BRA PAD AND METHOD FOR MANUFACTURING SAME

Abstract

A bra pad constructed from a combination of materials and configured to have two or more zones, each zone is constructed of different material and thus provides, in combination, a different level of stretchiness and firmness to an area of the bra pad for providing optimum support, comfort, fit and coverage for use in bras, camisoles, tank tops, slips, dresses, bathing suits, or any other breast covering garment where padding and/or support is desired.

Claims

1. A bra pad when placed on the body of a wearer comprising: a first zone comprising a stretchable material; and a second zone coupled to the first zone and comprising a rigid material.

2. The bra pad of claim 1 further comprising a third zone arranged between the first zone and the second zone and comprising a lightweight, stretchable material.

3. The bra pad of claim 2, wherein the first zone, the second zone and the third zone in the aggregate are coextensive with the entire surface area of the bra pad.

4. The bra pad of claim 1 wherein the first zone is a top zone of the bra pad that extends along and fits against the neckline of the wearer.

5. The bra pad of claim 1 wherein the stretchable material of the first zone comprises stretching properties sufficient to allow the first zone of the bra pad to cover a portion of the wearer's breast.

6. The bra pad of claim 4 wherein the first zone is adapted to recover and fit against the neckline of the wearer as the wearer's body fluctuates in size and shape.

7. The bra pad of claim 1 wherein the second zone is a bottom zone of the bra pad that extends along the bottom portion of a breast of the wearer to support the breast from the bottom of the bra pad.

8. The bra pad of claim 1 wherein the second zone comprises a portion of fabric that extends substantially vertically from the second zone along an outer edge of the bra pad and is coupled to the first zone, and further wherein the portion of fabric is adapted to push a breast of the wearer forward to prevent the breast from bulging out of the bra pad.

9. The bra pad of claim 8 wherein the portion of fabric is overlapped with a portion of the first zone to create a section of rigid material.

10. The bra pad of claim 1 wherein the rigid material comprises sufficient stretching properties to allow the second zone to flex along the bottom of the wearer's breast.

11. The bra pad of claim 1, wherein the bra pad is configured to be incorporated into one of a camisole, a tank top, a slip, a dress, and a bathing suit.

12. A method for manufacturing a bra pad, the method comprising: providing a first zone comprising a stretchable material; and coupling a second zone comprising a rigid material to the first zone.

13. The method of claim 12 further comprising arranging a third zone between the first zone and the second zone, wherein the third zone comprises a lightweight, stretchable material.

14. The method of claim 13, wherein the first zone, the second zone and the third zone in the aggregate are coextensive with the entire surface area of the bra pad.

15. The method of claim 12 wherein the first zone is a top zone of the bra pad that extends along and fits against the neckline of a wearer.

16. The method of claim 12 wherein the stretchable material of the first zone comprises stretching properties sufficient to allow the first zone of the bra pad to cover a portion of the wearer's breast.

17. The method of claim 15 wherein the first zone is adapted to recover and fit against the neckline of the wearer as the wearer's body fluctuates in size and shape.

18. The method of claim 12 wherein the second zone is a bottom zone of the bra pad that extends along the bottom portion of a breast of a wearer to support the breast from the bottom of the bra pad.

19. The method of claim 12 further comprising coupling a portion of fabric that extends substantially vertically from the second zone along an outer edge of the bra pad to the first zone, and further wherein the portion of fabric is adapted to push a breast of a wearer forward to prevent the breast from bulging out of the bra pad.

20. The method of claim 19 further comprising overlapping the portion of fabric with a portion of the first zone to create a section of rigid material.

21. The method of claim 12 wherein the rigid material comprises sufficient stretching properties to allow the second zone to flex along the bottom of the wearer's breast.

22. The method of claim 12, further comprising incorporating the bra pad into one of a camisole, a tank top, a slip, a dress, and a bathing suit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] 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).

[0024] 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.

[0025] FIG. 1 depicts a rear view of a right bra pad in an underwire configuration in accordance with an exemplary embodiment of the present disclosure;

[0026] FIG. 2 depicts a rear view of a right bra pad in a wireless configuration in accordance with another exemplary embodiment of the present disclosure; and

[0027] FIG. 3 depicts a front view of a bra comprising the left and right bra pads of the exemplary bra pad shown in FIG. 1.

DETAILED DESCRIPTION

[0028] 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, structures and methods of manufacturing the same 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.

[0029] 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.

