BRA WITH INTERMEDIARY FLEXIBLE LAYER AND METHOD FOR MANUFACTURING SAME

Abstract

A bra and method of manufacturing the same that is designed to (1) provide the optimum level of support, comfort, fit and coverage to a wearer of the bra, (2) visually enhance the wearer's figure by preventing cup gaping and side and top overflow or bulging, and (3) improve the breathability of the bra, thereby reducing sweat and irritation of the skin on or around the wearer's breasts. The bra of the present disclosure comprises bra cups that include intermediary flexible layers that are configured such that they allow the bra cups to stretch and contract to accommodate and fit snugly around the wearer's breasts.

Claims

1. An article of clothing to support the breasts of a wearer, comprising: first and second laterally positioned bra cups configured to receive the breasts of the wearer, each bra cup having an inner edge and outer edge, wherein the inner edges of the bra cups are near the sternum of the wearer, and the outer edges of the bra cups are near the sides of the wearer's body when the article of clothing is worn; first and second intermediary flexible layers, wherein the top portion of the first intermediary flexible layer is connected along the bottom portion of the first bra cup, and the top portion of the second intermediary flexible layer is connected along the bottom portion of the second bra cup; and first and second bust support members, wherein the top portion of the first bust support member is connected to the bottom portion of the first intermediary flexible layer and the top portion of the second bust support member is connected to the bottom portion of the second intermediary flexible layer.

2. The article of clothing of claim 1, wherein the first bust support member has an inner edge and an outer edge, and further wherein the inner edge of the first bust support member is connected to the inner edge of the first bra cup.

3. The article of clothing of claim 2, wherein the outer edge of the first bust support member is connected to the outer edge of the first bra cup.

4. The article of clothing of claim 2, wherein the first intermediary flexible layer is tapered near where the inner edge of the first bust support member is connected to the inner edge of the first bra cup, and further wherein the first intermediary flexible layer is connected to the inner edge of the first bra cup and the inner edge of the first bust support member.

5. The article of clothing of claim 3, wherein the first intermediary flexible layer is tapered near where the outer edge of the first bust support member is connected to the outer edge of the first bra cup, and further wherein the first intermediary flexible layer is connected to the outer edge of the first bra cup and the outer edge of the first bust support member.

6. The article of clothing of claim 1, wherein the second bust support member has an inner edge and an outer edge, and further wherein the inner edge of the second bust support member is connected to the inner edge of the second bra cup.

7. The article of clothing of claim 6, wherein the outer edge of the second bust support member is connected to the outer edge of the second bra cup.

8. The article of clothing of claim 6, wherein the second intermediary flexible layer is tapered near where the inner edge of the second bust support member is connected to the inner edge of the second bra cup, and further wherein the second intermediary flexible layer is connected to the inner edge of the second bra cup and the inner edge of the second bust support member.

9. The article of clothing of claim 7, wherein the second intermediary flexible layer is tapered near where the outer edge of the second bust support member is connected to the outer edge of the second bra cup, and further wherein the second intermediary flexible layer is connected to the outer edge of the second bra cup and the outer edge of the second bust support member.

10. The article of clothing of claim 1, wherein the article of clothing is selected from the group consisting of: a bra, a camisole, a tank top, a slip, a dress, and a bathing suit.

11. The article of clothing of claim 1, wherein the first and second intermediary flexible layers comprise one of LYCRA®, spandex, elastane, rubber, polyester, and nylon.

12. The article of clothing of claim 1, wherein the first and second intermediary flexible layers comprise an amount of fabric to allow first and second intermediary flexible layers to stretch.

13. The article of clothing of claim 1, wherein the first and second bust support members may be selected from the group consisting of an underwire channel comprising a wire, a bust support band and a panel.

