Patent Publication Number: US-8113909-B2

Title: Cushioning structure for an underwire of a brassiere or the like

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to brassieres or the like. More particularly, the present invention relates to a cushioned underwire for use in a brassiere or similar undergarments including swimwear. A method for making a cushioning structure for an underwire is also provided. 
     BACKGROUND OF THE INVENTION 
     A conventional brassiere comprises of a pair of breast cups intended to cover and support the breasts of the wearer, a connector securing together the inner edges of the cups at the wearer&#39;s cleavage, and at least one strap-like back or wing that extends from outer edges of the breast cups around the back of the wearer. The brassiere may further include shoulder straps that extend from upper edges of the breast cups over the shoulders of the wearer to attachment points on the strap-like back or wing crossing the wearer&#39;s back. 
     It is common for a brassiere or similar undergarments to use an underwire to shape and support the lower periphery of each breast cup. An underwire typically consists of a U-shaped frame formed from metal or a rigid plastic material. Usually a pair of underwires is incorporated into a brassiere or other undergarment to provide shape and support for a pair of breast cups. However, in some forms the underwire may comprise a single underwire frame which traverses both breast cups. 
     Underwires are typically inserted into fabric sleeves positioned about the lower periphery of each breast cup. It is important that the underwires exhibit sufficient stiffness to provide the desired support and shaping functions, but do not poke through the fabric sleeve causing discomfort and possibly damaging the wearer&#39;s skin or clothing. 
     It would be desirable to provide an improved cushioning structure for an underwire which provides enhanced comfort to a wearer. 
     Other objects and advantages of the invention will become apparent to those of ordinary skill in the art having reference to the following specification together with its drawings. 
     SUMMARY OF THE INVENTION 
     According to an aspect of the present invention, there is provided a cushioning structure for an underwire of a brassiere or the like comprising: 
     an inner sleeve for receiving the underwire, the inner sleeve having two major surfaces and opposed elongate edges; 
     a cushioning material covering at least one of the major surfaces; and 
     a panel of outer fabric having first and second opposed elongate edges; 
     wherein the first and second elongate edges of the panel of outer fabric each folds over an opposed elongate edge of the inner sleeve to substantially cover the cushioning material. 
     In a preferred form, the second elongate edge of the panel of outer fabric overlaps the first elongate edge of the panel of outer fabric. 
     More preferably, a casing formed by the panel of outer fabric is sealed by bonding an inwardly facing region proximal to the second elongate edge of the panel of outer fabric to an outwardly facing region proximal to the first elongate edge of the panel of outer fabric. 
     The casing may be bonded to the inner sleeve such that an inwardly facing region proximal to the first elongate edge of the panel of outer fabric is bonded to a major surface of the inner sleeve. 
     In a particular embodiment, the cushioning material is bonded to at least one of the major surfaces of the inner sleeve. The bonding is preferably by lamination, or by means selected from one or more of an adhesive or one or more stitches. 
     The cushioning material may be elected from one or more of foam, fibre fill, silicon gel, or a bladder filled with air or fluid. 
     According to another aspect of the present invention, there is provided an improved brassiere comprising: 
     a pair of breast cups; 
     a connector securing together an inner edge of each of the breast cups; 
     a back wing or pair of back wings for securing the brassiere to the torso of a wearer; 
     an underwire disposed about a lower periphery of each breast cup; 
     a cushioning structure for the underwire comprising:
         an inner sleeve for receiving the underwire, the inner sleeve having two major surfaces and opposed elongate edges;   a cushioning material covering at least one of the major surfaces; and   a panel of outer fabric having first and second opposed elongate edges;       

     wherein the first and second elongate edges of the panel of outer fabric each folds over an opposed elongate edge of the inner sleeve to substantially cover the cushioning material. 
     In a preferred form, the second elongate edge of the panel of outer fabric overlaps the first elongate edge of the panel of outer fabric. 
     More preferably, a casing formed by the panel of outer fabric is sealed by bonding an inwardly facing region proximal to the second elongate edge of the panel of outer fabric to an outwardly facing region proximal to the first elongate edge of the panel of outer fabric. 
     In one embodiment, an inwardly facing region proximal to the first elongate edge of the panel of outer fabric is bonded to a major surface of the inner sleeve. 
     In one particular form, the cushioning material is bonded to at least one of the major surfaces of the inner sleeve. The bonding is preferably by lamination, or by means selected from one or more of an adhesive or one or more stitches. 
     The cushioning material may be selected from one or more of foam, fibre fill, silicon gel, or a bladder filled with air or fluid. 
     According to yet another aspect of the present invention, there is provided a method of making a cushioning structure for an underwire of a brassiere or the like, the method comprising the following steps: 
     providing an inner sleeve for receiving the underwire, the inner sleeve having two major surfaces and opposed elongate edges; 
     covering at least one major surface of the inner sleeve with a cushioning material; 
     bonding a panel of outer fabric to the inner sleeve with the cushioning material secured thereto, the panel of outer fabric having first and second opposed elongate edges which extend beyond the opposed elongate edges of the inner sleeve; 
     folding the first and second opposed elongate edges of the panel of outer fabric which extend beyond the elongate edges of the inner sleeve with the cushioning material secured thereto to substantially cover the cushioning material; and 
     trimming the cushioning structure to fit an underwire. 
     Preferably, the second elongate edge of the panel of outer fabric is folded so as to overlap the first elongate edge of the panel of outer fabric. 
     More preferably, the method further comprises the step of bonding an inwardly facing region proximal to the second elongate edge of the panel of outer fabric to an outwardly facing region proximal to the first elongate edge of the panel of outer fabric. 
     Even more preferably, the method further comprises the step of bonding an inwardly facing region proximal to the first elongate edge of the panel of outer fabric to a major surface of the inner sleeve. 
     The bonding may occur by means selected from one or more of an adhesive or one or more stitches. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       It will be convenient to hereinafter describe the invention in greater detail by reference to the accompanying figures which facilitate understanding of the method according to this invention. The particularity of the figures and the related description is not to be understood as superseding the generality of the broad identification of the invention as given in the attached claims. 
         FIG. 1  is a schematic drawing of a brassiere incorporating the cushioning structure for an underwire embodying the principles of the present invention. 
         FIG. 2A  is a perspective view showing an inner sleeve for receiving an underwire. 
         FIG. 2B  is a perspective view of the inner sleeve of  FIG. 2B  with cushioning material secured thereto. 
         FIG. 2C  is a perspective view of the inner sleeve and cushioning material structure of  FIG. 2B  covered in part by a panel of outer material. 
         FIG. 2D  is a perspective view of the inner sleeve and cushioning material structure covered in part by a panel of outer material of  FIG. 2C  finished off to form a cushioning structure for receiving an underwire. 
     
    
    
     DETAILED DESCRIPTION 
     Referring firstly to  FIG. 1 , there is shown a typical brassiere  100  comprising of a pair of breast cups  110  intended to cover and support the breasts of the wearer, a connector  120  securing together the inner edges of the cups  130  at the wearer&#39;s cleavage, and at least one strap-like back or wing  140  that extends from the outer edges  150  of the breast cups around the back of the wearer. The brassiere  100  may further include shoulder straps  160  that extend from upper edges  170  of the breast cups  110  over the shoulders of the wearer to attachment points  180  on the back wing or wings  140  crossing the wearer&#39;s back. 
     The brassiere  100  further includes a pair of substantially U-shaped under wires to shape and support the lower periphery of each breast cup  110 . An underwire (see  FIG. 2A ) typically consists of a U-shaped frame formed from metal or a rigid plastic material. In this case the brassiere includes a pair of underwires positioned about the lower periphery  190  of each breast cup  110 . 
     Referring now to  FIGS. 2A to 2D , the present invention provides an improved cushioning structure  200  for brassiere underwires  210  intended to enhance wearer comfort and to help prevent damage to the wearer&#39;s skin or clothing. 
     Referring firstly to  FIG. 2A , there is shown an underwire  210  inserted into an inner sleeve  220 . The inner sleeve  220  has two major surfaces  230 A and  230 B and two opposed elongate edges  240 A and  240 B. The inner sleeve  220  may be formed of fabric and could be, for example a conventional fabric sleeve used to encase an underwire. 
     Referring now to  FIG. 2B , a cushioning material  250  covers at least one of the major surfaces  230 A,  230 B of the inner sleeve  220 . Preferably, the cushioning material  250  is bonded to at least one of the major surfaces  230 A,  230 B, for example by laminating. 
     Referring now to  FIG. 2C , a panel of outer fabric  260  covers the cushioning material  250 . the panel of outer fabric has two opposed elongate edges running along the length of the fabric, i.e. a first elongate edge  270  and a second elongate edge  280 . 
     Referring now to  FIG. 2D , the first elongate edge  270  and second elongate edge  280  of the panel of outer fabric  260  each folds over an opposed elongate edge  240 A,  240 B of the inner sleeve  220  to substantially cover the cushioning material  250 . In the illustrated embodiment, the second elongate edge  280  of the panel of outer fabric  260  overlaps the first elongate edge  270  of the panel of outer fabric. 
     The casing formed by the panel of outer fabric  260  is preferably sealed by bonding an inwardly facing region  290  proximal to the second elongate edge  280  of the panel of outer fabric  260  to an outwardly facing region  300  proximal to the first elongate edge  270  of the panel of outer fabric. The bonding may be achieved by the application of a suitable adhesive  310 . Moreover, it is preferred that an inwardly facing region  320  proximal to the first elongate edge  270  of the panel of outer fabric  260  is bonded to a major surface  230 B of the inner sleeve  220  using an adhesive  330 . 
     The panel of outer fabric preferably consists of the same or similar fabric exhibiting at least some elasticity which is used to form a substantial portion of the brassiere. The cushioning material is selected from any suitable resilient material providing the desired cushioning properties such as foam, fibre fill, silicon gel, or a bladder filled with air or fluid. 
     The improved cushioning structure  200  described with reference to  FIGS. 2A to 2D  is readily incorporated into a brassiere  100  by trimming the cushioning structure to size and securing the cushioning structure about the lower periphery  190  of each breast cup  110 . The cushioning structure  200  may be secured to the lower periphery  190  of each breast cup  110  by any suitable means such as stitching. Generally at least one end of the cushioning structure  200  will remain open until such time that an underwire  210  has been received therein. After such time, the open end of the cushioning structure  200  is closed, i.e. by stitching to secure the underwire  210  within the cushioning structure. 
     The cushioning structure  200  of the present invention may be manufactured by firstly transferring an adhesive to the inner sleeve  220  using a release paper. The inner sleeve with the adhesive applied is then subjected to a heat moulding process together with a panel of cushioning material. This process laminates the inner sleeve  220  to the cushioning material  250  and at the same time moulds the cushioning material to the desired shape. This results in the precursor cushioning structure shown in  FIG. 2B . 
     Adhesive is also applied to the panel of outer fabric  260  using a release paper. This outer panel of fabric  260  is laminated with the inner sleeve  220  and cushioning material  250  assembly shown in  FIG. 2B , to form the assembly shown in  FIG. 2C . 
     Adhesive is then applied to the first and second opposed elongate edges  270  and  280  of the panel of outer fabric  260  using two strips of release paper. The cushioning structure  200  is fully formed by successive folding of the first and second opposed elongate edges  270  and  280  of the panel of outer fabric  260  which extend beyond the elongate edges  240 A and  240 B of the inner sleeve  220  with the cushioning material  250  secured thereto. The second elongate edge  280  of the panel of outer fabric  260  is preferably folded so as to overlap the first elongate edge  270  of the panel of outer fabric as shown in  FIG. 2D . 
     Use of the adhesive on the first and second opposed elongate edges  270  and  280  of the panel of outer fabric  260  ensures that an inwardly facing region  290  proximal to the second elongate edge  280  of the panel of outer fabric  260  is bonded to an outwardly facing region  300  proximal to the first elongate edge  270  of the panel of outer fabric  260 . The inwardly facing region  320  proximal to the first elongate edge  270  of the panel of outer fabric  260  is bonded to a major surface  230 B of the inner sleeve  220 . 
     Preferably, the adhesive referred to herein is a hot melt adhesive, however, it will be understood that various other suitable types of suitable adhesives are available which could be used to form the cushioning structure of the present invention. Moreover, alternative bonding methods including mechanical means such as sewing or stapling may be used to achieve a similar result. 
     It is an advantage of the present invention that the cushioning structure reduces the discomfort associated with wearing an underwire brassiere and ameliorates the problems of damaging clothes and/or skin or a wearer. The cushioning structure serves as a buffer between the underwire and the wearer&#39;s skin. 
     While the invention has been described in conjunction with a limited number of embodiments, it will be appreciated by those skilled in the art that many alternative, modifications and variations in light of the foregoing description are possible. Accordingly, the present invention is intended to embrace all such alternative, modifications and variations as may fall within the spirit and scope of the invention as disclosed.