Abstract:
An underwire brassiere and breast cup for use in the underwire brassiere. The breast cup provides improved comfort for the wearer by isolating the support wire from the skin of the wearer. Particularly the support wire is positioned along an outer side of a laminated foam core. The laminated foam core can be shaped to have an embossed ridge projecting toward the inner side of the foam core, in a region mirroring the location of the support wire.

Description:
FIELD OF THE INVENTION 
       [0001]    The present disclosure generally relates to apparel, particularly brassieres. More particularly, the present disclosure relates to brassieres having supportive underwire. 
       BACKGROUND OF THE INVENTION 
       [0002]    Brassieres have long been part of women&#39;s daily attire. To increase support under, or along the lower periphery of brassiere cups, rigid wires have been added. Brassieres having these wires are often referred to as “underwire” brassieres. Often an underwire brassiere will include a pair of U-shaped wires, one for each respective breast cup. Alternatively, a single wire may span the bottom of both cups. 
         [0003]    While the rigidity of an underwire brassiere provides improved support, there are also disadvantages. For example, the narrow cross-section of the support wire of the brassiere can produce discomfort due to relatively sharp pressure points. The wire&#39;s rigidity can also cause discomfort during movement. Friction between the wire and the materials of the brassiere can cause the wire to become exposed over time. Exposed wires can poke the wearers skin or snag on the wearer&#39;s clothing. 
         [0004]    A variety of techniques have been attempted to increase the comfort of underwire brassieres, with varied levels of success. Thus, there remains a need for an underwire brassiere having improved comfort that maintains the relatively high degree of support for which underwire brassieres are known. 
       SUMMARY OF THE INVENTION 
       [0005]    The present disclosure is directed to an improved construction for a brassiere having a support wire. The support wire can be disposed on the outside of a molded cup in order to increase comfort. Further, the molded cup may provide a padded ridge in the region opposite the support wire. 
         [0006]    A first aspect of this disclosure is a breast cup for a brassiere. An exemplary breast cup may include a molded cup having an interior laminated fabric, an exterior laminated fabric, and at least one foam layer between the interior and exterior laminated fabrics. The interior laminated fabric, the exterior laminated fabric and the at least one foam layer are laminated together to create the molded cup. The molded cup may further comprise a first raised portion adjacent to a lower peripheral edge of the molded cup. The first raised portion can extend toward an inner side of the molded cup. The exemplary breast cup can also include a support wire disposed along the lower peripheral edge of the molded cup. The support wire is configured to be positioned outwardly of the exterior laminated fabric. 
         [0007]    A second aspect of this disclosure is a brassiere. The brassiere includes a pair of breast cups connected to each other by a bridge or central gore. Each breast cup includes a portion of a torso band attached to an end thereof, opposite the bridge. Each breast cup comprises an interior laminated fabric, an exterior laminated fabric, and at least one foam layer between the interior and exterior laminated fabrics. The interior laminated fabric, the exterior laminated fabric and the at least one foam layer are laminated together to create a molded core. The molded core may further comprise a first raised portion adjacent to a lower peripheral edge thereof. The first raised portion can extend toward an inner side of the molded core. The exemplary breast cup can also include a support wire disposed along the lower peripheral edge of the molded core and positioned outwardly of the exterior laminated fabric. The first raised portion and the support wire&#39;s location combine to improve comfort for the wearer. 
         [0008]    These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments, when considered in conjunction with the drawings. It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The foregoing and still other objects and advantages of the present invention will be more apparent from the following detailed explanation of embodiments of the invention in connection with the accompanying drawings. 
           [0010]      FIG. 1  shows a perspective view of an exemplary brassiere according to this disclosure. 
           [0011]      FIG. 2  shows a front view of an exemplary breast cup according to this disclosure. 
           [0012]      FIG. 3  shows a back view of an exemplary breast cup according to this disclosure. 
           [0013]      FIG. 4  shows a cut-away view of the exemplary breast cup of  FIGS. 1-3  along line IV-IV shown in  FIG. 3 . 
           [0014]      FIG. 5  shows a detailed cut-away view of an exemplary encased support wire according to the present disclosure. 
           [0015]      FIG. 6  shows across section of a molded core according to a second embodiment. 
           [0016]      FIG. 7  shows a cross section of a molded core according to a third embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Exemplary embodiments of this disclosure are described below and illustrated in the accompanying figures, in which like numerals refer to like parts throughout the several views. The embodiments described provide examples and should not be interpreted as limiting the scope of the invention. Other embodiments, and modifications and improvements of the described embodiments, will occur to those skilled in the art and all such other embodiments, modifications and improvements are within the scope of the present invention. Features from one embodiment or aspect may be combined with features from any other embodiment or aspect in any appropriate combination. For example, any individual or collective features of method aspects or embodiments may be applied to apparatus, product or component aspects or embodiments and vice versa. 