14. An article of clothing to support the breasts of a wearer, comprising: first and second laterally positioned bra cup configurations, the first bra cup configuration comprising: a first bra cup configured to receive one of the breasts of the wearer, the first bra cup having an inner edge and an outer edge, a first bust support member having an inner edge and an outer edge, wherein the first bust support member is connected to the first bra cup near their respective inner edges and their respective outer edges such that a space is formed between the first bra cup and the first bust support member, and a first intermediary flexible layer disposed within the space formed between the first bra cup and the first bust support member, wherein the first intermediary flexible layer is configured to connect a portion of the first bra cup to the first bust support member; and the second bra cup configuration comprising: a second bra cup configured to receive one of the breasts of the wearer, the second bra cup having an inner edge and an outer edge, wherein the inner edges of the first and second bra cups are near the sternum of the wearer, and the outer edges of the first and second bra cups are near the sides of the wearer's body when worn, a second bust support member having an inner edge and an outer edge, wherein the second bust support member is connected to the second bra cup near their respective inner edges and their respective outer edges such that a space is formed between the second bra cup and the second bust support member, and a second intermediary flexible layer disposed within the space formed between the second bra cup and the second bust support member, wherein the second intermediary flexible layer is configured to connect a portion of the second bra cup to the second bust support member.

15. A method of manufacturing an article of clothing to support the breasts of a wearer, comprising: providing first and second laterally positioned bra cups configured to receive the breasts of the wearer, each bra cup having an inner edge and an outer edge, wherein the inner edges of the bra cups are near the sternum of the wearer, and the outer edges of the bra cups are near the sides of the wearer's body when worn; affixing a first intermediary flexible layer to the first bra cup, wherein the top portion of the first intermediary flexible layer is connected along the bottom portion of the first bra cup, affixing a first bust support member to the first intermediary flexible layer, wherein the top portion of the first bust support member is connected to the bottom portion of the first intermediary flexible layer; affixing a second intermediary flexible layer to the second bra cup, wherein the top portion of the second intermediary flexible layer is connected along the bottom portion of the second bra cup; and affixing a second bust support member to the second intermediary flexible layer, wherein the top portion of the second bust support member is connected to the bottom portion of the second intermediary flexible layer.

16. The method of claim 15, and further comprising affixing an inner edge of the first bust support member to an inner edge of the first bra cup.

17. The method of claim 16, and further comprising affixing an outer edge of the first bust support member to an outer edge of the first bra cup.

18. The method of claim 16, and further comprising tapering the first intermediary flexible layer as it approaches the connection between the inner edge of the first bust support member and the inner edge of the first bra cup, and further affixing the first intermediary flexible layer to the inner edge of the first bra cup and the inner edge of the first support member.

19. The method of claim 17, and further comprising tapering the first intermediary flexible layer as it approaches the connection between the outer edge of the first bust support member and the outer edge of the first bra cup, and further affixing the first intermediary flexible layer to the outer edge of the first bra cup and the outer edge of the first support member.

20. The method of claim 15, and further comprising affixing an inner edge of the second bust support member to an inner edge of the second bra cup.

21. The method of claim 20, and further comprising affixing an outer edge of the second bust support member to an outer edge of the second bra cup.

22. The method of claim 20, and further comprising tapering the second intermediary flexible layer as it approaches the connection between the inner edge of the second bust support member and the inner edge of the second bra cup, and further affixing the second intermediary flexible layer to the inner edge of the second bra cup and the inner edge of the second support member.

23. The method of claim 21, and further comprising tapering the second intermediary flexible layer as it approaches the connection between the outer edge of the second bust support member and the outer edge of the second bra cup, and further affixing the second intermediary flexible layer to the outer edge of the second bra cup and the outer edge of the second support member

24. The method of claim 15, wherein the article of clothing is selected from the group consisting of: a bra, a camisole, a tank top, a slip, a dress, and a bathing suit.

25. The method of claim 15, wherein the first and second intermediary flexible layers comprise one of LYCRA®, spandex, elastane, rubber, polyester, and nylon.

26. The method of claim 15, wherein the first and second intermediary flexible layers comprise an amount of fabric to allow first and second intermediary flexible layers to stretch.

