# Patent

## Title
Breast support for a garment or garment part

## Abstract

A breast support (12a, 12b) for a garment or garment part is disclosed as including a first piece of elongate resilient material formed by a piece of substantially straight resilient material (16a, 16b) with a first planar major surface, and a second piece of elongate resilient material formed by a piece of arcuate resilient material (14a, 14b) with a second planar major surface (18), an inner arcuate edge (13a, 13b) and an outer arcuate edge (15a, 15b), the first piece of elongate resilient material (16a, 16b) being fixedly engaged and in contact with the second piece of elongate resilient material (14a, 14b) along the whole length of the first piece of elongate resilient material (16a, 16b).

## Background
This invention relates to a breast support for a garment or garment part, including, but not limited to, brassieres, unlined brassieres, swimwear, sports bra, crop tops, sports tops, sleepwear, lingerie, intimate apparel, shapewear, corsets, wedding gowns and brassiere pads, a garment or garment part with such a breast support, a method of forming such a breast support and a method of forming a garment or garment part with such a breast support.
BACKGROUND OF THE INVENTION
Existing brassieres generally have pads to provide support for the breasts of a wearer. For this purpose, such pads are usually provided with a metal wire or plastic wire along and adjacent a lower side in order to provide support to and enhance the shape of the breasts of the wearer. However, such conventional brassieres suffer from one or more of the following disadvantages:

    (a) such a metal wire or plastic wire is usually in the form of a U shape, which is not shaped to meet the horizontal cross sectional curvature of the body, and thus the wire does not fit the body of the wearer properly;
    (b) the U-shaped wire also causes discomfort to the wearer as it presses against the ribs of the wearer or even digs into the flesh in the underarm region of the wearer; and
    (c) a metal wire may cause serious damage to the brassieres during washing and drying cycles, such that the wire may poke through a wire channel in the brassieres, and poke out from the side or bottom of the brassieres to cause injury or discomfort to the wearer.


It is thus an objective of the present invention to provide a breast support for a garment or garment part, a garment or garment part with such a breast support, a method of forming such a breast support and a method of forming a garment or garment part with such a breast support in which the aforesaid shortcomings are mitigated or at least to provide a useful alternative to the trade and public.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a breast support for a garment or garment part, said breast support comprising a first piece of elongate resilient material formed by a piece of resilient material with a first planar major surface and of a first curvature, and a second piece of elongate resilient material formed by a piece of resilient material with a second planar major surface and of a second curvature which is different from the first curvature, wherein said first piece of elongate resilient material is fixedly engaged and in contact with said second piece of elongate resilient material along at least a majority of the length of said first piece of elongate resilient material.
According to a second aspect of the present invention, there is provided a garment or garment part including at least one breast support for a garment or garment part, said breast support comprising a first piece of elongate resilient material formed by a piece of resilient material with a first planar major surface and of a first curvature, and a second piece of elongate resilient material formed by a piece of resilient material with a second planar major surface and of a second curvature which is different from the first curvature, wherein said first piece of elongate resilient material is fixedly engaged and in contact with said second piece of elongate resilient material along at least a majority of the length of said first piece of elongate resilient material.
According to a third aspect of the present invention, there is provided a method of forming a breast support for a garment or garment part, said method comprising (a) providing a first piece of elongate material with a first planar major surface and of a first curvature, (b) providing a second piece of elongate resilient material with a second planar major surface and of a second curvature which is different from the first curvature, and (c) fixedly engaging and contacting said first piece of elongate resilient material with said second piece of elongate resilient material along at least a majority of the length of said first piece of elongate resilient material.
According to a fourth aspect of the present invention, there is provided a method of forming a garment or garment part including incorporating at least one breast support in a garment or garment part, wherein said at least one breast support is formed by (a) providing a first piece of elongate material with a first planar major surface and of a first curvature, (b) providing a second piece of elongate resilient material with a second planar major surface and of a second curvature which is different from the first curvature, and (c) fixedly engaging and contacting said first piece of elongate resilient material with said second piece of elongate resilient material along at least a majority of the length of said first piece of elongate resilient material.



BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of examples only, with reference to the accompany drawings, in which:
FIG. 1 is a front view of two brassiere pads, each including a breast support for a garment or garment part according to the present invention;
FIG. 2 is an inside view of the two brassiere pads of FIG. 1;
FIG. 3 is a side sectional view of one of the brassiere pads of FIG. 1, shown as supporting a breast of a wearer;
FIG. 4 shows two pieces of arcuate elongate resilient material and two pieces of straight elongate resilient material for making two breast supports according to the present invention;
FIG. 5 shows one of the pieces of straight elongate resilient material and one of the pieces of arcuate elongate resilient material of FIG. 4 in contact with each other for forming a breast support according to the present invention;
FIG. 6 shows a first breast support according to the present invention;
FIG. 7 shows a second breast support according to the present invention;
FIG. 8 shows a top perspective view of a breast support according to the present invention;
FIG. 9 shows a top perspective view of a further breast support according to the present invention; and
FIGS. 10 to 18 show a method for manufacturing the two brassiere pads of FIG. 1 according to the present invention.



DESCRIPTION OF THE EMBODIMENTS
FIG. 1 shows a front view of two brassiere pads, generally designated as 10a and 10b respectively, and FIG. 2 is an inside view of the brassiere pads 10a, 10b. Each of the brassiere pads 10a, 10b is fixedly embedded with a breast support 12 according to the present invention along and adjacent their respective lower sides 11a, 11b. As shown in more detail in FIG. 3, when a brassiere (not shown) incorporating the two brassiere pads 10a, 10b is worn by a wearer, and taking the breast support 12a within the brassiere pad 10a as an example, the breast support 12a is under and provides support to a breast (B) of the wearer.
The breast support 12a is made of a piece of arcuate elongate resilient material 14a and a piece of straight elongate resilient material 16a; and the breast support 12b is made of a piece of arcuate elongate resilient material 14b and a piece of straight elongate resilient material 16b. FIG. 4 shows the top views of the two pieces of arcuate elongate resilient material 14a, 14b and the two pieces of straight elongate resilient material 16a, 16b. The straight elongate resilient material 16a, 16b on the one hand and the arcuate elongate resilient material 14a, 14b on the other hand are of different curvatures. Each of the two pieces of arcuate elongate resilient material 14a, 14b and the two pieces of straight elongate resilient material 16a, 16b has respectively an upper planar major surface and a lower planar major surface which are parallel to each other. The arcuate elongate resilient material 14a has an inner arcuate edge 13a and an outer arcuate edge 15a, both adjoining the upper and lower surfaces of the arcuate elongate resilient material 14a. The outer arcuate edge 15a is longer than the inner arcuate edge 13a. The arcuate elongate resilient material 14b has an inner arcuate edge 13b and an outer arcuate edge 15b, both adjoining the upper and lower surfaces of the arcuate elongate resilient material 14b. The outer arcuate edge 15b is longer than the inner arcuate edge 13b. 
Though not strictly necessary, the length of the inner arcuate edge 13a of the piece of arcuate elongate resilient material 14a is usually longer than the length of the piece of straight elongate resilient material 16a; and the length of the inner arcuate edge 13b of the piece of arcuate elongate resilient material 14b is usually longer than the length of the piece of straight elongate resilient material 16b. 
The two pieces of arcuate elongate resilient material 14a, 14b and the two pieces of straight elongate resilient material 16a, 16b may be made of the same material or different materials. In particular, they may each be made of ethylene vinyl acetate, compressed polyurethane, compressed fibrefill, and/or a resilient coated fabric, so that the pieces of arcuate elongate resilient material 14a, 14b and the pieces of straight elongate resilient material 16a, 16b are resilient when bent to form a curve. More particularly, while the two pieces of arcuate elongate resilient material 14a, 14b and the two pieces of straight elongate resilient material 16a, 16b may each be bent into a curved shape, they are resilient to such bending and tend to return to their stable original shape in which their respective upper and lower surfaces are planar.
To form the breast support 12a, and as shown in FIG. 5, the piece of straight elongate resilient material 16a is placed on the piece of arcuate elongate resilient material 14a such that a lower planar major surface of the piece of straight elongate resilient material 16a is in contact with an upper planar major surface 18 of the piece of arcuate elongate resilient material 14a. The piece of arcuate elongate resilient material 14a and the piece of straight elongate resilient material 16a are then fixedly engaged with each other, by sewing and/or lamination, along at least a majority of the length (e.g. along the whole length) of the piece of straight elongate resilient material 16a. Because of the difference between the length of the inner arcuate edge 13a of the piece of arcuate elongate resilient material 14a and the length of the piece of straight elongate resilient material 16a, the resultant breast support 12a is forced to form a curved shape and is resilient to any further change of shape. More particularly, when the breast support 12a is in the curved shape as shown in FIG. 6 or 7, it will remain in this stable curved shape unless subject to external force. While the breast support 12a may be bent by an external force to change its shape (curvature), when the external force is removed, it will return to the stable curved shape. Because of such a characteristic, the breast support 12a will provide support to a breast of a wearer of a garment or garment part incorporating the breast support 12a. 
