Patent Description:
Traditional pad inserts that are removably inserted within a pocket space of a breast covering portion of a bra are generally triangular shaped, circular shaped, or elliptical shaped and tend to shift and rotate within the pocket space during wear and wash. A pad insert with the features of the preamble of claim <NUM> is known from <CIT>.

The subject matter of the present invention is defined by the claims. The description itself is not intended to limit the scope of the invention as defined by the claims. Moreover, although the terms "step" and/or "block" might be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among of between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

Traditional pad inserts that are removably inserted within a pocket space of a breast covering portion of a support garment such as a bra are generally triangular shaped, circular shaped, or elliptical shaped and tend to shift and rotate within the pocket space during wear and wash. Moreover, the perimeter shape of traditional pad inserts typically differs from a perimeter shape of the pocket space of the breast covering portion which contributes to the shifting and/or rotating of the insert within the pocket space as the pad insert fails to sit securely within the pocket space.

The invention is directed to a pad insert configured to be removably positioned within a pocket space formed in one or more breast covering portions of a support garment such as a bra. The pad insert has a perimeter shape according to claim <NUM> that includes three or more concave edges and one or more linear edges. The pocket space of the breast covering portion(s) of the bra has a perimeter shape that is substantially the same as the perimeter shape of the pad insert. Thus, when the pad insert is positioned within the pocket space, the concave edges of the pad insert align with concave edges of the pocket space, and the linear edges of the pad insert align with linear edges of the pocket space. The result of the configuration described is that the pad insert is "locked" into place within the pocket space which prevents the pad insert from shifting and/or rotating during wash and wear.

The term "bra" as used herein is meant to be construed broadly to cover any type of support garment configured to cover, provide support, and/or provide modesty to a wearer's breasts. Thus, the term bra may include a traditional bra, a sport bra, a bandeau, a camisole, a swimsuit, and the like. The term "breast covering portion" when used in relation to a bra means the portion of the bra that substantially or entirely covers respective right and left breasts of a wearer.

The term "perimeter shape" is an outermost boundary of an article such as the pad insert or the pocket space of the breast covering portion. The perimeter shape of the pad insert and the pocket space is defined by one or more edges. The term "edge" when used to describe the pad insert means a free, terminal edge or a folded edge. The term "edge" when used to describe the pocket space of the breast covering portion(s) may mean an outer boundary of the pocket space, where the outer boundary may be defined by an area of affixation between layers of material used to form the breast covering portion(s). Alternatively, the outer boundary of the pocket space may be an artificial boundary demarcating the limits of the respective breast covering portion(s). The use of positional terms when describing the edges of the pad insert assumes that the pad insert is properly positioned within a pocket space of a breast covering portion(s) of a bra. The term "medial" when used to describe an edge means an edge located closer to a midline of, for example, the bra. Thus, a medial edge of the pad insert is closer to the midline of the bra when the pad insert is positioned within the pocket space. The term "lateral" when used to describe an edge means an edge located farther from the midline of the bra. Thus, a lateral edge of the pad insert is located farther from the midline of bra and closer to, for instance, an arm opening of the bra or a side of the bra. The term "upper" means closer to a neck opening of the bra, and the term "lower" means closer to a torso opening of the bra. The term "right side portion" means located on a right side of the bra when worn, and the term "left side portion" means located on a left side of the bra when worn. The term "concave" means an edge that curves inwardly toward the center of, for example, a pad insert or a pocket space of a breast covering portion. The term "linear" means extending along a straight or nearly straight line. The term "innermost" when describing a layer of material forming the breast covering portion means the layer that is positioned closest to a body surface of a wearer with respect to other layers forming the breast covering portion. The term "outermost" when describing a layer of material forming the breast covering portion means the layer that is furthest away from the wearer's body surface compared to other layers of the breast covering portion. The term "directly extends" when describing the relationship between a first edge and a second edge means that there are no intervening edges between the first edge and the second edge.

