Patent Abstract:
The invention is directed to a wireless support system for a brassiere. The wireless support system comprises at least one centerfront support and two sideback supports which are composed of a material such as a polyester film. The two sideback supports may be attached to the centerfront support via a stabilizing ribbon or stitches. The brassiere of the present invention has the advantage of providing comfortable support that is form fitting.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This invention claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/507,126 filed Oct. 1, 2003, which is herein incorporated by reference in its entirety. 

   FIELD OF THE INVENTION 
   This invention is directed to brassieres. More particularly, this invention is directed to a wireless support system for a brassiere or other breast supporting garments. 
   BACKGROUND OF THE INVENTION 
   Brassieres provide support and enhance the shape of breasts. Brassieres often have a device in the cups of the brassiere to provide support. Devices intended to provide support and shaping for the cups of a bra and similar articles have long been known. These devices are commonly known as underwires and are inserted into and held within a fabric sleeve disposed about the periphery of the lower section of the bra cup. They are made from materials, such as bone, metal or plastic, and are provided in various forms, shapes and cross-sections. Most commonly, the underwire is formed of relatively thin metallic pieces of rectangular cross-section, shaped into an essentially semi-circular or U-shaped form that allows the underwire to be fitted within a sleeve disposed about the periphery of the lower half of the bra cup. 
   While such underwire structures have achieved widespread usage, a number of significant disadvantages result from their use. In particular, the underwires can damage the fabric sleeve into which the underwire is inserted or irritate the skin of a user leading to discomfort and sometimes bruising. Deformation or distortion of the underwires arises from washing and drying of bras containing underwires. Multiple washings lead to degradation of the fabric of the garment due to shrinkage of the fabric and/or the relative movement occurring between the stiff, rigid metal underwire and the fabric of the bra brought about in machine washing and drying. Using underwires coated with a polymeric material or metal underwires that have plastic tips at their ends does not alleviate these problems completely. 
   SUMMARY OF THE INVENTION 
   It is a primary object of the present invention to provide a wireless support structure for breast-supporting articles, such as bras (with or without straps), swimwear, sportswear, contour or bra pads, daywear, camisoles and the like, that provides the necessary rigidity to accomplish its supporting function. 
   It is another object of the present invention to provide a wireless support structure for breast supporting articles that is form fitting, to avoid unsightly gaps in the supporting articles underneath the breast. 
   It is a preferred object of the present invention to provide a brassiere comprising (i) an outer layer having two front bra cups and two back bands extending from the lateral sides of the two front bra cups; (ii) two sideback supports adhered to the outer sides of the front bra cups and inside the outer layer; (iii) at least one centerfront support adhered to the inner sides of the front bra cups and inside the outer layer, as shown in the drawings; and (iv) an inner layer having two front bra cups with side backs extending from the lateral sides of the two front bra cups, wherein the two side backs end approximately at the outermost edge of the two sideback supports, and further wherein the inner layer is adhered to the two sideback supports and at least one centerfront support. The sideback supports and the centerfront support(s) are preferably made of Mylar®. 
   It is a second preferred object of the present invention to provide a brassiere comprising (i) an outer layer having two front bra cups and a single back band extending from the lateral side of the first bra cup to the lateral side of the second bra cup; (ii) two sideback supports adhered to the outer sides of the front bra cups and inside the outer layer; (iii) two centerfront supports adhered to the inner sides of the front bra cups and inside the outer layer, as shown in the drawings; and (iv) two inner layers each having one front bra cup with a side back extending from the lateral sides of each of the two front bra cups, wherein the two side backs end approximately at the outermost edge of the two sideback supports, and further wherein the inner layer is adhered to the two sideback supports and two centerfront supports. The sideback supports and the centerfront support(s) are preferably made of Mylar®. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1   a  is a perspective view of a brassiere showing the front of a frame of a wireless support system according to one embodiment of the present invention. 
       FIG. 1   b  is a perspective view of a brassiere showing the back of a frame of a wireless support system according to one embodiment of the present invention. 
       FIGS. 2   a - 2   f  are perspective views of embodiments of sideback supports for the wireless support system of the present invention. 
       FIGS. 3   a - 3   e  are perspective views of embodiments of centerfront supports for the wireless support system of the present invention. 
       FIG. 4  is a perspective view of a brassiere showing a frame of a wireless support system according to a second embodiment of the present invention, in which the brassiere is strapless. 
       FIG. 5   a  is a perspective view of a brassiere showing a frame of a wireless support system according to a third embodiment of the present invention, in which the brassiere connects at the front of the body. 
       FIG. 5   b  is a perspective view of a brassiere showing the back of a frame of a wireless support system according to a third embodiment of the present invention, in which the brassiere connects at the front of the body. 
       FIG. 6  is a perspective view of a brassiere showing a frame of a wireless support system according to a fourth embodiment of the present invention, a banded set in bra cup brassiere, in which the bra cups are produced separately from the rest of the brassiere frame, and subsequently attached to the appropriate place on the frame. 
       FIG. 7   a  is a perspective view of a brassiere showing a wireless support system according to a fifth embodiment of the present invention, a bandless, or un-banded, set in bra cup brassiere, in which the bra cups, front band and back bands are each produced separately and subsequently attached to one another, with the front band located between the two bra cups and the back bands attached to the lateral sides of said bra cups. 
       FIG. 7   b  is a perspective view of the back of the front band of the brassiere according to the fifth embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring to  FIG. 1   a , a perspective view of a bra  10  made according to the present invention is shown. It will be understood that the present invention can be incorporated into any style bra, swimsuit or other undergarment known to those of ordinary skill in the art. The bra  10  features an outer layer,  12 , having two front bra cups,  14  and  16 , and two back bands,  18  and  20 , extending from the lateral sides of the two outer layer front bra cups,  14  and  16 , and preferably having a back retaining device,  22 , attached to the ends of the back bands and including a set of locking pieces engageable with each other. Preferably, the outer layer is made of two or more pieces of material, but in an alternative embodiment the outer layer may be made of one piece of material. 
   The bra  10  also features at least one centerfront support  24  and two sideback supports  26  and  28 . The centerfront support  24  is located between the two outer layer front bra cups,  14  and  16 . The centerfront support  24  may be in the shape of an inverted V, as shown in  FIGS. 3   a - 3   d , the sides of the V following the shape of the two outer layer front bra cups,  14  and  16 . The opening between the two bottom ends of the inverted V may be of varying shapes and sizes. Alternatively, the centerfront support  24  may be comprised of two separate support pieces,  68  and  70 , as shown in  FIG. 3   e , that follow the shape of the outer layer front bra cups. The sides of the centerfront support  24 , as shown in  FIGS. 3   a - 3   d , or the two separate centerfront supports,  24 , as shown in  FIG. 3   e , may be joined together by a stabilizing ribbon. 
   The bra  10  also features two sideback supports,  26  and  28 . The sideback supports  26  and  28  follow the shapes of the outer layer front bra cups,  14  and  16 , from the bottom of the outer layer front bra cups to the outer sides. The sideback supports,  26  and  28 , may have one or multiple slits,  32 , and/or legs,  34 , on the side (see  FIGS. 2   a - 2   f ) that allow for proper fitting of the bra  10  to the body. The legs,  34 , may be joined together by stabilizing ribbons or alternatively by various stitch-type configurations known in this art (such as single needle, double needle, three step zig zag, two step zig zag, etc.). A flexibility gap  80  exists between the sideback supports,  26  and  28 , and the centerfront support(s),  24 . This flexibility gap allows for proper fitting, without bulges, to the body. The sideback supports  26  and  28  may be held to the centerfront support(s)  24  by stabilizing ribbons which span the flexibility gaps,  80  or alternatively by various stitch-type configurations known in this art (such as single needle, double needle, three step zig zag, two step zig zag, basting, etc.). 
   The centerfront supports,  24 , and the sideback supports,  26  and  28 , are preferably made of a flexible, stable, and rigid plastic or polyester material. More preferably, the centerfront support(s),  24 , and sideback supports,  26  and  28 , are made of a polyester film that is flexible, stable and rigid. The polyester film is preferably Mylar®, and is preferably pre-bonded with an adhesive, such as an adhesive film. For example, the Mylar® used in the present invention may be Mylinex® #561 (obtained from Tecra®) which is a Mylar® film pre-bonded with Bemis #3402, an adhesive film, and pretreated on both sides for improved adhesion of inks and coatings, and specially formulated for improved die cutting. Bemis #3402 is a soft, highly elastic, polyurethane adhesive film designed for intimate apparel applications, to provide excellent bond strength while maintaining the softness, stretch, recovery, and molding properties that are critical in intimate apparel. 