         [0018]    As used herein, the terms “inside,” “inner,” “interior,” and “back” are used to reference elements of a breast cup that are relatively positioned toward the skin of a wearer. On the other hand, the terms “outside,” “outer,” “exterior,” and “front” are used to reference elements of a breast cup that are relatively positioned in a direction away from the skin of a wearer. 
         [0019]    Turning to the figures,  FIG. 1  shows an exemplary brassiere  100  comprising a pair of breast cups  120 . The breast cups  120  are connected together with a central gore, or bridge  150 . A torso strap  130  may extend from the lateral sides  122  of each breast cup  120 . The respective torso straps  130  may combine to encircle the torso of a wearer. Conventional adjustable fasteners (not shown) may be affixed at the ends of the respective torso straps  130  opposite the breast cups  120 . The respective torso straps  130  may be replaced by a single continuous torso band (not shown). Optionally, adjustable shoulder straps  140  may connect to the top edge  124  of each breast cup  120  and connect to the torso strap  130  of the corresponding breast cup  120 . 
         [0020]      FIG. 2  shows a close up view of the front of an exemplary breast cup  120 . The breast cup  120  may comprise an outermost fabric  250 . The outermost fabric  250  is preferably sewn only to the periphery of the breast cup  120  and has an unattached portion over a central portion of the breast cup  120 . The resulting unattached portion helps to conceal a support wire  300  disposed behind the outermost fabric  250 . The outermost fabric  250  may be formed of a nylon/spandex blend, or any other suitable fabric, so the outermost fabric  250  provides a pleasing appearance and feel to the brassiere  100 . 
         [0021]      FIG. 3  shows a close up view of the back of an exemplary breast cup  120 . In a preferred embodiment, the innermost layer of the breast cup  120  may comprise an interior laminated fabric  205  formed as part of a molded core  200  (see  FIG. 4 ). Interior laminated fabric  205  is a fabric intended to be laminated to form the molded core  200 . The interior laminated fabric  205  may comprise, for example, polyester, or a polyester/spandex blend. In an exemplary embodiment, the molded core  200  comprises a first embossed ridge  230  projecting from the inner side of the breast cup  120 . The first embossed ridge  230  is located along the lower peripheral portion  126  of the breast cup  120  or layers thereof. The first embossed ridge  230  is configured to correspond with the location of a support wire  300  (see  FIG. 4 ). 
         [0022]    As best seen in  FIG. 4 , each breast cup  120  comprises a multi-layer construction. Each breast cup  120  may comprise a molded core  200 . Preferably, the molded core  200  includes an interior laminated fabric  205 , an exterior laminated fabric  210 , and foam layers  215 ,  220  disposed between the interior laminated fabric  205  and the exterior laminated fabric  210 . While  FIG. 4  shows two foam layers  215 ,  220 , the invention is not limited to the use of two foam layers. The molded core  200  is formed by laminating the foam layers  215 ,  220  between the interior laminated fabric  205  and the exterior laminated fabric  210  using a heated bullet/bubble mold or other processes as known in the art. 
         [0023]    According to one embodiment, the foam layers  215 ,  220  may comprise polyurethane, polyester, or polyether. In an exemplary embodiment, the thickness of the foam layers  215 ,  220  may be between about % and about ½ inches prior to molding. The thickness of the foam layers  215 ,  220  and the spacing between a male (bullet) and a female (bubble) cast of a molding machine can be adjusted to provide a finished molded core  200  with the desired thickness, density, and rigidity. 
         [0024]    Continuing with  FIG. 4 , a support wire  300  is configured to be attached to the outside of the molded core  200 . The support wire  300  is preferably constructed from either a metallic or a rigid polymer material. The support wire  300  preferably has a relatively flat cross-section and may be bent into an arcuate shape. The support wire  300  preferably extends from the lateral side  122  of each breast cup  120 , along the lower peripheral portion  126  of the breast cup  120  and ends at the central edge  128  of the breast cup  120  adjacent the bridge  150 . 
         [0025]    In the embodiment shown in  FIG. 4 , and detailed in  FIG. 5 , the support wire  300  is wrapped between one or more fabric plies  305 ,  310 . The one or more fabric plies  305 ,  310  may be separate from one another. In a preferred embodiment, the inner ply  305  may comprise a first material, while the outer ply  310  comprises a second, different, material. The inner ply  305  is likely to rub against the support wire  300 . Therefore the first material may be selected to be relatively strong and highly resistant to abrasion. On the other hand, the second material can be selected to help furnish a smooth appearance to front of the brassiere  100 . 