27. The method of claim 15, wherein the first and second bust support members may be selected from the group consisting of an underwire channel comprising a wire, a bust support band and a panel.

28. An article of clothing to support the breasts of a wearer, comprising: at least one bra cup configured to receive the breasts of the wearer, the at least one bra cup having first and second side edges, wherein the first side edge of the at least one bra cup is near the left side of the wearer's body, and the second side edge of the at least one bra cup is near the right side of the wearer's body when the article of clothing is worn; at least one intermediary flexible layer, wherein the top portion of the at least one intermediary flexible layer is connected along the bottom portion of the at least one bra cup; and at least one bust support member, wherein the top portion of the at least one bust support member is connected to the bottom portion of the at least one intermediary flexible layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] A further understanding of the subject matter described herein can be obtained by reference to exemplary embodiments set forth in the illustrations of the accompanying drawings. Although the illustrated embodiments are merely exemplary of apparatuses described herein, both the organization and method of operation and manufacture thereof, in general, together with further objectives and advantages thereof, may be more easily understood by reference to the drawings and the following description. Like reference numbers generally refer to like features (e.g., functionally similar and/or structurally similar elements).

[0020] The drawings are not necessarily depicted to scale; in some instances, various aspects of the subject matter disclosed herein may be shown exaggerated or enlarged in the drawings to facilitate an understanding of different features. Also, the drawings are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended hereto or as subsequently amended, but merely to clarify and exemplify the present disclosure.

[0021] FIG. 1 depicts a rear view of a bra in accordance with an exemplary embodiment of the present disclosure;

[0022] FIG. 2 depicts a rear perspective view of the right bra cup of the bra shown in FIG. 1;

[0023] FIG. 3 depicts a close-up view of the inner edge of the right bra cup shown in FIG. 2; and

[0024] FIG. 4 depicts a close-up view of the outer edge of the right bra cup shown in FIG. 2.

DETAILED DESCRIPTION

[0025] The present disclosure may be understood more readily by reference to the following detailed descriptions of exemplary embodiments of the subject matter disclosed herein. However, devices, apparatuses, systems, and structures in accordance with the present disclosure may be embodied in a wide variety of forms and modes, some of which may be quite different from those in the disclosed embodiments. Also, the features and elements disclosed herein may be combined to form various combinations without exclusivity, unless expressly stated otherwise. Consequently, the specific structural and functional details disclosed herein are merely representative. Yet, in that regard, they are deemed to afford the best embodiments for purposes of disclosure and to provide a basis for the claims herein, which define the scope of the invention. It should also be noted that, as used in the specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly indicates otherwise.

[0026] Use of the term “exemplary” means illustrative or by way of example, and any reference herein to “the invention” is not intended to restrict or limit the present disclosure to the exact features of any one or more of the exemplary embodiments disclosed herein. Also, repeated use of the phrase “in one embodiment,” “in an exemplary embodiment,” or similar phrases do not necessarily refer to the same embodiment, although they may. It is also noted that terms such as “preferably,” “commonly,” and “typically,” are not used herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, those terms are merely intended to highlight alternative or additional features that may or may not be used in a particular embodiment of the present disclosure.

[0027] The present disclosure is directed to an article of clothing, such as a bra, and, particularly, to a bra that (1) provides the optimum level of support, comfort, fit and coverage to a wearer of the bra, (2) visually enhances the wearer's figure by preventing cup gaping and side and top overflow or bulging, and (3) improves the breathability of the bra, thereby reducing heat, sweat and irritation of the skin on or around the wearer's breasts. In certain embodiments, the bra comprises bra cups or bra pads that are configured such that they can stretch and contract to accommodate and fit snugly around the wearer's breasts. In other words, so that the bra cups can move with the wearer in order to improve wearer comfort and prevent unsightly cup bulging or gaping. To achieve these benefits, each bra cup comprises an intermediary flexible layer between the bottom of the bra cup and the support band, which allows the bra cup to freely stretch away from the support band, as needed. The intermediary flexible layer is also able to fully recover and contract, when necessary, so that the bra cups remain snugly against the wearer's breasts.

