Abstract:
A push-up bra has an envelope between the front panel and the rear panel of the bra cups, that receives a flexible pouch containing a body of lubricous, malleable material such as lightly cross-linked organo-polysiloxanes containing a dispersion of lightweight, finely-divided filler such as silica. The malleable material can be molded into a shape under and/or to either side of a breast to control the shape, amount of lift and the cleft between breasts and the lubricity of the siloxane resin prevents the filler from abrading the inner wall of the pouch.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part of International Application Serial No: PCT/US99/02700 filed Feb. 9, 1999. 
    
    
     TECHNICAL FIELD 
     The present invention relates to an improved pad for a brassiere and, more particularly to a pad comprising a flexible envelope containing a body of malleable material that can be incorporated into a push-up bra or into a pad for placement in a conventional bra. 
     BACKGROUND OF THE INVENTION 
     Brassieres are worn not only to provide support for women&#39;s breasts, but also to enhance the shape of the breasts within the brassieres, to enhance the shape of the portion and amount of the breasts above the brassieres and to modify the cleavage between the breasts. 
     Push-up bras are designed to shape and elevate the breasts. Push-up bras usually contain a rubber pad received in a pocket in the lower front panels of the bra cups. The pad is formed by molding into a complex arcuate shape. Rubber pads are both stiff and uncomfortable and do not exhibit the natural feel of breast tissue. Rubber pads also cause insecurity due to straying of the pads. Other push-up bras used a more yielding silicone foam and some use Nylon (polyamide) padding to shape and lift. 
     Push-up bras with liquid filled envelopes have recently appeared on the market. These pads more clearly emulate the consistency of breast tissue. However, the liquids used to fill the envelopes are not satisfactory. Silicone oil liquids are very expensive and are hard to seal. Hydrocarbon oils have also been utilized as the liquid either alone or in a mixture with water. Hydrocarbons can attack the envelope. The liquids in the envelope are heated to body temperature of about 99° F. At this temperature, evaporation is increased and the hydrocarbon vapors can permeate through the wall of the envelope, creating offensive, unpleasant odors. Furthermore, water vapor is also able to permeate through the wall of the envelope decreasing the liquid volume in the envelope. The envelope could rupture on impact or when pierced by a sharp object causing embarrassment, discomfort and destruction of the pad. 
     
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 List of References 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Patentee 
                 U.S. Pat. No. 
               
               
                   
                   
               
               
                   
                 Block, et al. 
                 3,620,222 
               
               
                   
                 Kirby, et al. 
                 3,845,507 
               
               
                   
                 Lynch 
                 3,986,123 
               
               
                   
                 Miller 
                 5,235,974 
               
               
                   
                   
               
             
          
         
       
