Patent Publication Number: US-2005130559-A1

Title: Protected underwire

Description:
RELATED APPLICATIONS  
      This application is a continuation-in-part of U.S. application Ser. No. 10/313,992 filed Dec. 26, 2002. 
    
    
     BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates to brassieres. More particularly, the present invention relates to a protected brassiere underwire and method of making the same.  
      2. Description of the Related Art  
      The use of underwire elements, especially U-shaped underwires, for shaping and supporting the lower periphery of brassiere or bra cups has long been known in the art. The term “underwire” has been in common use to refer to such elements. An underwire includes metal wires, coated metal wires, as well as wire elements made of many different materials, such as plastic or other polymeric materials. These underwires must be rigid enough, particularly in the plane of the brassiere, to provide adequate support for the bust and yet flexible enough to conform easily to the wearer&#39;s body for comfort and appearance. Such underwires are provided in a variety of shapes and configurations and must satisfy a number of requirements. For example, the underwire must not poke through the fabric to cause damage to the clothing of the wearer, and possibly injury to the wearer. It also must be readily insertable. Commonly, such underwires have been inserted into fabric sleeves disposed about the lower periphery of the bra cups.  
      Modern underwires are generally formed of relatively thin lengths of metal or polymeric material having a rectangular or rounded cross-section. A fairly stiff length of such material is shaped into a generalized U-shape and positioned in a sleeve disposed about the lower periphery of each bra cup. These stiff metal underwires are sometimes coated with various polymeric materials and often have plastic or enamel tips disposed at each end of the underwire.  
      While underwires have achieved widespread usage, certain disadvantages result from their use. These disadvantages relate to the relative stiffness, and therefore discomfort of these conventional underwires, and to the uniformity of that stiffness and, thus, the lack of adaptability to the needs of various users.  
      In light of the foregoing, there is an ongoing need for underwires or underwire structures, that are comfortable to wear, resilient, and adequately support the breasts of the wearer.  
     SUMMARY OF THE INVENTION  
      It is an object of the present invention to provide a cushion feel underwire or underwire structure.  
      It is an another object of the present invention to provide such an underwire structure that has a greater cushioning ability or greater “loft” than the underwire structures of the prior art.  
      It is still another object of the present invention to provide such an underwire structure that avoids having a thick appearance and/or a stiff feel.  
      It is yet another object of the present invention to provide such an underwire structure that can be used in a number of different sized brassieres.  
      It is a further object of the present invention to provide such an underwire structure that is particularly comfortable to wear, and can be conveniently assembled in the brassiere.  
      It is still a further object of the present invention to provide such an underwire structure that has its own casing.  
      These and other objects and advantages of the present invention are achieved by the underwire structure of the present invention. In a first embodiment, there are provided two or more outer fabric layers. The outer fabric layers each have gelatinous strips associated therewith. The gelatinous strips separate the outer fabric layers into sections. An inner fabric layer is positioned upon the gelatinous strips of the first outer fabric layer. This inner fabric layer is preferably non-woven. An underwire is positioned on the inner fabric layer opposite the outer fabric layer. The outer fabric layers are then folded to enclose the gelatinous strips, the inner fabric layer and the underwire. Thus, the underwire is enclosed in a casing formed by the outer fabric layers. Once the outer fabric layers are folded, a fold line is created.  
      In a second embodiment, there is provided four fabric layers and an underwire. As in the first embodiment, the first and second outer fabric layers each have at least one surface with gelatinous strips, thereby separating the surface and/or outer fabric layer into sections. The second outer fabric layer forms an outside covering for the underwire. As in the first embodiment, an inner fabric layer is positioned on the underwire to form an inside covering for the underwire. The inner fabric layer is preferably non-woven. An intermediate fabric layer is positioned between the first outer and inner fabric layers to form a second interior covering for the underwire. The underwire is positioned on the inner fabric layer opposite the intermediate fabric layer. The second and first outer fabric layers are folded to enclose the inner and intermediate fabric layers and the underwire. Thus, the underwire is encased by all four fabric layers. In this second embodiment, a fold line is knitted into the second outer fabric layer and first outer fabric layer prior to folding.  