[0028] FIGS. 1-4 illustrate an exemplary embodiment of bra (100) in accordance with the present disclosure. Referring first to FIG. 1, there is shown a rear view of bra (100). As shown, bra (100) comprises two laterally-spaced bra cups (102 and 104), a front support panel (106), bust support members or underwire channels (108 and 110) and intermediary flexible layers (112 and 114).

[0029] Front support panel (106) of bra (100) is illustrated as including two laterally-positioned bra cups (102 and 104) configured to receive the wearer's breasts; however, depending on the type of bra, the cups may be replaced by a single cup or panel. As shown, each bra cup (102 and 104) has an inner edge (109 and 111), respectively, and an outer edge (113 and 115), respectively, wherein inner edges (109 and 111) are near the sternum of the wearer, and outer edges (113 and 115) are near the respective sides of the wearer's body when bra (100) is worn. Bra cups (102 and 104) may be any known bra cup in the art and may be formed of a sturdy generally inelastic material or, alternatively, may be constructed of an elastic material, which still provides support, but is also stretchable to accommodate the wearer's breasts. Moreover, bra (100) may incorporate the bra pads taught and disclosed in co-pending application filed on the same date as the present application by inventors Emily Suess and Valerie Ann McArdle and Applicant Chico's Brands Investments, Inc., entitled “Bra Pad and Method for Manufacturing Same.”

[0030] Below each bra cup (102 and 104) is provided bust support member or underwire channel (108 and 110), respectively, which are attached to front support panel (106). Bust support members may be underwire channels (108 and 110) housing underwire (not shown) therein, which are commonly used in the art to increase the sturdiness of bra cups and thus provide additional support to the wearer's breasts. It should be understood that the present disclosure is not limited to underwire channels (108 and 110) and that any bottom or bust support member that provides support to bra cups (102 and 104), such as underwire channels, a support panel made from rigid material, a band, and the like, may be used with bra (100). Bust support members, such as underwire channels (108 and 110), may be omitted from bra (100) as well. It is also noted that illustrated bra cups (102 and 104) are full coverage cups, which cover over 50% of the wearer's breasts; however, it should be appreciated that smaller or larger bra cups may be used in connection with the bra of the present disclosure.

[0031] As shown in FIG. 1, between each bra cup (102 and 104) and underwire channel (108 and 110) is provided intermediary flexible layer (112 and 114), respectively. As will be described in detail below, intermediary flexible layers (112 and 114) comprise stretchable material such as LYCRA®, spandex, elastane, rubber, polyester, nylon and the like, and are provided to allow bra cups (102 and 104), respectively, to stretch away from and contract back to underwire channels (108 and 110), as needed, to accommodate the wearer's breasts. Intermediary flexible layers (112 and 114) may also comprise additional or excess fabric, which may also be made from LYCRA®, spandex, elastane, rubber, polyester, nylon and the like, to allow the bra cup to stretch even further, if necessary. Bra cup (102), underwire channel (108) and intermediary flexible layer (112) together are referred to as bra cup configuration (101). Likewise, bra cup (104), underwire channel (110) and intermediary flexible layer (114) together are referred to as bra cup configuration (103).

[0032] Bra (100) may also have certain elements and components that a conventional bra in the art may have. For example, bra (100) may comprise three distinct support panel segments: a front support panel (106), a left support panel (116), and a right support panel (118), which in combination are used to attach bra (100) around a wearer's torso. Front support panel (106) comprises left and right bra cups (102 and 104, respectively) for receiving the breasts of the wearer and, to the extent bra cups are not directly attached, comprises fabric portion (107) that extends in-between and connects bra cups (102 and 104) together. Left support panel (116) is attached to and extends away from the left side of front support panel (106) and right support panel (118) is attached to and extends away from the right side of front support panel (106). Front support panel (106), left support panel (116) and right support panel (118) may be comprised of any suitably flexible, yet sturdy material known in the art. To secure bra (100) to the wearer, left and right support panels (116 and 118) are extended around the left and right side of the wearer's torso, respectively, and may be fastened together against the wearer's back using fastening means known in the art, such as a releasable clasp, a hook-and-eye fastening system, toggles and loops, hook and loop fasteners, snaps, buckles, tie-able ribbons or strings, a button and hole combination, and the like. Bra (100) may also be constructed such that the support panel is fastened in the front between bra cups (102 and 104) at point (107) using the same or similar fastening means. Alternatively, and as well known in the art, bra (100) may comprise a one-piece, single support cup or panel, without a fastener, in lieu of the three distinct aforementioned support panel segments.