     
     STATEMENT OF THE PRIOR ART 
     Block, et al. discloses a foam, push-up brassiere pad. Kirby, et al. discloses a breast prosthesis to be worn inside a brassiere cup containing an inner bag. A gel-like liquid such as carboxymethyl cellulose is sealed within an outer bag containing air. Miller discloses an electrically heated bra for lactating mothers containing a fluid impermeable chamber filled with water. Lynch discloses a breast prosthesis filled with a low density silicone gel. The gel used by Lynch is not malleable. 
     The improved push-up pad described in copending application Ser. No. 09/132,572, filed Aug. 11, 1998, the disclosure of which is expressly incorporated herein by reference, contains a flexible envelope filled with a mixture of water and an odorless, organic hygroscopic agent in specified proportions providing no unpleasant aroma and little evaporation of water through the film of the envelope. The envelope is formed of a film of a tough synthetic resin resistant to puncture, preferably a thermoplastic resin capable of being heat-sealed. The film has low transmission rate for water vapor. The hygroscopic agent is able to drive water vapor from outside the envelope through the film into the envelope so that liquid volume is maintained. 
     This push-up bra looks and feels more natural and the bra eliminates discomfort and insecurity caused by stiff, sharp edged or straying inner pads. The inner cup lining adjacent the skin is soft and wicks moisture away from the skin. 
     However, though the push-up pad does not stray, the liquid in the pad, will distribute throughout the envelope depending on the compression forces applied to the envelope during wearing the bra. Even if a portion of the pad is positioned on the sides of a cup, most of the liquid will tend to position at the bottom of the cup. 
     In an earlier experiment, a body of malleable material was synthesized from water thickened with a small amount usually about 0.5% by weight of a polyacrylamide thickener and containing about 20% by weight of a filler such as silica microspheres. The material was malleable. However, when placed in a thin film pouch for use in a bra pad, the forces of the filler against the inner wall of the film abraded the film of the bag until it failed. 
     STATEMENT OF THE INVENTION 
     In the present invention, a push-up bra pad contains a lubricous body of malleable material. The pad can be placed in any position, under or to the sides of the breast and molded into a desired shape. The malleable material will retain the desired shape during normal usage. The malleability of the material is similar to natural tissue. Unlike a prosthesis which has a volume and shape equal to a breast, the push-up pad of the invention has a volume less than that of a breast, usually from 10% to 40% of the volume of a bra cup. 
     The malleable material has no elastic memory. It does not flow unless placed under pressure. The desired properties can be provided by forming a partially cross-linked, self-lubricating polymer material. Suitably, cross-linking less then 10% of the material is sufficient to form a 3-dimensional matrix when cross-linked. The amount of cross-linking is controlled by presence of cross-linkable groups such as unsaturated groups, suitably vinyl groups. The curing reaction can be accelerated by the presence of a curing catalyst. The size of the molecules of cross-linked polymer material is too large to permeate through the wall of the pouch containing a body of the material. 
     The push-up pad adds additional weight to be carried by the wearer of the bra. The weight of the pad can be reduced and strength increased by dispersing a reinforcing filler in the matrix of the material. The reinforcing filler also contributes to the desired malleability. Suitable materials are finely divided minerals such as fumed silica or glass or polymeric microspheres suitably having a diameter from 10 to 500 microns and present in an amount from 3-40%, suitably from 10-30% by weight of the material. As the polymer material cross-links the particles of filler are immobilized within the cross-linked matrix. 
     The pads of the invention can also be used in outerwear such as bathing suit tops and athletic tops. 
     These and many other features and attendant advantages of the invention will become apparent as the invention becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is front view in elevation illustrating the push-up bra of the invention with the malleable material in a lower central position in a cup; 
     FIG. 2 is a view in section taken along line  2 — 2  of FIG. 1; 
     FIG. 3 is a front view in elevation of a bra with the malleable material molded to the outside of the cup; 
     FIG. 4 is a view in section of a bra pad taken along line  4 — 4  of FIG. 3; 
     FIG. 5 is a front view in elevation of a push-up pad molded to position the malleable material higher in the cup; 
     FIG. 6 is a view in section taken along line  6 — 6  of FIG. 5; 
     FIG. 7 is a perspective view of a malleable bra pad according to the invention; and 
     FIG. 8 is a view in section taken along line  8 — 8  of FIG.  7 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to FIGS. 1 and 2, a push-up bra  10  useful with the malleable material pouch  38  of the invention is formed of two cups  12 ,  14 , a stretchable strap, not shown, connected to the outside periphery of each cup  12 ,  14  with releasable fastener, not shown, and optional shoulder straps  16 ,  18 . 
     The cups  12 ,  14  are formed of an outer layer  20  of fabric and an inner layer  22  of fabric. The outer layer  20  of fabric can be covered with a layer of decorative material such as lace. The surface  24  of the inner layer  22  is preferably covered with a layer of a soft material  27  which absorbs and wicks moisture such as woven cotton or polypropylene cloth. A long narrow sleeve  26  following the curved outline of the bra cup can be formed along the lower periphery  29  of the bra cups  12 ,  14 . A curved metal stiffening rod  28  can be received in the sleeve  26 . 
     The outer layers  20  are stitched around their common peripheries  30 ,  32  to form pockets  34 ,  36  for receiving flexible pouches  38 ,  40  containing a body  42  of malleable material as shown in FIG.  2 . The pouches  38 ,  40  can have the general exterior shape of a bra cup  12 ,  14 . The pouches  38 ,  40  are formed of a front film  43  heat sealed at their common perimeters to a rear panel  44  forming a lip  46 . The pouches  38 ,  40  are preferably anchored to the outer layer  20  or inner layer  22  of fabric. The lip  46  could be formed by adhering the outer peripheries of the two panels by adhesive or stitching. However, stitching or adhesive could make the lip  46  more susceptible to tear. It is preferred that the pouches  38 ,  40  be provided with an extended tab, not shown, which before thermal bonding serves as a filling spout. The two layers  20 ,  22  of the pouch are completely thermal sealed within the tab into a unitary film. Two thermally generated beads, not shown, can be provided normal to the axis of the pouches to reinforce the tab from tearing. 
     The tab can be sewn into the edge of the outer layer of fabric  20  near the outside periphery of the pockets  34 ,  36 . The pouches  38 ,  40  are then inserted into the pockets  34 ,  36 . The edge of the inner layer  22  of fabric is then stitched to the edge of the outer layer  20 . 
     The skin of the pouch is a tough, puncture-resistant, leak resistant, flexible film such as a 0.01 to 5 mm thick film, preferably a film having a thickness from 0.05 to 0.5 mm. Suitable films are thermoplastic, thermally bondable films such as polyethylene, vinyl, silicone resins or polyurethane which can be in the form of a closed cell foam. The surface of the pouch has good wetability for water, is resistant to hydrolysis, has flame retardence and resistance to U.V. radiation. It is stable to being agitated with hot soapy water in a washing machine. The film can have a Shore A Hardness from 50 to 100, a Specific Gravity of 1.1 to 1.3, an elongation of at least 300% and a minimum tear strength of 200 Lb/in. The film should have a high melting temperature above 180° C. in order to be capable of surviving temperatures encountered in washing and drying machines. However, hand washing and air drying of the bra are preferred. 
     The malleable material which is placed in the pouches is preferably odorless and stable to the heat and forces encountered during use. A preferred material is a lightly cross-linked organo-polysiloxane optionally reinforced with finely divided silica or microspheres of glass or epoxy resin. The cross-linking can be provided by unsaturated sites on the starting materials. The malleable material is preferably made from two cross-linkable liquids which can be of polymeric length which are mixed together and reacted to form the cross-linked material. The reinforcing agent is dispersed in one or both of the starting liquids. Catalyst is added, such as an addition polymerization, platinum metal and the mixed material reacted to form a cross-linked, malleable material similar to a viscous paste. 
     Organo-polysiloxanes are preferred because of their known biocompatibility with human tissue and excellent lubricating properties. Cross-linking is provided by adding at least one vinyl group to the starting dialkyl alkyl silicone materials. The major portion of the malleable material can be formed of a dialkyl alkyl vinyl siloxane in which each alkyl group contains 1-6 carbon atoms. A minor portion of the material can be an alkyl vinyl, dialkyl alkyl hydrogen siloxane where the alkyl groups contain 1-6 carbon atoms. 
     An example of practice follows: 
     Part A 
     100 parts by weight 50% Dimethyl and 50% Methyl vinyl siloxane liquid copolymer 
     Part B 
     0.1 parts by weight 50% Methyl vinyl and 50% dimethyl methyl hydrogen siloxanes liquid copolymer 
     The mixture of A and B contains 20% by weight of silica microspheres. 
     Physical Properties—Part A 
     Boiling point: &gt;260° C. 
     Specific Gravity (water=1): 0.7 
     Vapor Pressure at 25° C.: &gt;1 mm Hg—essentially non-volatile 
     Vapor Density (air=1): N/A—essentially non-volatile 
     Water Solubility: nil 
     Evaporation Rate (Ethyl Ether=1): nil 
     Appearance and Odor: Colorless, translucent, viscous, paste 
     Physical Properties—Part B 
     Boiling point: &gt;260° C. 
     Specific Gravity (water=1): 0.9 
     Vapor Pressure at 25° C.: negligible—essentially non-volatile 
     Vapor Density (air=1): N/A—essentially non-volatile 
     Water Solubility: nil 
     Evaporation Rate (Ethyl Ether=1): N/A 
     Appearance and Odor: Colorless, translucent, fluid 
     Parts A and B were mixed with platinum catalyst and cross-linked to form a malleable matrix material. 
     A prototype of the push-up bra of the invention was prepared by filling an elastomeric polyurethane pouch. 
     The pouch was formed from a closed cell polyurethane film having the following properties: 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 Properties 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Color APHA 
                 5 
               