         [0026]    Preferably the inner ply  305  and the outer ply  310  are not directly attached to the support wire  300 . The inner and outer fabric plies  305 ,  310  may be wrapped around the support wire  300  in an inverted U-shaped configuration, with the free ends of the at least one fabric ply  305 ,  310  being turned inwardly before being stitched onto the outside of the molded core  200 . The support wire  300  is held in place along the lower periphery of the outside of the molded core  200  by first stitching  315 . Preferably stitching  315  begins from the outside direction, through the inner and outer plies  305 ,  310 , and into, but not completely through, the molded core  200 . 
         [0027]    The outermost fabric  250  (described above) can also be seen in the cross-section of  FIG. 4 . The embodiment of  FIG. 4  also includes an optional cup liner  260  that may be disposed between the outermost fabric  250  and the molded core  200 . In a preferred embodiment, the cup liner  260  comprises 100% polyester. The cup liner  260  shields the molded core  200  from view, helping to prevent visibility of “yellowing” of the molded core  200  that can occur in laminated foam layers  215 ,  220  after a series of launderings. When the fabric layers (e.g.  205 ,  250 ) used to form the brassiere  100  are of a dark color (e.g. black), the cup liner  260  may not be required: “yellowing” is already masked by the dark fabric. 
         [0028]    As shown in  FIG. 3 , the molded core  200  of the present disclosure includes a first embossed ridge  230  that extends arcuately along the lower peripheral portion  126  of each breast cup  120 . As show in  FIG. 4 , preferably, the first embossed ridge  230  projects inwardly toward the wearer. The first embossed ridge  230  mirrors the position where the support wire  300  resides along the outside of the molded core  200 . 
         [0029]    The first embossed ridge  230  provides supplemental cushioning to the support wire  300 . In the embodiment of  FIG. 4 , an area comprised of foam layers  215 ,  220 , which has increased thickness, defines the first embossed ridge  230 . 
         [0030]    In one embodiment, a single layer of foam  215  is used to form cup  120 . The first embossed ridge  230  can be created by providing the male cast of a molding machine with a groove corresponding to the first embossed ridge  230 . When the single layer of foam  215  is pressed in the mold, the area of the first embossed ridge  230  will be compressed less than the remainder of the molded core  200 . 
         [0031]    In a second embodiment, as shown in  FIG. 4 , both a first layer of foam  215  and a second layer of foam  220  may be used. The first layer of foam  215  may be configured to be coextensive with the entire breast cup  120 , providing padding therefore. For example, the first layer of foam  215  may be between about ⅛ and about ¼ inches thick. The second layer of foam  220  may be configured to primarily correspond only with the lower peripheral portion  126  of the molded core  200 . The second layer of foam  220  may be between about ¼ and about ⅜ inches thick. Use of the second layer of foam  220 , substantially dedicated to the creation of the first embossed ridge  230 , will allow for an increase in height and density of the first embossed ridge  230 . To facilitate proper placement in the molding machine, the second layer of foam  220  may have a perimeter that corresponds to the perimeter of the first layer of foam  215 . When this is the case, the second layer of foam  220  may have central portions removed that would otherwise correspond to the majority, or central portion, of the finished molded core  200 . 
         [0032]    Visual enhancement of the first embossed ridge  230  may also be desirable. Second stitching  245  on either side, and along substantially the entire length, of the first embossed ridge  230  can provide a visual delineation on the back of each breast cup  120 . 
         [0033]      FIG. 6  shows another embodiment of a molded core  200  according to the present disclosure. In this embodiment, a recessed channel  235  is formed in the molded core  200  during the molding process. The recessed channel  235  corresponds to the shape and placement of the support wire  300  in the finished breast cup  120 . The recessed channel  235  may be between about 3/16 inches and about 7/16 inches wide. The recessed channel  235  is sized to accommodate the support wire  300  and the at least one fabric ply  305 ,  310 . In one embodiment, the recessed channel  235  is dimensioned to maintain the support wire  300  substantially flush with the outer surface of the molded core  200 . This substantially flush surface arrangement contributes to improve the appearance of the brassiere  100  by helping to hide the support wire  300  behind the outermost fabric  250 . The recessed channel  235  corresponds to the first embossed ridge  230 , each on an opposite side of the molded core  200 . The recessed channel  235  may be formed by providing a female portion of a mold with a projection to correspond with a groove in a male portion of the mold. The projection will form the recessed channel  235  and the groove will allow the formation of the first embossed ridge  230 . 
         [0034]      FIG. 7  shows another embodiment of a molded core  200  according to the present disclosure. Molded core  200  of the instant embodiment comprises a second embossed ridge  240  extending toward the outer side of the molded core  200 . The second embossed ridge  240  is disposed opposite to the first embossed ridge  230 . The first and second embossed ridges  230 ,  240  combine to form an area of increased foam thickness in the finished molded core  200 . The thickness of foam provided by first and second embossed ridges  230 ,  240  provide even more cushioning compared to first embossed ridge  230  alone. 
         [0035]    Although the above disclosure has been presented in the context of exemplary embodiments, it is to be understood that modifications and variations may be utilized without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents.