Abstract:
A bra comprising a front portion and two side portions. The front portion comprises bra cups. Each side portion extends from a respective side of the front portion and the side portions are adapted to encircle a torso of a wearer of the bra. The front portion and the side portions comprise an outer layer and a frame layer beneath the outer layer. The frame layer comprises: an outer frame layer, and an inner frame layer disposed inward from the outer frame layer with respect to the torso of the wearer of the bra. The inner frame layer comprises a plurality of panels. The panels alternate between primary panels primarily stretchable in a first direction and secondary panels primarily stretchable in a second direction.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 13/652,696, filed Oct. 16, 2012, which is based on and derives the benefit of the filing date of U.S. Provisional Patent Application No. 61/547,889, filed Oct. 17, 2011. The entire content of the foregoing are herein incorporated by reference in their entireties. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing summary and the following detailed description are better understood when read in conjunction with the appended drawings. Example embodiments are shown in the drawings, however, it should be understood that the embodiments are not limited to the specific methods and instrumentalities depicted herein. In the drawings: 
       FIGS. 1 a  and 1 b    illustrate perspective outer and inner front views of a bra, respectively, according to an embodiment. 
       FIG. 2  illustrates a perspective back view of a bra, according to an embodiment. 
       FIG. 3  illustrates a perspective side view of a bra, according to an embodiment. 
       FIG. 4  illustrates an inner layer of a bra, according to an embodiment. 
       FIG. 5  illustrates an inner frame layer of a bra, according to an embodiment 
       FIG. 6  illustrates an outer frame layer of a bra, according to an embodiment 
       FIG. 7  illustrates an outer layer of a bra, according to an embodiment 
       FIGS. 8 a  and 8 b    illustrate a front portion and a side portion, respectively, of a bra assembly, according to an embodiment. 
       FIG. 9  illustrates a method of manufacturing bra  100 , according to an embodiment. 
       FIG. 10  illustrates a perspective side view of a bra, according to an embodiment. 
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     With reference to  FIGS. 1 a  and 1 b   , front views of a bra  100 , according to an embodiment, are illustrated.  FIG. 1 a    provides a front view of the outer side of the bra  100 , while  FIG. 1 b    provides a front view of the inner side of the bra  100 . The bra  100  can include a front portion  110  with bra cups  112  and  114 . The bra  100  can also include side portions  120  and  122 , each extending from a respective side of the front portion  110 . The side portions  120 ,  122  can be adapted to encircle a torso of a wearer of the bra  100 . 
     The bra  100  can also include shoulder straps  130  and  132 . The shoulder straps  130 ,  132  can extend from a top portion of the front portion  110  to respective top portions of the two side portions  120 ,  122  so that the shoulder straps  130 ,  132  encircle the shoulders of the wearer of the bra  100 . Connector components  160 ,  162  may be used to secure or attach the shoulder straps  130 ,  132  to the top portion of the front portion  110 . The connector components  160 ,  162  may, together with a loop(s) on the shoulder straps  130 ,  132  and a hook(s) at the end of the shoulder straps  130 ,  132 , provide for the wearer of the bra  100  to adjust the shoulder straps  130 ,  132  to obtain a customized fit. The loops on the shoulder straps  130 ,  132  may be made from the same fabric utilized elsewhere on the bra  100 , with the frame fabric at core and welded to form loops. 
     A chest band  140  may be an extension, according to some embodiments, of the front portion  110  and/or the side portions  120 ,  122  at a bottom portion of the front portion  110  and/or the side portions  120 ,  122 . According to an additional embodiment, the chest band  140  may be a piece of material (e.g., elastic) attached or otherwise secured to the bottom portion of the front portion  110  and/or the side portions  120 ,  122 . If the chest band  140  is made of elastic, the elastic may be 25 mm in width and may have a content of 68% nylon and 32% spandex, or any other combination of fibers. The elastic may be woven or any other type of construction. The elastic may have a modulus of 1.25 lbf at 20% elongation. The elastic may be brushed or any other surface treatment may be used. 