               
                   
                 Thickness 
                 0.1 mm 
               
               
                   
                 Hardness 
                 87 Shore A 
               
               
                   
                 Specific Gravity 
                 1.20 
               
               
                   
                 Tensile Strength 
                 6525 psi 
               
               
                   
                 Elongation 
                 480% 
               
               
                   
                 Tear Strength 
                 400 lb/in 
               
               
                   
                 Melting Temperature 
                 180-190° C. 
               
               
                   
                   
               
             
          
         
       
     
     The malleable material containing pouch of the invention can also be incorporated into an uplift bra pad  100  as shown in FIGS. 7-8. The pad  100  has an oval-shaped front panel  102  and an oval shaped rear panel  104 . The panels can be formed of woven or non-woven fabrics, preferably a soft woven synthetic fabric such as Nylon (linear polyamide) or polyester. The peripheral edges  106 ,  108  of the panels  102 ,  104  are joined, suitably by stitching  110  to form a cavity  118  for receiving a pouch  112  containing a body  114  of malleable material. 
     The panels may have a thin layer of flexible foam usually {fraction (1/16)} to ¼ inch thick attached to the inside surface, suitably by adhesive and/or thermal lamination. An optional strip  116  of flexible foam my extend across the upper portion of the cavity  118 . The strip  116  is usually from ¼ to ½ inch thick and occupies no more than 45% of the height of a cavity  118  usually about 30-40% of the cavity. The lower edge  120  of the strip  116  can be bound by stitching to the peripheral edges of the pad  100 . 
     Another optional feature is to laminate the front panel  102 , rear panel  104  and flexible foam strip  116  together by heat or adhesive to form a closed, flat upper portion  124  decreasing the size of the cavity  118  to form a smaller cavity  126 . The upper portion  124  will have a convex front face  128  and a concave rear face  130 . When the pouch  132  is inserted into the cavity  126  the lower portion  134  of the front face and lower portion  136  of the rear face will both have a convex shape. The pouch  112  has a tab  138  which can be placed between the outer edges of the panels  102 ,  104  and sewn to anchor the pouch  132  within the smaller cavity  126 . 
     Referring again to FIGS. 1 and 2, the pads  100  contain pouches  38 ,  40  filled with a body  42  of malleable material. The body  42  of malleable material shown in dotted lines, can be formed into a crescent shape and centrally positioned under a breast  150 . The breast  150  will be uniformly lifted above the top edge  152  of the bra  154  to form a first cleavage  156 . As shown in FIGS. 3-4, when the body of malleable material  42  is molded into a thicker, shorter body  158 , placed toward the outside of each breast  150 , the breasts will be lifted up and pressed closer together to form a second longer cleavage  160 . 
     When the body  42  of the malleable material, as shown in FIGS. 5 and 6, is placed higher in the bra cup the cleavage  164  is still longer. 
     It is to be realized that only preferred embodiments of the invention have been described and that numerous substitutions, modifications and alterations are permissible without departing from the spirit and scope of the invention as defined in the following claims.