   Mylinex® #561 is a tough, general purpose film that is transparent and pretreated to have a textured surface to provide ease of handling, good adhesion, and processability. Mylinex® #561 is translucent in heavier gauges and has balanced tensile properties and excellent resistance to moisture and most chemicals. Mylinex® #561 can withstand temperature extremes from −100° F. to 300° F., and does not become brittle with age under normal conditions. Of course, other polyester films with properties similar to Mylar® or Mylinex® #561, and other adhesives or adhesive films to be applied to Mylar®, may be used in the present invention. For example, adhesive webs, powders, or dots may be applied to the polyester film. 
   The bra  10  also features an inner layer,  38 , having two front bra cups,  40  and  42 , and two back bands,  44  and  46 , extending from two lateral sides thereof, respectively, wherein the two back bands,  44  and  46 , end approximately at the outermost edge of the two sideback supports,  26  and  28  (see  FIG. 1   b ). In an alternative embodiment, the inner layer,  38 , extends beyond the two sideback supports,  26  and  28 , to the end of the back bands,  18  and  20  of the outer layer. The inner layer may be composed of one or more pieces of material. The front bra cups of the inner layer,  40  and  42 , are formed such that they fit together with the front bra cups of the outer layer,  14  and  16 , and together they form the front bra cups of the bra,  48  and  50 . 
   The outer layer is typically made of a decorative/non-decorative material such as lace, jacquard or satin. The inner layer is preferably made of a soft material that absorbs and wicks moisture away, such as cotton or polypropylene cloth. The stabilizing ribbons are preferably made of a cotton or polypropylene cloth. The type of fabric used for the bra of the present invention will of course depend on the proposed use of the bra (everyday use, sports bra, swimsuit, etc.). 
   The optional shoulder straps,  52  and  54 , are each located with a first end,  56  and  58 , attached to the top edge of the bra cups,  48  and  50 , and a second end,  60  and  62 , attached to the back bands,  18  and  20 , and have a conventional plastic buckle attached thereto that allows for the straps to be adjusted for length. Alternative embodiments of the shoulder straps include a “racerback” design, in with the shoulder straps join together in the back of the bra and connect as one to the back bands (in the case of a bra without locking pieces) or divide again into two, each connecting to either side of the back retaining device,  22 .  FIG. 4  depicts an embodiment of the present invention that does not have the optional shoulder straps. 
   In an alternative embodiment of the present invention, the bra has a front retaining device,  64  including a set of locking pieces engageable with each other (see  FIG. 5   a ) instead of a back retaining device. In this embodiment, the outer layer,  12 , has two separated front bra cups,  14  and  16 , and a single back band,  66 , connecting said two separated front bra cups,  14  and  16 . Similar to the previous embodiment, this embodiment of the present invention includes two sideback supports,  26  and  28 . The bra of this embodiment has two centerfront supports,  68  and  70 , one each located between the front bra cups,  14  and  16 , and the front retaining device. 
   In this alternative embodiment, the inner layer may be comprised of two separate pieces of material,  72  and  74  (see  FIG. 5   b ). Alternatively, the inner layer may be comprised of a single piece of material that follows the same pattern as the outer layer,  12  (embodiment not depicted). 
   In any of the embodiments of the present invention, the bra cups,  48  and  50 , may further comprise bra pads, which will enhance the shape of the bust. These bra pads may be made of material known to one of skill in the art, including commonly known foam (polyester or polyether), spacer, fiberfill or gel, and may or may not be removable from the bra. 
   Furthermore, as depicted in  FIG. 6 , in any of the embodiments of the present invention (i.e., whether strapless, front clasp, or rear clasp), the bra cups may be set in bra cups,  82  and  84 , set within a frame,  86 . In the art, such a brassiere is referred to as a banded set in bra cup brassiere. The set in bra cups,  82  and  84 , are made separately from the frame,  86 , of the brassiere, and then attached to the frame,  86 , prior to completion. In such an embodiment, the outer and inner layers,  88  and  90 , of the frame of the brassiere have two U-shaped cut-outs in the front of the frame, into which the completed set in bra cups,  82  and  84 , are set and attached. Prior to or after attaching the set in bra cups,  82  and  84 , to the front of the frame,  86 , the shoulder straps (if present) are attached to the set in bra cups,  82  and  84 . The set in bra cups,  82  and  84 , may have a bra pad, as disclosed above, and may further be comprised of an outer and/or inner layer of material. 
   In addition, as depicted in  FIG. 7   a , in any of the embodiments of the present invention (i.e., whether strapless, front clasp, or rear clasp), the bra cups may be set in bra cups,  92  and  94 , and the brassiere frame may be composed of a center band,  96 , which is affixed between the bra cups,  92  and  94 , and two back bands,  98  and  100 , may be affixed to the lateral sides of the set in bra cups,  92  and  94 . In the art, such a brassiere is referred to as a bandless set in bra cup brassiere. In this embodiment, the center band,  96 , has an outer and an inner layer,  102  and  104 , and the centerfront support,  24 , is placed between the outer and inner layers,  102  and  104 , of the center band,  96 , prior to attaching the center band,  96 , to the set in bra cups,  92  and  94 . Similarly, the back bands,  98  and  100 , have outer and inner layers,  106  and  108 , and the sideback supports,  26  and  28 , are placed between the outer and inner layers,  106  and  108 , of the back bands,  98  and  100 , prior to attaching the back bands,  98  and  100 , to the set in bra cups,  92  and  94 . The set in bra cups,  92  and  94 , may have a bra pad, as disclosed above, and may further be comprised of an outer and/or inner layer of material. 
   Moreover, in any of the embodiments of the present invention, the bra may be a maternity and/or nursing bra, in which front bra cups,  14  and  15 , can be partially detached by the wearer to expose the breast for breastfeeding. 
   The bra,  10 , of the present invention is made generally by cutting the inner layer,  38  (using a GERBERCUTTER® or die cutter), to the appropriate size, removing release paper (not shown) and placing the sideback supports,  26  and  28 , and the centerfront support(s),  24  or  72  and  74 , on the appropriate location on the inside part of the outer layer (also cut using a GERBERCUTTER® or die cutter), with the film (texturized) side up. The sideback supports,  26  and  28 , the centerfront support(s),  24  or  72  and  74 , and the inner layer,  38 , are preferably pre-bonded with an adhesive. The sideback supports and the centerfront support(s) may be adhered to the inner layer with a glue stick and/or a heat regulated tool type-gun so as to spot seal them, reinforcing the proper placement prior to the final press bond sealing. The outer layer,  12 , cut to the appropriate size, is then placed on top of the inner layer/centerfront support/sideback support assembly, and aligned properly. This assembly is then heat pressed, permanently bonding all layers. As an exemplary embodiment, the heat press has a temperature of about 350-400.degree. F., and is left on the assembly for approximately 25-45 seconds (dwell time). One of skill in the art could easily adjust the temperature of the press and the dwell time in accordance with the types of fabric, adhesive, and polyester film used to make the bra of the present invention. After the bra assembly is cooled, it is cut into the desired shape using an automated cutter. As an alternative, the bra assembly may be die cut into the desired shape. In the embodiment in which set in bra cups  82  and  84 , or  92  and  94 , are used (whether in a banded or bandless set in bra cup brassiere), the brassiere frame or the center band and back bands (including the inner and outer layer, sideback supports, and centerfront supports) is/are constructed, similar to as described above, and the set in bra cups  82  and  84 , or  92  and  94 , are made separately and then attached to the brassiere frame (as described above) or to the center band and back bands (as described above). 
   While it is apparent that the illustrative embodiments of the invention herein disclosed fulfill the objectives stated above, it will be appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. For example, the present invention could be made of a variety of materials. Furthermore, the centerfront and sideback supports could be shaped differently to provide different support for different bust sizes. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments which come within the spirit and scope of the present invention.

Technology Classification (CPC): 0