      In a third embodiment, there is also provided an underwire. The underwire is surrounded by a non-woven fabric layer. A bladder containing a gelatinous material is encased by a rigid-type fabric. The bladder is positioned on the non-woven fabric layer opposite the underwire. The purpose of the non-woven fabric is to reduce the risk of the underwire poking through the rigid fabric encasing the bladder. The bladder is preformed or pre-made into a preshaped configuration. The fabric encasing the bladder is preferably a rigid fabric. More preferably, the fabric encasing the bladder is a tricot or warp knit fabric. The non-woven fabric is wrapped around the underwire, and the bladder is positioned against the body fabric that forms the breast cup of the brassiere.  
      In all embodiments, the non-woven fabric layer may also be made of a stretchable material. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The objects and advantages of the present invention will be more apparent from the following detailed description of the present invention, in conjunction with the accompanying drawings wherein:  
       FIG. 1  is a schematic drawing showing a first embodiment of the present invention;  
       FIG. 2  is a magnified view of the stretch fabric used for any of the outer layers in the first embodiment of the present invention;  
       FIG. 3  is a schematic drawing showing an alternative to the first embodiment of the present invention;  
       FIG. 4  is a schematic drawing showing a second alternative to the first embodiment of the present invention;  
       FIG. 5  is a schematic drawing showing a second embodiment of the present invention;  
       FIG. 6  is a schematic drawing showing an alternative to the second embodiment of the present invention; and  
       FIG. 7  is a schematic drawing showing a third embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring to the drawings, and in particular,  FIG. 1 , there is provided a first embodiment of an underwire structure of the present invention generally represented by reference numeral  10 . Underwire structure  10  has a first outer layer of material  20  upon which a first gelatinous material  50  is applied. Underwire structure  10  also has a second outer layer of material  70  upon which a second gelatinous material  75  is applied. It should be noted that, while first and second outer material layers are preferred, multiple layers may be employed to provide enhanced cushioning effect. Gelatinous materials  50  and  75  are preferably applied in one or more strips to first outer material layer  20  and second outer material layer  70 . However, it should be noted that gelatinous materials  50  and  75  may be applied in any manner known in the art. Non-limiting examples include sinusodial, dashed or dotted patterns. An inner layer of material  30  is positioned adjacent to gelatinous material  50  on first outer material layer  20 , and an underwire  40  is positioned on or adjacent to inner material layer  30  opposite first outer material layer  20 .  
      As shown in  FIG. 2 , outer material layers  20  and  70  (outer layer  20  represented) preferably have two strips of gelatinous material  50  placed thereon. Accordingly, the outer material layers preferably have three regions that are not covered by gelatinous material  50 . These three regions are two sew regions or edges  24 , and a fold line or third sew region  28 . Fold line  28  is located along the center of outer material layer  20 .  
      Referring again to  FIG. 1 , second outer material layer  70  with gelatinous material  75  is adjacent to first outer material layer  20  with gelatinous material  50 . First outer material layer  20  with gelatinous material  50  is also adjacent to inner material layer  30  with one side of inner material layer  30  contacting gelatinous material  50 . Second outer material layer  70 , gelatinous material  75 , first outer material layer  20 , gelatinous material  50  and inner material layer  30  are wrapped around underwire  40 . A body fabric  60  is positioned on a side of underwire  40  opposite inner material layer  30 . Second outer material layer  70  with gelatinous material  75  and first outer material layer  20  with gelatinous material  50  provide a cushioned feel and loft about underwire  40  thereby making the underwire structure more comfortable for the wearer. Inner material layer  30  prevents underwire  40  from-poking through outer material layer  20 .  