Unless otherwise noted, all measurements provided herein are measured when the pad insert and/or bra is at standard ambient temperature and pressure (<NUM> degrees Celsius or <NUM> and <NUM> bar) and is in a resting (e.g., un-stretched) state.

<FIG> depicts a view of a first surface <NUM> of an example pad insert <NUM>. The pad insert <NUM> is configured for a left breast covering portion of a bra such as the bra shown in <FIG>. A pad insert for the right breast covering portion of the bra shown in <FIG> would be the mirror image of the pad insert <NUM>. In example aspects, the pad insert <NUM> may be formed of a foam material such as, for example, a polyurethane foam although other foam materials are contemplated herein. The pad insert <NUM> may be formed through an injection molding process and may optionally be formed to include a plurality of apertures <NUM> that extend through the pad insert <NUM> from the first surface <NUM> to an opposite second surface (not shown). The plurality of apertures <NUM> help to improve the permeability, breathability, and flexibility of the pad insert <NUM>. They also help to make the pad insert <NUM> lightweight. Although the plurality of apertures <NUM> are shown as ovoid in shape, other shapes are contemplated herein such as circles, triangles, squares, and the like. The pad insert <NUM> may have a uniform thickness throughout ranging from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>. As used herein, the term "about" means within ± <NUM>% of an indicated value. It is also contemplated herein that the pad insert <NUM> may have a non-uniform thickness with some areas of the pad insert <NUM> being thicker than other areas.

In example aspects, a mesh fabric <NUM> is laminated to the first surface <NUM> of the pad insert <NUM>, to the second surface of the pad insert <NUM>, or to both the first surface <NUM> and the second surface of the pad insert <NUM>. The mesh fabric <NUM> may help to protect the integrity of the pad insert <NUM> during wash and wear. In further example aspects, the edges of the pad insert <NUM> may be flattened by, for instance, a pressing process, to create a smoother aesthetic when the pad insert <NUM> is positioned within a pocket space of a bra.

The pad insert <NUM> has a perimeter shape referenced generally by the numeral <NUM>. The perimeter shape <NUM> generally includes concave edge and linear edges. According to the invention, the concave edges are separated by one or more linear edges. The perimeter shape <NUM> includes at least a medial concave edge <NUM> and a lateral concave edge <NUM> positioned opposite the medial concave edge <NUM>. The pad insert <NUM> includes additional edges such as a lower linear edge <NUM> that directly extends horizontally from the medial concave edge <NUM>. The pad insert <NUM> may additionally include a medial linear edge <NUM> that directly extends upward from the medial concave edge <NUM>. The pad insert <NUM> also includes an upper concave edge <NUM> opposite the lower linear edge <NUM> and directly extending from the medial linear edge <NUM>. An upper lateral edge <NUM> that may be linear or concave, extends directly between the upper concave edge <NUM> and the lateral concave edge <NUM>. In addition, the pad insert <NUM> includes a lower lateral linear edge <NUM> that extends directly between the lateral concave edge <NUM> and the lower linear edge <NUM>.

The combination of the different edges described above forms a number of interior obtuse angles and interior acute angles. For example, the pad insert <NUM> may include at least obtuse angle <NUM> formed between the lateral concave edge <NUM> and the upper lateral edge <NUM>, and obtuse angle <NUM> formed between the medial concave edge <NUM> and the medial linear edge <NUM>. The pad insert <NUM> may also include at least acute angle <NUM> formed between the upper lateral edge <NUM> and the upper concave edge <NUM>. The perimeter shape <NUM> described for the pad insert <NUM> creates a unique shape similar to, for example, a jigsaw piece which allows the pad insert <NUM> to lock into place when inserted into a pocket space of a breast covering portion as described below.

<FIG> depicts a view of a first surface <NUM> of another example pad insert <NUM>. The pad insert <NUM> is configured for a left breast covering portion of a bra such as the bra shown in <FIG>. A pad insert for the right breast covering portion of the bra shown in <FIG> would be the mirror image of the pad insert <NUM>. Similar to the pad insert <NUM>, the pad insert <NUM> may comprise a perforated foam material having an optional plurality of apertures <NUM> that extend through the pad insert <NUM> from the first surface <NUM> to an opposite second surface (not shown). The plurality of apertures <NUM> help to improve the permeability, breathability, and flexibility of the pad insert <NUM>. They also help to make the pad insert <NUM> lightweight. Although the plurality of apertures <NUM> are shown as ovoid in shape, other shapes are contemplated herein such as circles, triangles, squares, and the like. The pad insert <NUM> may have a uniform thickness throughout ranging from about <NUM> to about <NUM>, or from about <NUM> to about <NUM>. It is also contemplated herein that the pad insert <NUM> may have a non-uniform thickness with some areas of the pad insert <NUM> being thicker than other areas.

The pad insert <NUM> has a perimeter shape referenced generally by the numeral <NUM>. Similar to the pad insert <NUM>, the perimeter shape <NUM> generally comprises concave edges and linear edges. According to the invention, the concave edges are separated by one or more linear edges. The perimeter shape <NUM> includes at least a medial concave edge <NUM> and a lateral concave edge <NUM> positioned opposite the medial concave edge <NUM>. The pad insert <NUM> includes additional edges such as a lower linear edge <NUM> that directly extends horizontally between the medial concave edge <NUM> and the lateral concave edge <NUM>. The pad insert <NUM> may additionally include a medial linear edge <NUM> that directly extends upward from the medial concave edge <NUM>. The pad insert <NUM> may also include a first upper concave edge <NUM> that directly extends from the medial linear edge <NUM> and a second upper concave edge <NUM>. The first upper concave edge <NUM> and the second upper concave edge <NUM> are connected by an upper linear edge <NUM>. The pad insert <NUM> further includes a lateral linear edge <NUM> that directly extends upward from the lateral concave edge <NUM>. Edge <NUM>, which may be linear or concave, joins the lateral linear edge <NUM> to the second upper concave edge <NUM> to complete the perimeter shape <NUM> of the pad insert <NUM>.

The combination of the different edges described above forms a number of interior obtuse angles and interior acute angles. For example, the pad insert <NUM> may include at least obtuse angle <NUM> formed between the lower linear edge <NUM> and the medial concave edge <NUM>, obtuse angle <NUM> formed between the first upper concave edge <NUM> and the upper linear edge <NUM>, obtuse angle <NUM> formed between the second upper concave edge <NUM> and the edge <NUM>, obtuse angle <NUM> formed between the lateral linear edge <NUM> and the lateral concave edge <NUM>, and obtuse angle <NUM> formed between the lateral concave edge <NUM> and the lower linear edge <NUM>. The pad insert <NUM> may also include at least acute angle <NUM> formed between the upper linear edge <NUM> and the second upper concave edge <NUM>. Similar to the pad insert <NUM>, the perimeter shape <NUM> described for the pad insert <NUM> creates a unique shape which allows the pad insert <NUM> to lock into place when inserted into a pocket space of a breast covering portion as described below.

<FIG> depicts a view of an outer-facing surface of a front portion <NUM> of an example support garment in the form of a bra <NUM> having the pad insert <NUM> removably positioned within a pocket space of one of the breast covering portions of the bra <NUM>. In addition to the front portion <NUM>, the bra <NUM> includes first and second shoulder straps <NUM> configured to extend over shoulders of a wearer when the bra <NUM> is in an as-worn configuration. The bra <NUM> also includes an underband <NUM> extending from a lower edge <NUM> of the front portion <NUM>, where the underband <NUM> is configured to encircle a torso area of the wearer when the bra <NUM> is in the as-worn configuration. In example aspects, the underband <NUM> may comprise a separate panel piece having a top edge that is affixed by seaming, bonding, and the like to the lower edge <NUM> of the front portion <NUM>. In another example, the underband <NUM> may comprise a seamless extension of the front portion <NUM>.

The front portion <NUM> includes a first breast covering portion <NUM> and a second breast covering portion <NUM> separated from the first breast covering portion <NUM> by a central region <NUM> of the bra <NUM> where the central region <NUM> is configured to be positioned overlying a sternum area of a wearer when the bra <NUM> is worn. The first breast covering portion <NUM> is configured to substantially cover a left breast of the wearer when the bra <NUM> is in the as-worn configuration and generally extends from a left arm opening <NUM> to the central region <NUM> and from a neckline edge <NUM> of the bra <NUM> to the lower edge <NUM> of the front portion <NUM>. Similarly, the second breast covering portion <NUM> is configured to substantially cover a right breast of the wearer when the bra <NUM> is in the as-worn configuration and generally extends from a right arm opening <NUM> to the central region <NUM> and from the neckline edge <NUM> of the bra <NUM> to the lower edge <NUM> of the front portion <NUM>.

In example aspects, the front portion <NUM> of the bra <NUM> is formed from a first layer of material <NUM> that forms an innermost layer of both the first breast covering portion <NUM> and the second breast covering portion <NUM>, and a second layer of material <NUM> that forms an outermost layer of both the first breast covering portion <NUM> and the second breast covering portion <NUM>. It is contemplated herein, that the first layer of material <NUM> may be unaffixed from the second layer of material <NUM> except for one or more perimeter edges to form a space between the first and second layers of material <NUM> and <NUM>. The space may comprise a pocket space into which the pad insert <NUM> is removably positioned.

In example aspects, both the first layer of material <NUM> and the second layer of material <NUM> may comprise a knit mesh material such as a warp knit mesh. Use of a mesh material contributes to the lightweight nature of the bra <NUM> and also makes the bra <NUM> permeable and breathable all of which contribute to wearer comfort. As well, the first layer of material <NUM> and the second layer of material <NUM> may include one or more elastic yarns to impart stretch and recovery properties to the first and second layers of material <NUM> and <NUM> making the bra <NUM> easier to don, doff, and wear. For example, the first and second layers of material <NUM> and <NUM> may comprise about <NUM>% nylon and <NUM>% elastane, about <NUM>% nylon and <NUM>% elastane, or about <NUM>% nylon and <NUM>% elastane. Use of nylon yarns with their high abrasion resistance, contributes to the durability of the bra <NUM>. The low moisture regain of nylon yarns facilitates the movement of moisture through the material by, for example, capillary action between the yarns and/or between the filaments of the individual yarns. It is contemplated herein that other yarns, such as polyester, may be used in accordance with aspects herein.

In some example aspects, one or more of the first layer of material <NUM> and the second layer of material <NUM> may comprise a layer of material that extends continuously from the left arm opening <NUM> across the central region <NUM> to the right arm opening <NUM> and from the neckline edge <NUM> to the lower edge <NUM> of the front portion <NUM>. In this example, the first layer of material <NUM> and the second layer of material <NUM> may optionally be vertically joined together using stitching, bonding, and the like at the central region <NUM> to better define a pocket space as described below. In other example aspects, one or more of the first layer of material <NUM> and the second layer of material <NUM> may comprise a first panel piece that extends from, for example, the left arm opening <NUM> to the central region <NUM> and from the neckline edge <NUM> to the lower edge <NUM> of the front portion <NUM>, and a second panel piece that extends from the right arm opening <NUM> to the central region <NUM> and from the neckline edge <NUM> to the lower edge <NUM> of the front portion <NUM>. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.

It is contemplated herein that the first layer of material <NUM> and the second layer of material <NUM> may have different perimeter shapes. For example, as shown in <FIG>, the second layer of material <NUM> includes a cutout <NUM> at the lower edge <NUM> of the front portion <NUM> and positioned generally at the central region <NUM> of the bra <NUM> where the cutout <NUM> extends upward into both the first breast covering portion <NUM> and the second breast covering portion <NUM>. In example aspects, the first layer of material <NUM> may also optionally include a cutout having edges coincident with the cutout <NUM>. Thus, a wearer's skin surface may be exposed in the area of the cutout <NUM>. The second layer of material <NUM> may also include lateral cutouts <NUM> adjacent to the left and right arm openings <NUM> and <NUM>. In this location, the first layer of material <NUM> may extend up to and partially form or define the left and right arm openings <NUM> and <NUM>. In example aspects, the lateral cutouts <NUM> may comprise pocket openings in communication with the space between the first layer of material <NUM> and the second layer of material <NUM>.