[0033] Bra (100) may also comprise left and right shoulder straps (120 and 122) respectively, that, when bra (100) is worn, bridge the front and back portions of bra (100) and are provided over the shoulders of the wearer. One end of straps (120 and 122) are preferably affixed to the top portion of bra cups (102 and 104), respectively. At the other end, straps (120 and 122) are preferably affixed to the top portion of left and right support panels (116 and 118), respectively. Bra straps (120 and 122) may be comprised of any material known or used in the art. Bra straps (120 and 122) are provided largely to assist in keeping bra (100) in place on the wearer and to provide additional support and lift to the wearer's breasts. It is further contemplated that one or more portions of the underside surface of shoulder straps (120 and 122) may be comprised of LYCRA®, spandex, elastane, rubber, polyester, nylon or the like to prevent shoulder straps (120 and 122) from slipping off the wearer's shoulders. Alternatively, bra (100) may be strapless, or comprise straps that are removable or adjustable such that the straps may cross-over in the front or the back of bra (100), or the straps may be connected in any other feasible manner. Further, straps (120 and 122) may be affixed to bra (100) such that they are adjustable, as is commonly known in the art.

[0034] Turning now to FIG. 2, shown is a close-up of a rear perspective view of right bra cup configuration (103), which more closely illustrates the details thereof. It should be understood that bra cup configurations (101 and 103) are substantially the same and thus the following description of bra cup configuration (103) applies equally to bra cup configuration (101). Bra cup configuration (103) comprises bra cup (104), underwire channel (110) and intermediary flexible layer (114) arranged in the configuration shown in FIG. 2.

[0035] As shown in FIG. 2, bra cup (104) is only directly affixed to bust support member or underwire channel (110) at two points: (1) near inner edge (202) of bra cup configuration (103), and (2) outer edge (204) of bra cup configuration (103), which is on the opposite of inner edge (202). This configuration creates an open space (not shown) between bra cup (104) and underwire channel (110) where these two components are not directly connected. Intermediary flexible layer (114) is provided in this open space and indirectly connects bra cup (104) and underwire channel (110) as illustrated in FIG. 2. That is, bra cup configuration (103) is configured such that a portion of bottom edge (206) of bra cup (104) is affixed to top edge (208) of intermediary flexible layer (114) and bottom edge (210) of intermediary flexible layer (114) is affixed to top edge (212) of underwire channel (110).

[0036] In other words, bra cup configuration (103) is configured such that at least a portion of bottom edge (206) of bra cup (104) is not directly affixed to top edge (212) of underwire channel (110). Instead, as shown, intermediary flexible layer (114) is provided between the aforementioned portion of bottom edge (206) of bra cup (104) and top edge (212) of underwire channel (110), such that intermediary flexible layer (114) connects those components together. Intermediary flexible layer (114) comprises stretchable material such as LYCRA®, spandex, elastane, rubber, polyester, nylon and the like. This aforementioned configuration of bra cup configuration (103) in combination with the flexible material of intermediary flexible layer (114) allows bra cup (104) to stretch away from and contract back to underwire channel (110), as needed, to accommodate the wearer's breasts. Intermediary flexible layer (114) may also comprise additional or excess fabric, which may also be made from LYCRA®, spandex, elastane, rubber, polyester, nylon and the like, to allow the bra cup to stretch even further, if necessary.