      During assembly, second outer material layer  70  and first outer material layer  20  are positioned adjacent to one another. Inner material layer  30  is positioned adjacent to gelatinous material  50  of outer material layer  20 . Underwire  40  is positioned on or adjacent to inner material layer  30  opposite outer material layer  20 . Body fabric  60  is positioned on one side of underwire  40  opposite inner material layer  30 . Preferably, a portion of body fabric  60  is positioned on one side of underwire  40  such that body fabric  60  is in the same plane as underwire  40 . Second outer material layer  70  and first outer material layer  20  are then folded about fold line  28  to enclose gelatinous material  75 , gelatinous material  50 , and inner material layer  30  about the end of body fabric  60  and underwire  40 . When outer material layer  20  and inner material layer  30  are folded along fold line  28 , a channel is created for underwire  40 . Thus, in this embodiment, a casing for underwire  40  is formed by second outer material layer  70 , gelatinous material  75 , first outer material layer  20 , gelatinous material  50  and inner material layer  30 . In the first embodiment shown in  FIG. 1 , the underwire casing is sealed using single needle stitching.  
      Body fabric  60  may be positioned in alternative locations in relation to underwire structure  10 . Referring to  FIG. 3 , body fabric  60  may be positioned such that it is not in the same plane as underwire  40 . Instead, when second outer material layer  70  and first outer material layer  20  are folded, body fabric  60  is sandwiched directly between the ends of second outer fabric layer  70  and does not come into contact with underwire  40 .  
      Referring to  FIG. 4 , body fabric  60  may be connected to second outer material layer  70  at an upper edge of underwire structure  10 . This type of underwire casing is sealed using double needle stitching.  
      In a second embodiment of the present invention, shown in  FIG. 5 , underwire structure  10  has at least four layers of material, second outer material layer  70 , first outer material layer  20 , an inner material layer  30  and an intermediate material layer  25  positioned between first outer material layer  20  and inner material layer  30 , and an underwire  40  positioned on inner material layer  30  opposite intermediate material layer  25 . Gelatinous material  50  is placed on an interior surface of first outer material layer  20 . Gelatinous material  75  is placed on an interior surface of second outer material layer  20 . Second outer material layer  70  forms an outside covering around gelatinous material  75 , first outer material layer  20 , gelatinous material  50 , intermediate layer  25 , inner material layer  30  and underwire  40 .  
      Inner material layer  30  is positioned on underwire  40  to form an inside covering for the underwire. The function of inner material layer  30  is to prevent underwire  40  from poking through the other layers of material.  
      Intermediate material layer  25  is positioned between outer material layer  20  and inner material layer  30  to form a second interior covering for underwire  40 . Body fabric  60  is preferably positioned on one side of underwire  40  opposite inner material layer  30 . The positioning of body fabric  60  in  FIG. 5  is analogous to the positioning shown in  FIG. 1  in that a portion of the body fabric is in the same plane as underwire  40 .  
      Second outer material layer  70  and first outer material layer  20  are folded about fold line  28  to enclose inner material layer  30  and intermediate material layer  25  about the end of body fabric  60  and underwire  40  creating a multi-layer underwire channel for housing the underwire. Thus, in this embodiment, a casing for underwire  40  is formed by second outer material layer  70 , gelatinous material  75 , first outer material layer  20 , gelatinous material  50 , intermediate material layer  25  and inner material layer  30 . In this embodiment, stitching, preferably, single needle stitching, is used to seal the casing.  
      As discussed with reference to  FIGS. 3 and 4 , body fabric  60  may be positioned in alternative locations in relation to underwire structure  10 . As shown in  FIG. 6 , body fabric  60  is positioned such that it is not in the same plane as underwire  40 . Instead, when second outer material layer  70  and first outer material layer  20  are folded, body fabric  60  is sandwiched directly between the ends of intermediate fabric layer  25 . In another alternative, body fabric  60  is connected to second outer material layer  70  at an upper edge of underwire structure  10 . As in  FIG. 4 , this type of casing is sealed utilizing stitching, preferably double needle stitching.  
      Second outer material layer  70  and first outer material layer  20  are preferably made of a stretchable material. More preferably, second outer material layer  70  and first outer material layer  20  are made of a three bar powernet knit. Second outer material layer  70  and first outer material layer  20  may be made of varying combinations of nylon and spandex. The percentage of nylon ranges from about 78% to about 84% based on fabric content, while the percentage of spandex ranges from about 16% to about 22% based on fabric content. Preferably, second outer material layer  70  and first outer material layer  20  are made of about 81% nylon and about 19% spandex. Second outer material layer  70  and first outer material layer  20  are lightweight, ranging from about 5 ounces per yard squared (oz/yd 2 ) to about 5.8 oz/yd 2 . The tensile length of second outer material layer  70  and first outer material layer  20  is minimally about 25 pounds (lbs.), while the tensile width of second outer material layer  70  and first outer material layer  20  is minimally about 33 lbs.  
