupled to one another by a center gore 17. The method may further comprise fashioning the second fabric having intrinsically sticky fibers into a pair of bra wings 10, each bra wing 10 in the pair having a first end 19 and a second end 21, coupling each first end 19 to a respective one of the outer edges 15 of the bra cups 12, and configuring the second ends 21 to be coupled to one another, as shown at 1407. In one example, the second ends 21 are coupled to one another with a hook and eye closure 23. The method further comprises situating the pair of bra cups 12 and the pair of bra wings 10 such that the first fabric having intrinsically sticky fibers and the second fabric, having intrinsically sticky fibers both contact a wearer's skin while the bra is being, worn so as to cause the bra to cling to the wearer's skin, as shown at 1409.
The intrinsically sticky fibers may comprise one or more of thermoplastic polyurethane polymers, spandex, and latex. The first fabric may comprise a knitted spacer fabric. The knitted spacer fabric may comprise an inner face knitted of spandex that contacts the wearer's skin. The second fabric may comprise a three layer fabric, and the three layer fabric may comprise an inner face knitted of thermoplastic polyurethane polymer that contacts the wearer's skin.
The method may further comprise providing a pair of underwire casings 16 having silicone stripes 18 fur contacting the wearer's skin, and coupling each underwire casing 16 to a lower edge 26 of each of the bra cups 12, respectively. The method may further comprise fashioning an inner bra cup 28 of a first size and an outer bra cup 30 of a second size that is larger than the first size and situating a layer of foam 32 between the inner and outer bra cups 28, 30. The layer of foam 32 forms a thin ledge 34 proximate the lower edge 26 of the bra cup 12, gradually widens to a thickest portion 36 above an apex of a wearer's breast, and gradually thins toward an upper edge 38 of the bra cup 12. The method may further comprising coupling elastic bands 14 to an upper edge 40 and a lower edge 42 of each bra wing 10 in the pair of bra wings 10. The method may further comprise gluing the elastic bands 14 to each bra wing 10.
In the above description certain terms have been used for brevity, clarity, and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. The different articles of manufacture and methods described herein above may he used in alone or in combination with other articles of manufacture and methods.
This application claims priority to U.S. Provisional Application No. 61/892,678, filed Oct. 18, 2013, which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61892678 | Oct 2013 | US |