       FIG. 2  provides a perspective back view of the bra  100 , according to one embodiment. As shown in  FIG. 2 , a fastening mechanism  150  may be provided to secure the bra  100  to the bra wearer. The fastening mechanism  150  may include, according to an embodiment, at least one hook and a corresponding at least one eye. The set of hooks may be attached to an end portion of one of the two side portions  120 ,  122 , and the set of eyes may be attached to an end portion of the other of the two side portions  120 ,  122 . Other known fastening mechanisms may also be utilized. 
       FIG. 10  provides a perspective side view of another embodiment of a bra, where the shoulder straps are different than bra  100  shown in  FIGS. 1 a   - 3  and  FIGS. 8 a   - 8   b.    
       FIG. 3  provides a perspective side view of the bra  100 , according to one embodiment. The bra  100  can comprise a plurality of layers, each described below with reference to  FIGS. 4-7 . An innermost layer (inner layer  400 ) may be a spacer fabric that provides coverage as well as compression. The spacer fabric may be cut with ultrasonic waves to seal all the edges of the fabric. The inner layer  400  may be viewed as a set of molded cups that may be attached to a bra frame. The frame (inner frame layer  500  and outer frame layer  600 ) may include two layers of fabric that can provide support to the base of a wearer&#39;s breasts while also adding compression. An outermost layer (outer layer  700 ) can provide an aesthetic appearance due to its seamless quality, as well as providing wicking qualities by pulling away moisture from the frame and innermost layer. The outermost layer may also provide additional compression and coverage to the breast area. 
     An inner layer  400  is illustrated in  FIG. 4 . The inner layer  400  includes molded bra cups  412  and  414 . The bra cups  412 ,  414  may be molded to give the bra  100  a desired bra cup shape to support and adequately cover the breasts of a wearer of the bra  100 . According to an embodiment, stitching may be added around the circumference of the molded bra cups  412 ,  414  to provide support and compression to the breasts. The stitching may be, for example, a zigzag stitching pattern. 
     The inner layer  400  may be a warp knitted fabric. Moreover, the fabric may be a four-way stretch fabric, capable of stretching horizontally and vertically. According to another embodiment, the fabric may be a two-way stretch fabric, capable of stretching horizontally. The fabric of the inner layer  400 , according to an embodiment, can be a wicking fabric or material, able to draw away moisture from skin to the next layers. As such, the fabric can be breathable. According to an embodiment, the fabric of the inner layer  400  can be 89% nylon and 11% spandex (e.g., LYCRA, ELASPAN, CREORA, ROICA, DORLASTAN, LINEL, ESPA), although other proportions of nylon and spandex, as well as other materials, may be used. The incorporation of spandex can provide support and compression, which can be enhanced with the stitching around the bra cups  412 ,  414 . The fabric of the inner layer  400  may range from 150 to 340 GSM (grams per square meter). For example, according to an embodiment, the fabric of the inner layer may be 240 GSM. 
       FIG. 5  illustrates an inner frame layer  500 , according to one embodiment. The inner frame layer  500  can include at least one panel  510  that can be primarily stretchable in a first direction, which according to an embodiment may be a horizontal direction. 
     According to an embodiment, the panel  510  may include a plurality of panels including alternating primary panels  520  and secondary panels  530 . The primary panels  520  can be primarily stretchable in a first direction, which according to an embodiment may be a horizontal direction, while the secondary panels  530  can be primarily stretchable in a second direction, which according to an embodiment may be a vertical direction. The use of “horizontal” and “vertical” describes the direction of the panels  520 ,  530  when the bra  100  is held upright in a position in which the bra  100  is placed on a wearer. The second direction may be perpendicular to the first direction. According to another embodiment, the panels  520 ,  530  may be oriented at slight angles to the horizontal and vertical lines. Moreover, according to another embodiment, the direction of the orientation of the panels  520 ,  530  may be angles other than 90° with respect to one another. In some embodiments, the panels  520 ,  530  may also be oriented in any direction and at any angle with respect to each other. In addition, the panels can also be included in other layers (e.g.,  400 ,  600 ,  700 ). In this way, layering different fabrics (e.g., using gluing, laminating, welding, or stitching, or any combination thereof) in different directions can allow pressure points to be generated around the breast, adding support and reducing breast movement (e.g., when walking, when moving, when exercising). 
       FIG. 6  illustrates an outer frame layer  600 , according to one embodiment. The outer frame layer  600  can be primarily stretchable in the first direction, for example, the horizontal direction as defined above. However, the outer frame layer  600  can be stretchable in any direction. 
     The inner frame layer  500  and the outer frame layer  600  can form a frame layer that encapsulates the breasts and provide support to the base of the breasts. The frame layer can be connected to the side portions  120 ,  122  (e.g., using gluing, laminating, welding, or stitching, or any combination thereof.) The side portions  120 ,  122  can provide circular pressure around the body to allow the frame layer to be held in place. Both the inner frame layer  500  and the outer frame layer  600  can have cutout sections,  512 ,  514  and  612 ,  614 , respectively. The cut-out sections  512 ,  514  and  612 ,  614  can correspond in size to the bra cups  412 ,  414 , providing for the bra cups  412 ,  414  formed in the inner layer  400  to extend through the frame layer. According to an embodiment, stitching can be added around the cut-out sections  512 ,  514  and  612 ,  614  to provide support to the breasts. The stitching may be, for example, a zigzag stitching pattern. The secondary panels  530  of the inner frame layer  500 , according to an embodiment, may be vertical panels oriented in the portion near and surrounding the bra cups  412 ,  414 , that serve to limit the stretch of the frame layer in the horizontal direction. 
     The inner frame layer  500  and the outer frame layer  600  may be a wicking fabric or material, able to draw away moisture to the next layer. As described above, the fabric of the frame layer (i.e., the inner frame layer  500  and the outer frame layer  600 ) may be a two-way stretch fabric, capable of stretching in a horizontal or vertical direction. The fabric of the inner and outer frame layers  500 ,  600  may be a warp knitted fabric. According to an embodiment, the fabric of the inner frame layer  500  and the outer frame layer  600  can be 87% nylon and 13% spandex, although other proportions of nylon and spandex, as well as other fabrics or materials, may be used. The fabric of the frame layer may range from 200 to 320 GSM. For example, the fabric of the frame layer, according to an embedment, can be 245 GSM. According to an additional embodiment, the inner frame layer  500  and the outer frame layer  600  may be fabrics with a different GSM. 
     A chest band, such as the chest band  140  described above with reference to  FIG. 1 , may be part of the bra  100 . According to an embodiment, the chest band, made of the same material as the frame layers  500 ,  600 , can be attached to or extend from a bottom portion of one or both of the frame layers  500 ,  600 . The chest band may include elastic material. The chest band may be attached to the frame layers  500 ,  600  by a variety of methods, such as gluing using hot melt or similar adhesives. The chestband elastic may be sewed by using zig zag sewing to the outer layer of fabric  600  and then glued to the outer frame fabric  500  by using either Bemis 3918 high recovery Thermoplastic Polyurethane (TPU) Elastomer tape, hot melt, or a similar adhesive, or any combination thereof. 
     Additionally, shoulder straps, such as the shoulder straps  130 ,  132  described above with respect to  FIG. 1 , may be an extension of the frame layers  500 ,  600 . Thus, the shoulder straps  130 ,  132  may include two layers of two-way stretch, warp knitted wicking fabric of a composition of 87% nylon and 13% spandex, for example. The shoulder straps  130 ,  132  may be or may not be of the same material or composition as the frame layers  500 ,  600 . The shoulder straps may be a fabric with a weight range of 200 to 320 GSM. The material of the shoulder straps  130 ,  132  can provide support to the breasts by reducing bounce due to the limited amount of stretch inherent in the material. 
       FIG. 7  illustrates an outer layer  700 , according to one embodiment. The outer layer  700  can be molded to conform to a size of the bra cups  412 ,  414 . Thus, the outer layer  700  can seamlessly cover the bra cups  412 ,  414  that extend from the inner layer  400  through the cut-out sections  512 ,  514  and  612 ,  614  of the frame layers  500  and  600 . 
     The outer layer  700  may be a weft knitted fabric. Moreover, the fabric may be a four-way stretch fabric, capable of stretching horizontally and vertically. The fabric of the outer layer  700 , according to an embodiment, can be a wicking fabric or material, able to draw away moisture from the inner layers and spread out the moisture for quick drying. According to an embodiment, the fabric of the outer layer  700  may be of a range of 23% to 30% spandex and 70 to 77% nylon, such as 77% nylon and 23% spandex, although other proportions of nylon and spandex, as well as other materials, may be used. For example, the relatively high spandex content of 23% to 30% can provide compression to the outer layer  700 . The fabric of the outer layer  700  may be of a range from 220 to 340 GSM, such as, for example, 240 GSM. 
     The outer layer  700 , in addition to covering the bra cups  412 ,  414 , may also cover shoulder straps, such as the shoulder straps  130 ,  132  described above with respect to  FIG. 1 . The outer layer  700  can also cover the area around the fastening mechanism  150 . For example, the outer layer  700  can be provided with laser cut holes from which the hooks and eyes protrude. Thus, the outer layer  700  can serve to provide a clean seamless look, as well as a soft feel, to the bra  100 . 
     According to an embodiment, the outer layer  700  can be bonded to the frame layer by, for example, a hot melt process which allows for moisture and air movement between the layers. The outer frame layer  600  and the inner frame layer  500  can be secured together by, for example, being glued together by, a hot melt process allowing for moisture and air movement between the frame layers  500  and  600 . The plurality of panels in the inner frame layer  500  (the alternating primary panels  520  and secondary panels  530 ) can be, according to an embodiment, connected to one another by ultrasonic welding. The inner layer  400  may be stitched to the frame layer using an overlock marrow stitch, for example. The connection of the various layers and the panels are not limited to these techniques, and other known connection techniques may be employed to connect the layers and the panels. 
       FIGS. 8 a  and 8 b    illustrate a bra assembly  800  including the layers  400 ,  500 ,  600 , and  700  described above, according to one embodiment. (Note that  FIG. 8 a    illustrates the front view of the inner side of the bra.) The bra assembly  800  may include a front assembly  810  for the front portion  110  of the bra  100 , as well as a side assembly  820  for the side portions  120 ,  122  of the bra  100 . 
     According to an embodiment, one or more layers  400 ,  500 ,  600 , and  700  included in the front portion  110  and the side portions  120 ,  122  may be one continuous piece of material. As such, layers of the front assembly  810  and the side assembly  820  may be continuous layers. 
     As shown in  FIG. 8 a   , the front assembly  810  for the front portion  110  can include the outer layer  700 , the outer frame layer  600 , the inner frame layer  500 , and the inner layer  400 . Also included in the front assembly  810  can be attachment layers  812  and  814  for respectively connecting the outer layer  700  and the outer frame layer  600 , and the outer frame layer  600  and the inner frame layer  500 . 
     The side assembly  820  for the side portions  120 ,  122  can include the outer layer  700  and the frame layer made up of the outer frame layer  600  and the inner frame layer  500 . Also included in the side assembly  820  can be attachment layers  812  and  814 . 
       FIG. 9  illustrates a process for manufacturing bra  100 , according to one embodiment. Those of ordinary skill in the art will see that multiple other embodiments are also possible. In  905 , some or all of the material for the various layers and elements of the bra  100  (e.g., outer frame layer  600 , inner frame layer  500 , inner layer  400 , chest band  140 ) may be cut (e.g., according to size), using, for example, a straight knife, a band knife, an electric cutter, laser, etc. In  910 , holes can be cut (e.g., for the hook(s) and eye(s) or other bra connecting items or materials) on the fabric for the outer frame layer  600 , using, for example, a laser. In  915 , the edges of the inner layer  400  (e.g., made of nylon spacer fabric) can be cut and/or melted and/or sealed (e.g., using an ultrasonic welding machine). (Note that in one embodiment, the nylon spacer fabric may have wire throughout the nylon spacer fabric that needs to be melted and/or sealed so that is doesn&#39;t poke or hurt anyone.) In  920 , the outer frame layer  600  and the inner frame layer  500  can be attached, along with any other layers, to form a frame layer (e.g., by gluing, laminating, welding, or stitching, or any combination thereof). (Note that, in some embodiments, an attachment layer  814  (e.g., a sticky material or a material that is used to connect other materials) can be used to attach the inner frame layer  500  to the outer frame layer  600 .) In  921 , the outer layer  700  can be attached to the frame layer (e.g., by gluing, laminating, welding, or stitching, or any combination thereof). (Note that, in some embodiments, an attachment layer  812  (e.g., a sticky material or a material that is used to connect other materials) can be used to attach the outer layer  700  to the frame layer.) The above process can be utilized for the front assembly  810  and the side assembly  820 . In  922 , ultrasonic sealing of the inner layer  400  (spacer) edges may be done. For the front assembly, in addition, in  925 , the inner layer  400  can be attached to the frame layer (e.g., using a stitch froman overlock serger). In  930 , the hook(s) and eye(s) (or other bra connecting items or material) can be mounted on the ends of the chest band  140 . In  935 , sewing (e.g., zig zag) can be done around the cups  412 ,  414  of bra  100 . In  940 , hardware (e.g.,  160 ,  161 ,  162 ,  163 ) or another item of another material can be attached to the bra straps so that the bra straps are adjustable. This can be done by running the ends of the bra straps and the ends of the tops of the front assembly that meet the bar straps through the hardware, and sewing the ends to the bra straps or the tops, as appropriate. In  950 , the chest band  140  (e.g., made of a power luxtreme fabric) can be attached (e.g., by gluing, laminating, welding, or stitching, or any combination thereof) to the frame layer and the inner layer  400 . For example, high recovery glue may be applied, in, for example, a dot form, to the chest band  140  and the frame layer and inner layer  400 , and the frame layer and inner layer  400  can then be turned over and attached to the chest band  140 . (Note that, in some embodiments, any substance may be applied in a dot form to connect one part of the bra to another.) In  965 , the bra  100  can be put in a mold frame at a high temperature (e.g., 160-200 degrees centigrade) for 30-60 seconds to allow the bra cups to be molded and/or to allow any laminate or attachment material or item (e.g., hot melt film, high recovery glue) to melt and/or form a bond. Those of ordinary skill in the art will see that the above process is merely an example, and that many other processes could be utilized to manufacture the bra, including adding or taking away steps, or putting the steps in different order. 
     It should be noted, that, in the embodiment of the bra  900  shown in  FIG. 10 , the shoulder straps are adjusted in a manner different from the shoulder straps in the bra  100  of  FIG. 1 . In bra  900 , a material (e.g., a power luxtreme fabric) can be used to form the shoulder loop shapes, which can be formed using a template while applying a high temperature weld. 
     The foregoing examples are provided merely for the purpose of explanation and are in no way to be construed as limiting. While reference to various embodiments are shown, the words used herein are words of description and illustration, rather than words of limitation. Further, although reference to particular means, materials, and embodiments are shown, there is no limitation to the particulars disclosed herein. Rather, the embodiments extend to all functionally equivalent structures and uses, such as are within the scope of the appended claims. 
     In addition, it should be understood that any figures which highlight the functionality and advantages, are presented for example purposes only. The disclosed methodology and system are each sufficiently flexible and configurable, such that it may be utilized in ways other than that shown. 
     Further, the purpose of the Abstract of the Disclosure is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract of the Disclosure is not intended to be limiting as to the scope of the present invention in any way. 
     It should also be noted that when the term “a”, “an”, etc. is used, it is to be interpreted as “at least one” throughout the application, drawings, and claims. 
     Finally, it is the applicant&#39;s intent that only claims that include the express language “means for” or “step for” be interpreted under 35 U.S.C. 112, paragraph 6. Claims that do not expressly include the phrase “means for” or “step for” are not to be interpreted under 35 U.S.C. 112, paragraph 6.