[0037] The size of the portion of bottom edge (206) of bra cup (104) that is affixed to underwire channel (110) via intermediary flexible layer (114) directly affects the stretch-ability of bra cup (104). For example, if all or nearly all of bottom edge (206) of bra cup (104) is connected to underwire channel (110) via intermediary flexible layer (114), bra cup (104) is configured such that it can achieve maximum stretch-ability. Conversely, if only a small portion of bottom edge (206) of bra cup (104) is connected to underwire channel (110) via intermediary flexible layer (114) and a majority of bottom (206) of bra cup (104) is directly affixed to underwire channel (110), bra cup (104) will be comparatively less stretchable.

[0038] FIG. 3 illustrates a close-up, rear perspective view of inner edge (202) of bra cup configuration (103). As shown, intermediary flexible layer (114) extends along the bottom of bra cup (104) towards inner edge (202) of bra cup configuration (103) and is provided between bra cup (104) and underwire channel (110). As further shown, intermediary flexible layer (114) tapers as it approaches inner edge (202) and is connected or sewn to both bottom edge (206) of bra cup (104) and top edge (212) of underwire channel (110) at connection point (302) of bra cup configuration (103) so that intermediary flexible layer (114) contains less or negligible excess fabric at connection point (302) and as it leads up to connection point (302). All three components, bra cup (104), intermediary flexible layer (114), and underwire channel (110), may be affixed or sewn together at connection point (302). With intermediary flexible layer (114) containing less or negligible excess fabric as it tapers to connection point (302), the bra cup's ability to stretch is reduced near that point, and thus more support is provided to the wearer's breasts in that area.

[0039] FIG. 4 illustrates a close-up, rear perspective view of outer edge (204) of bra cup configuration (103). As shown, intermediary flexible layer (114) extends along the bottom of bra cup (104) towards outer edge (204) of bra cup configuration (103) and is provided between bra cup (104) and underwire channel (110). As further shown, intermediary flexible layer (114) tapers as it approaches outer edge (204) and is connected or sewn to both bottom edge (206) of bra cup (104) and top edge (212) of underwire channel (110) at connection point (402) of bra cup configuration (103) so that intermediary flexible layer (114) contains less or negligible excess fabric at connection point (402) and as it leads up to connection point (402). All three components, bra cup (104), intermediary flexible layer (114), and underwire channel (110), may be affixed or sewn together at connection point (402). With intermediary flexible layer (114) containing less or negligible excess fabric as it tapers to connection point (402), the bra cup's ability to stretch is reduced near that point, and thus more support is provided to the wearer's breasts in that area.

[0040] While bra cup configuration (103)—e.g., the right bra cup configuration—of the present disclosure has been shown and described in detail, it should be appreciated that bra cup configuration (101)—e.g., the left bra cup configuration—is essentially a mirror image thereof. As such, the drawings and disclosure of bra cup configuration (103) apply equally to bra cup configuration (101) of the present disclosures.

[0041] It should be understand that if no underwire channel, band or other bust support component is provided, the intermediary flexible layers may be disposed between the bottom of the bra cups and the front portion of the bra.

[0042] It is further contemplated that the bra of the present disclosure may incorporate the bra pads disclosed and described in commonly owned, co-pending application filed on the same date as the present application by inventors Emily Suess and Valerie Ann McArdle and Applicant Chico's Brands Investments, Inc., entitled “Bra Pad and Method for Manufacturing Same.”

[0043] While the subject matter discussed herein has been described in detail with reference to embodiments for the purposes of making a complete disclosure, such embodiments are merely exemplary and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention. It will be apparent to those of ordinary skill in the art that numerous changes may be made in such details, and the invention is capable of being embodied in other forms, without departing from the spirit, essential characteristics, and principles of the invention. Also, the benefits, advantages, solutions to problems, and any elements that may allow or facilitate any benefit, advantage, or solution are not to be construed as critical, required, or essential to the subject matter disclosed. The scope of the invention is to be limited only by the appended claims.