The curvature of the resultant breast support 12a depends mainly on the curvature of the piece of arcuate elongate resilient material 14a. Thus, the breast support 12a formed of the piece of straight elongate resilient material 16a and the piece of arcuate elongate resilient material 14a may be of a first curvature as shown in FIG. 6, or may be of a second curvature as shown in FIG. 7, depending on the curvature of the piece of arcuate elongate resilient material 14a. It should be noted in this connection that the word “arcuate” in the present invention should not be understood in the strict geometrical sense. It thus means that the piece of arcuate elongate resilient material 14a needs not be in the exact shape of part of a circumference of a circle, but that its shape only needs to loosely resemble that of an arc.
FIG. 8 shows the breast support 12a and FIG. 9 shows the breast support 12b, both sitting on a horizontal surface. It is found that the breast supports 12a, 12b are of such a resilience that they can both stably sit on a horizontal surface with the respective outer arcuate edge 15a, 15b of their respective piece of arcuate elongate resilient material 14a, 14b in contact with the horizontal surface and the respective inner arcuate edge 13a, 13b of their respective piece of arcuate elongate resilient material 14a, 14b above and spaced apart from the horizontal surface.
FIGS. 10 to 18 show a method for manufacturing the brassiere pads 10a, 10b of FIG. 1 according to the present invention. FIG. 10 shows a first piece of precursor material 102 formed of a layer of fabric material 104 and a layer of foam material 106 fixedly engaged with each other by an adhesive and/or heat lamination, and a second piece of precursor material 108 formed of a layer of foam material 110 and a layer of fabric material 112 fixedly engaged with each other by an adhesive and/or heat lamination.
As shown in FIG. 11, the first piece of precursor material 102 is placed between an upper mold M1 and a lower mold M2 of a mold to be molded (by pressure and preferably with heat as well) to form at least two cup-shaped portions, as shown in FIG. 13. Similarly, and as shown in FIG. 12, the second piece of precursor material 108 is placed between the upper mold M1 and lower mold M2 to be molded (by pressure and preferably with heat as well) to form at least two cup-shaped portions, again as shown in FIG. 13.
As shown in FIG. 14, a layer of adhesive 114 is applied to the layer of foam material 106 of the molded first piece of precursor material 102 which, when the brassiere pads 10a, 10b are duly assembled, contacts the molded second piece of precursor material 108. Alternatively or in addition, a layer of adhesive is applied to the layer of foam material 110 of the molded second piece of precursor material 108 which, when the brassiere pads 10a, 10b are duly assembled, contacts the molded first piece of precursor material 102.
The breast supports 12a, 12b are then placed on the molded second piece of precursor material 108, as shown in FIG. 15. Further as shown in FIG. 16, the molded first piece of precursor material 102, the molded second piece of precursor material 108, with the breast supports 12a, 12b in between, are placed within the upper mold M1 and lower mold M2 for molding by pressure and preferably with heat as well. Although the breasts supports 12a, 12b are shown in FIG. 16 as being spaced away from the molded second piece of precursor material 108, it should be understood that, as mentioned earlier, the breast supports 12a, 12b are placed on the molded second piece of precursor material 108.
FIG. 17 shows the molded first piece of precursor material 102, molded second piece of precursor material 108, with the breast supports 12a, 12b in between, after being released from the mold comprising the upper mold M1 and lower mold M2 subsequent to further molding to form an integral laminated material 116. The brassiere pads 10a, 10b, as shown in FIG. 18, are then formed by being cut out from the integral laminated material 116.
The brassiere pads 10a, 10b may be used for forming a brassiere, or may be incorporated in other garments, e.g. swimwear. In addition, although the invention has thus far been discussed in the context in which the breast supports 12a, 12b are incorporated in the brassiere pads 10a, 10b by molding, it is envisaged that the breast supports 12a, 12b may be incorporated in the brassiere pads 10a, 10b by sewing and/or adhesive. Furthermore, the breast supports 12a, 12b may also be directly incorporated, e.g. by molding, sewing and/or adhesive, in other garments or garment parts, such as unlined brassieres, swimwear, sports bra, crop tops, sports tops, sleepwear, lingerie, intimate apparel, shapewear, corsets and wedding gowns.
It should be understood that the above only illustrates and describes examples whereby the present invention may be carried out, and that modifications and/or alterations may be made thereto without departing from the spirit of the invention. For example, while the invention has thus far been described in the context in which the breast support is made of a piece of straight elongate resilient material and a piece of arcuate elongate resilient material, it is envisaged that such can also be made of two pieces of arcuate elongate resilient material, each of a different curvature.
It should also be understood that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided or separately or in any suitable sub-combination.

## Claims

1. A breast support for a garment or garment part, said breast support comprising:
a first piece of elongate resilient material formed by a piece of resilient material with a first planar major surface, of a first curvature, and with a length, and
a second piece of elongate resilient material formed by a piece of resilient material with a second planar major surface and of a second curvature which is different from the first curvature,
wherein said first piece of elongate resilient material is fixedly engaged and in contact with said second piece of elongate resilient material along at least a majority of said length of said first piece of elongate resilient material, and
wherein said first piece of elongate resilient material and said second piece of elongate resilient material are fixedly engaged and in contact with each other only via said first planar major surface of said first piece of elongate resilient material and said second planar major surface of said second piece of elongate resilient material.

2. A breast support according to claim 1 wherein said first piece of elongate resilient material is substantially straight and said second piece of elongate resilient material is arcuate.

3. A breast support according to claim 1 wherein said second piece of elongate resilient material has an inner arcuate edge and an outer arcuate edge.

4. A breast support according to claim 3 wherein said first piece of elongate resilient material is shorter than said inner arcuate edge of said second piece of elongate resilient material.

5. A breast support according to claim 1 wherein said first piece of elongate resilient material is fixedly engaged and in contact with said second piece of elongate resilient material along substantially the whole of said length of said first piece of elongate resilient material.

6. A breast support according to claim 1 wherein said first piece of elongate resilient material is made of any one of ethylene vinyl acetate, compressed polyurethane, compressed fiberfill and a resilient coated fabric.

7. A breast support according to claim 1 wherein said second piece of elongate resilient material is made of any one of ethylene vinyl acetate, compressed polyurethane, compressed fiberfill and a resilient coated fabric.

8. A breast support according to claim 1 wherein said first piece of elongate resilient material and said second piece of elongate resilient material are made of a same material or different materials.

9. A breast support according to claim 1 wherein said first piece of elongate resilient material is fixedly engaged with said second piece of elongate resilient material by sewing and/or lamination.

10. A garment or garment part including at least one breast support according to claim 1.

11. A method of forming a breast support for a garment or garment part, said method comprising:
(a) providing a first piece of elongate material with a first planar major surface, of a first curvature, and with a length,
(b) providing a second piece of elongate resilient material with a second planar major surface and of a second curvature which is different from the first curvature, and
(c) fixedly engaging and contacting said first piece of elongate resilient material with said second piece of elongate resilient material along at least a majority of said length of said first piece of elongate resilient material,
wherein said first piece of elongate resilient material and said second piece of elongate resilient material are fixedly engaged and in contact with each other only via said first planar major surface of said first piece of elongate resilient material and said second planar major surface of said second piece of elongate resilient material.

12. A method according to claim 11 wherein said first piece of elongate resilient material is substantially straight and said second piece of elongate resilient material is arcuate.

13. A method according to claim 11 wherein said second piece of elongate resilient material has an inner arcuate edge and an outer arcuate edge.

14. A method according to claim 11 wherein said first piece of elongate resilient material is shorter than the inner arcuate edge of said second piece of elongate resilient material.

15. A method according to claim 13 wherein said first piece of elongate resilient material is fixedly engaged and in contact with said second piece of elongate resilient material along substantially the whole length of said first piece of elongate resilient material.

16. A method according to claim 11 wherein said first piece of elongate resilient material is made of any one of ethylene vinyl acetate, compressed polyurethane, compressed fiberfill and a resilient coated fabric.

17. A method according to claim 11 wherein said second piece of elongate resilient material is made of any one of ethylene vinyl acetate, compressed polyurethane, compressed fiberfill and a resilient coated fabric.

18. A method according to claim 11 wherein said first piece of elongate resilient material and said second piece of elongate resilient material are made of a same material or different materials.

19. A method according to claim 11 wherein, in said step (c), said first piece of elongate resilient material is fixedly engaged with said second piece of elongate resilient material by sewing and/or heat lamination.

20. A method of forming a garment or garment part including incorporating at least one breast support formed by a method according to claim 11 in a garment or garment part.

21. A method according to claim 20 wherein said at least one breast support is incorporated in said garment or garment part by molding, sewing and/or adhesive.