Each of the first breast covering portion <NUM> and the second breast covering portion <NUM> includes a pocket space formed between the first layer of material <NUM> and the second layer of material <NUM>. The respective pocket spaces of the first and second breast covering portions <NUM> and <NUM> have a perimeter shape that is defined by two or more edges including two or more concave edges separated by one or more linear edges. For instance, with respect to the first breast covering portion <NUM>, the pocket space is defined by a medial concave edge <NUM> formed by the cutout <NUM> and a lateral concave edge <NUM> opposite the medial concave edge <NUM> formed by the lateral cutout <NUM>. In example aspects, the lateral concave edge <NUM> forms a pocket opening to the pocket space. The perimeter shape of the pocket space includes additional edges such as the lower edge <NUM> of the front portion <NUM> where the lower edge <NUM> directly extends horizontally from the medial concave edge <NUM>, the neckline edge <NUM>, and a lateral side edge <NUM> that extends between the lateral concave edge <NUM> and the lower edge <NUM>. The one or more additional edges may also include a medial linear edge <NUM> that extends between the medial concave edge <NUM> and the neckline edge <NUM>, and a lateral upper edge <NUM> that extends from the lateral concave edge <NUM> and may form an edge of the shoulder strap <NUM>. One or more of the edges described above may be formed by affixing together the first layer of material <NUM> and the second layer of material <NUM>. It is contemplated herein that the lateral concave edge <NUM> formed by the lateral cutout <NUM> of the second layer of material <NUM> is not affixed to the inner layer of material <NUM> so as to form the opening to the pocket space.

The pad insert <NUM> is shown removably positioned within the pocket space of the first breast covering portion <NUM>. It is shown in dashed lines to indicate that it is positioned between the first layer of material <NUM> and the second layer of material <NUM>. When inserted, and as shown in <FIG>, the medial concave edge <NUM> of the pad insert <NUM> is aligned with the medial concave edge <NUM> of the pocket space, and the lateral concave edge <NUM> of the pad insert <NUM> is aligned with the lateral concave edge <NUM> of the pocket space. The lower linear edge <NUM> of the pad insert <NUM> is aligned with the lower edge <NUM> of the front portion <NUM> of the bra <NUM> and is further aligned with an upper edge of the underband <NUM>, and the upper concave edge <NUM> of the pad insert <NUM> is aligned with the neckline edge <NUM> of the front portion <NUM> of the bra <NUM>. The lower lateral linear edge <NUM> of the pad insert <NUM> is aligned with the lateral side edge <NUM> of the pocket space, the medial linear edge <NUM> of the pad insert <NUM> is aligned with the medial linear edge <NUM> of the pocket space, and the upper lateral edge <NUM> of the pad insert <NUM> is aligned with the lateral upper edge <NUM> of the pocket space.

As shown, the perimeter shape <NUM> of the pad insert <NUM> is substantially the same as the perimeter shape of the pocket space of the first breast covering portion <NUM>. As used herein, the term "substantially the same" means the perimeter shapes share the same geometric configuration but may differ slightly in dimensions. For example, edges forming the perimeter shape of the pocket space may be slighter longer than the edges that form the perimeter shape of the pad insert <NUM> so the pad insert <NUM> can be positioned within the pocket space without buckling or folding. Having the perimeter shapes of the pad insert <NUM> and the pocket space of the first breast covering portion <NUM> be substantially the same, positioning the pad insert <NUM> within the pocket space such that the perimeter shapes align or correspond, and configuring the perimeter shapes of each to include multiple edges including linear and concave edges helps to lock the pad insert <NUM> into place once positioned within the pocket space of the first breast covering portion <NUM>. Although not shown, a pad insert that is the mirror image of the pad insert <NUM> may be removably inserted into the pocket space of the second breast covering portion <NUM> and aligned similar to that described for the pad insert <NUM>.