[0030] The bra pad of the present disclosure is adapted to be used in or as bra cups for use in articles of clothing such as bras, camisoles, tank tops, slips, dresses, bathing suits, or any other breast covering garment where padding and/or support is desired and is configured to provide optimum support, comfort, fit, coverage and appearance to the wearer. The bra pad of the present disclosure is generally cup-shaped with an outer convex surface and an inner concave surface. It should be noted that unless indicated otherwise any discussion regarding the configuration of the bra pad of the present disclosure is with respect to the orientation of when the bra pad is placed on the body of a wearer

[0031] Referring generally to FIGS. 1 and 2, shown are exemplary embodiments of a bra pad (100) in accordance with the present disclosure. FIG. 1 depicts a version of bra pad (100) that may be used in connection with an article of clothing, such as bras and supportive garments that include an underwire support (not shown). FIG. 2 depicts a version of bra pad (100) that may be used in a connection with an article of clothing, such as bras and supportive garments that do not include an underwire support. While the shapes of bra pad (100) and their individual components in FIGS. 1 and 2 vary slightly, it should be understood, as explained below, that they contain generally the same or similar configuration, comprise the same or similar materials and achieve the same or similar benefits.

[0032] As shown in FIGS. 1 and 2, bra pad (100) comprises a top zone (102), a middle zone (104), and bottom zone (106) when viewed in the orientation of when bra pad (100) is placed on the body of a wearer. Top zone (102) has a top portion (108) and a bottom portion (110), is generally crescent-shaped and comprises a stretchable material. It should be understood that any fabric or material with some degree of stretch or flexibility known in the art can be used in connection with top zone (102). Moreover, it should also be understood that any fabric or material may be used in connection with top zone (102) that comprises sufficient stretching properties to allow top zone (102) to fit against and along the wearer's neckline or near the top of the wearer's breasts. When an article of clothing (not shown) containing bra pad (100) is worn, top zone (102) is configured such that it extends along the neckline or top of the wearer's breasts from the inner edge (120) of bra pad (100) to the outer edge (122) of bra pad (100).

[0033] Top zone (102) may comprise a stretchable material, which, when worn, may be designed to fit snugly against and along the wearer's neckline or near the top of the wearer's breasts and may be further designed to stretch and recover specific to the wearer's body to accommodate the wearer's body throughout the day and for extended periods of time. That is, top zone (102), comprising stretchable material, may contain stretching properties and may be designed to stretch and accommodate the wearer's body at the neckline or near the top of the wearer's breasts for extended periods of time to maintain comfort, support, fit, coverage and appearance. Top zone (102) may also contain properties that allow it to contract or fully recover from a stretched position back to its original position and, therefore, may be designed to adapt to the wearer's body and accommodate the wearer's breasts and body as it fluctuates in size and shape. In other words, top zone (102) may be constructed such that its stretching properties do not get exhausted or used up, and can snap back or recover to its original position so as to maintain a snug fit to the wearer's body. The stretching and recovery properties of top zone (102) of the bra pad may also provide improved support, comfort, fit and coverage, while preventing top and/or side cup overflow and cup gaping. For example, by stretching to sufficiently accommodate the wearer's breasts, top zone (102) of bra pad (100) may fully and comfortably cover the top and sides of the wearer's breasts and does not pinch or cut into the wearer's breasts, thus creating a comfortable, supportive fit that prevents the top and side portions of the wearer's breasts from overflowing or bulging out of the bra pad. Moreover, by fully recovering and maintaining a snug fit along the top of the wearer's breasts as the wearer's body and/or breasts fluctuate in size and shape, top zone (102) of bra pad (100) prevents cup gaping.

[0034] As also shown in FIGS. 1 and 2, bra pad (100) may further comprise middle zone (104). Middle zone (104) has a top portion (112) and a bottom portion (114), is generally crescent-shaped and comprises a lightweight, flexible foam material or similar materials. It should be understood that any fabric or material that is generally lightweight and has some degree of stretch or flexibility known in the art can be used in connection with middle zone (104). Bra pad (100) may be constructed such that top portion (112) of middle zone (104) is coupled to bottom portion (110) of top zone (102) preferably through a molding process. Middle zone (104) is designed to fit snugly and comfortably against the middle and lower portions of the wearer's breasts to provide additional support and comfort to those areas when bra pad (100) is worn.

[0035] Bra pad (100) may further comprise bottom zone (106). Bottom zone (106) has a top portion (116) and a bottom portion (118), is generally curved or crescent-shaped and comprises a generally rigid stabilizing material that provides some flexibility to accommodate the lower portion of the wearer's breasts. Bra pad (100) may be constructed such that top portion (116) of bottom zone (106) is coupled to bottom portion (114) of middle zone (104) preferably through a molding process. Bottom zone (106) extends along the entire bottom of bra pad (100) from inner edge (120) of bra pad (100) to outer edge (122) of bra pad (100). Bottom zone (106) is designed and configured such that when an article of clothing (not shown) containing bra pad (100) is worn, bottom zone (106) extends along and/or below the bottom portion of the wearer's breasts to fit snugly and comfortably, and to provide additional support and comfort to those areas.

[0036] As also shown in FIGS. 1 and 2, bottom zone (106) comprises an additional support component or sling portion (124) that extends substantially vertically along outer edge (122) or the armpit side of bra pad (100). Sling portion (124) may be coupled to both middle zone (104) and top zone (102), as shown in FIGS. 1 and 2, preferably through a molding process. When bra pad (100) is worn, sling portion (124) fits snugly around the side of the wearer's breasts and provides additional support to that area.

[0037] Bottom zone (106) may also curve upward along inner edge (120) of bra pad (100) following the general shape of the bottom and side portion of the wearer's breasts and may be coupled to top zone (102), preferably through a molding process, to provide additional support to that area.

[0038] Bottom zone (106) of bra pad (100) may comprise a firm, stabilizing material with minimal or restrictive stretching properties, which is designed to fit snugly along the bottom of the wearer's breasts to provide improved support, comfort, fit and appearance to the wearer. Bottom zone (106) of bra pad (100) may be designed to flex along the bottom of the wearer's breasts to provide additional support and to provide “lift” to the breasts. It should be understood that any firm or rigid fabric or material known in the art can be used in connection with bottom zone (106). Moreover, it should also be understood that any fabric or material may be used in connection with bottom zone (106) that is firm yet comprises sufficient stretching properties to allow bottom zone (106) to flex along the bottom of the wearer's breast and provide additional support to the breasts. While it may be flexible enough to accommodate the varying sizes of the wearer's breasts as they grow and/or shrink, bottom zone (106) is rigid enough to provide additional support to the wearer's breasts. Moreover, the material used to create bottom zone (106) may comprise certain properties that allow it to be flexible enough to not dig into the wearer's breast tissue but firm enough to provide adequate support to the wearer's breasts. Sling portion (124) may be constructed of similar or the same firm, stabilizing material. Sling portion (124) may provide further support to the side and bottom of the wearer's breasts and may push the wearer's breasts forward to prevent side bulge or cup overflow.

[0039] As shown in FIGS. 1 and 2, sling portion (124) may overlap with and be coupled (e.g., through a molding process) to top zone (102) at or near a strap point (126) of bra pad (100). Strap point (126) is where a bra strap (not shown) of a bra (not shown) may connect to bra pad (100). The combination of top zone (102) with sling portion (124) makes strap point (126) more rigid and thus provides additional support to the wearer near that area of bra pad (100).

[0040] Further, bottom zone (106) may overlap with and be coupled (e.g., through a molding process) to top zone (102) at a point (128) near inner edge (120) of bra pad (100). The combination of top zone (102) with bottom zone (106) makes point (128) more rigid and thus provides additional support to the wearer near that area of the bra pad (100).

[0041] It should be appreciated that while three zones are shown in FIGS. 1 and 2 and described above, it is contemplated that bra pad (100) may be comprised of just two of the aforementioned zones in any combination and in any configuration. For example, it is contemplated that bra pad (100) may comprise just top zone (102) and bottom zone (106). In such an embodiment, bra pad (100) may be constructed such that top portion (116) of bottom zone (106) is coupled to bottom portion (110) of top zone (102) preferably through a molding process. In another example, it is contemplated that bra pad (100) may comprise just top zone (102) and middle zone (104). In such an embodiment, bra pad (100) may be constructed such that top portion (112) of middle zone (104) is coupled to bottom portion (110) of top zone (102) preferably through a molding process. In yet another example, it is contemplated that bra pad (100) may comprise just middle zone (104) and bottom zone (106). In such an embodiment, bra pad (100) may be constructed such that top portion (116) of bottom zone is coupled to bottom portion (114) of middle zone preferably through a molding process.

[0042] It should be understood that each of the aforementioned zones (102, 104 and 106), including sling portion (124), of bra pad (100) may be coupled together using any molding process known in the art. For example, zones (102, 104 and 106) and sling portion (124) may be coupled together by positioning zones (102, 104 and 106) and sling portion (124) between two foam sheets and then molding the layered structure together under heat and pressure to create molded bra pad (100).

[0043] It should be further understood that while the bra pads of the present disclosure and their corresponding components have been shown and described to have certain shapes, the bra pads of the present disclosure and their corresponding components are not limited to any particular shape. That is, the bra pads disclosed herein and their corresponding components may be any shape without departing from the spirit of the present disclosure.

[0044] Turning to FIG. 3, bra pads (100) are illustrated in the context of a traditional bra (300) to show how they may be incorporated into an article of clothing. It is further contemplated that bra pads (100) may be incorporated into the bra 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 with Intermediary Flexible Layer and Method for Manufacturing Same.”

[0045] 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.