      Gelatinous material  75  and  50  is preferably silicone. However, any liquid material can be used that is safe for contact with a wearer and has a soft feel. Gelatinous material  75  and  50  is applied on second outer layer  70  and first outer material layer  20  in strips or tracks. Preferably, gelatinous material  75  is about 56% of the overall weight of the combination of outer material layer  70  and gelatinous material  75 . Preferably, gelatinous material  50  is about 56% of the overall weight of the combination of outer material layer  20  and gelatinous material  50 . The height or thickness of the strips of gelatinous material  75  and  50  ranges from about 0.02 inches to about 0.03 inches. The width of these strips ranges from about {fraction (3/16)} inches to about ¼ inches. The width between the strips ranges from about {fraction (1/16)} inches to about ⅛ inches. The width of sew region  24  ranges from about ⅛ inches to about {fraction (3/16)} inches.  
      Inner material layer  30  is preferably made of a non-woven, non-stretchable fabric material. However, inner material layer  30  may be made of a stretchable material. Inner material layer  30  is preferably made of polyester. More preferably, inner material layer  30  is made of 100% polyester. Inner material layer  30  is lightweight, preferably about 5 oz./yd 2 ±10%. The burst strength of inner material layer  30  is minimally about 110 lb. per square inch. The tensile strength of inner material layer  30  is minimally about 55 lbs. The preferred thickness of inner material layer  30  falls in the range of about 0.53 mm to about 0.84 mm. Inner material layer  30  is sold commercially under the name TIETEX® by Tietex International Ltd.  
      Intermediate material layer  25  is a preferably a woven, non-stretchable material. However, intermediate material layer  25  may be made of a stretchable material. More preferably, intermediate material layer  25  is a nylon taffeta. Intermediate material layer  25  is also lightweight, ranging from about 1.8 oz/yd 2  to about 2.2 oz/yd 2 . The tensile length of intermediate material layer  25  is minimally about 70 lbs., while the tensile width of intermediate material layer is minimally about 60 lbs.  
      It should be understood that these dimensions may vary depending upon the desired criteria for each group of potential customers.  
      In either embodiment, an important aspect of the present invention is that the casing of the underwire preferably be stretchable. However, it may be non-stretchable.  
      Referring to  FIG. 7 , there is provided a third embodiment of the underwire structure of the present invention generally represented by reference numeral  100 . Underwire structure  100  includes a two ply structure that has a bladder  110  having a gelatinous material placed in or on a layer of a first fabric  140 . The gelatinous material is preferably silicone, but may be any type of liquid material that is safe for contact with a wearer and has a soft feel. This structure is placed on a layer of a second fabric  120 , and an underwire  130 . In this embodiment, only second fabric layer  120  is wrapped around underwire  130 . First fabric layer  140  with bladder  110  is positioned on the second fabric layer  120 /underwire  130  structure with bladder  110  positioned against a body fabric  160  and opposite a garment or outer brassiere layer  170 . In this embodiment, double needle stitching is preferably used to seal the casing. First fabric layer  140  is a rigid fabric, such as a tricot or warp knit fabric, which does not stretch.  
      Significantly, the bladder configuration can fit a number of different underwire sizes. Preferably, one bladder will fit at least three sizes of underwires.  
      In all embodiments of the present invention, each end of the underwire optionally may have a protective tip positioned thereon. In addition, the wire casing or channel must have enough room at its ends to avoid poke-through of the underwire.  
      The present invention provides underwire structures that have the underwire encased by a gelatinous material. These structures provide a cushiony feel, yet are not thick or bulky. Moreover, the cushiony feel is so pronounced that there is a loft created so that the wearer has a softness and pliability, yet the desired support under the breast area.  
      The present invention having been described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made without departing from the spirit and scope of the invention as defined herein.