<FIG> depicts a view of an outer-facing surface of a front portion <NUM> of an example support garment in the form of a bra <NUM> having the pad insert <NUM> removably positioned within a pocket space of one of the breast covering portions of the bra <NUM>. In addition to the front portion <NUM>, the bra <NUM> includes first and second shoulder straps <NUM> configured to extend over shoulders of a wearer when the bra <NUM> is in an as-worn configuration. The bra <NUM> also includes an underband <NUM> extending from a lower edge <NUM> of the front portion <NUM>, where the underband <NUM> is configured to encircle a torso area of the wearer when the bra <NUM> is in the as-worn configuration. In example aspects, the underband <NUM> may comprise a separate panel piece that is affixed by seaming, bonding, and the like to the lower edge <NUM> of the front portion <NUM>. In another example, the underband <NUM> may comprise a seamless extension of the front portion <NUM>.

The front portion <NUM> includes a first breast covering portion <NUM> and a second breast covering portion <NUM> separated from the first breast covering portion <NUM> by a central region <NUM> of the bra <NUM> where the central region <NUM> is configured to overlie a sternum area of a wearer when the bra <NUM> is worn. The first breast covering portion <NUM> is configured to substantially cover a left breast of the wearer when the bra <NUM> is in the as-worn configuration and generally extends from a left arm opening <NUM> to the central region <NUM> and from a neckline edge <NUM> of the bra <NUM> to the lower edge <NUM> of the front portion <NUM>. Similarly, the second breast covering portion <NUM> is configured to substantially cover a right breast of the wearer when the bra <NUM> is in the as-worn configuration and generally extends from a right arm opening <NUM> to the central region <NUM> and from the neckline edge <NUM> of the bra <NUM> to the lower edge <NUM> of the front portion <NUM>.

Similar to the bra <NUM>, the front portion <NUM> of the bra <NUM> is formed from a first layer of material <NUM> that forms an innermost layer of both the first breast covering portion <NUM> and the second breast covering portion <NUM>, and a second layer of material <NUM> that forms an outermost layer of both the first breast covering portion <NUM> and the second breast covering portion <NUM>. It is contemplated herein, that the first layer of material <NUM> may be unaffixed from the second layer of material <NUM> except for one or more perimeter edges to form a space between the first and second layers of material <NUM> and <NUM>. The space may comprise a pocket space into which the pad insert <NUM> is removably positioned. The first layer of material <NUM> and the second layer of material <NUM> may comprise the same material construction as the first layer of material <NUM> and the second layer of material <NUM> of the bra <NUM>.

In some example aspects, one or more of the first layer of material <NUM> and the second layer of material <NUM> may comprise a layer of material that extends continuously from the left arm opening <NUM> across the central region <NUM> to the right arm opening <NUM> and from the neckline edge <NUM> to the lower edge <NUM> of the front portion <NUM>. In this example, the first layer of material <NUM> and the second layer of material <NUM> may optionally be vertically joined using stitching, bonding, and the like at the central region <NUM> to better define a pocket space as described below. In other example aspects, one or more of the first layer of material <NUM> and the second layer of material <NUM> may comprise a first panel piece that extends from, for example, the left arm opening <NUM> to the central region <NUM> and from the neckline edge <NUM> to the lower edge <NUM> of the front portion <NUM>, and a second panel piece that extends from the right arm opening <NUM> to the central region <NUM> and from the neckline edge <NUM> to the lower edge <NUM> of the front portion <NUM>. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.

As shown, the second layer of material <NUM> may have a different perimeter shape compared to the first layer of material <NUM>. For example, as shown in <FIG>, the second layer of material <NUM> may include cutout <NUM> at the lower edge <NUM> of the front portion <NUM> and positioned generally at the central region <NUM> of the bra <NUM> where the cutout <NUM> extends upward into the first breast covering portion <NUM> and the second breast covering portion <NUM>. The second layer of material <NUM> may also include lower lateral cutouts <NUM> adjacent to the lower edge <NUM> of the front portion <NUM>, upper lateral cutouts <NUM> positioned adjacent to and below the first and second shoulder straps <NUM>, and upper medial cutouts <NUM> positioned adjacent to the neckline edge <NUM> and the central region <NUM>. In example aspects, the upper lateral cutouts <NUM> may comprise pocket openings in communication with the space between the first layer of material <NUM> and the second layer of material <NUM>.

Each of the first breast covering portion <NUM> and the second breast covering portion <NUM> include a pocket space formed between the first layer of material <NUM> and the second layer of material <NUM>. The respective pocket spaces of the first and second breast covering portions <NUM> and <NUM> have a perimeter shape that is defined by two or more edges and including, for example, two or more concave edges separated by one or more linear edges. For instance, with respect to the first breast covering portion <NUM>, the pocket space is defined by a medial concave edge <NUM> formed by the cutout <NUM> and a lateral concave edge <NUM> opposite the medial concave edge <NUM> formed by the lower lateral cutout <NUM>. The perimeter shape of the pocket space includes additional edges such as the lower edge <NUM> of the front portion <NUM> where the lower edge <NUM> directly extends horizontally between the medial concave edge <NUM> and the lateral concave edge <NUM>, the neckline edge <NUM>, a lateral side edge <NUM> that directly extends upward from the lateral concave edge <NUM>, and a medial linear edge <NUM> that directly extends upward from the medial concave edge <NUM>. Additional edges include first upper concave edge <NUM> formed by the upper medial cutout <NUM> and second upper concave edge <NUM> formed by the upper lateral cutout <NUM>; the neckline edge <NUM> of the pocket space extends between the first upper concave edge <NUM> and the second upper concave edge <NUM>. The pocket space may include additional edge <NUM> that extends between the second upper concave edge <NUM> and the lateral side edge <NUM>. One or more of the edges described above may be formed by affixing together the first layer of material <NUM> and the second layer of material <NUM>. It is contemplated herein that the second upper concave edge <NUM> formed by the upper lateral cutout <NUM> of the second layer of material <NUM> is not affixed to the inner layer of material <NUM> so as to form the opening to the pocket space.

The pad insert <NUM> is shown removably positioned within the pocket space of the first breast covering portion <NUM>. It is shown in dashed lines to indicate that it is positioned between the first layer of material <NUM> and the second layer of material <NUM>. When inserted, and as shown in <FIG>, the medial concave edge <NUM> of the pad insert <NUM> is aligned with the medial concave edge <NUM> of the pocket space of the first breast covering portion <NUM>, the lateral concave edge <NUM> of the pad insert <NUM> is aligned with the lateral concave edge <NUM> of the pocket space of the first breast covering portion <NUM>, and the lower linear edge <NUM> of the pad insert <NUM> is aligned with the lower edge <NUM> of the front portion <NUM> of the bra <NUM> and is further aligned with an upper edge of the underband <NUM>. As well, the medial linear edge <NUM> of the pad insert <NUM> is aligned with the medial linear edge <NUM> of the pocket space of the first breast covering portion, and the lateral linear edge <NUM> is aligned with the lateral side edge <NUM> of the pocket space of the first breast covering portion <NUM>. Additionally, the first upper concave edge <NUM> of the pad insert <NUM> is aligned with the first upper concave edge <NUM> of the pocket space of the first breast covering portion <NUM>, the second upper concave edge <NUM> of the pad insert <NUM> is aligned with the second upper concave edge <NUM> of the pocket space of the first breast covering portion <NUM>, and the upper linear edge <NUM> of the pad insert <NUM> is aligned with the neckline edge <NUM> of the front portion <NUM> of the bra <NUM>. Lastly, the edge <NUM> of the pad insert <NUM> is aligned with the edge <NUM> of the pocket space of the first breast covering portion <NUM>.

As shown, the perimeter shape <NUM> of the pad insert <NUM> is substantially the same as the perimeter shape of the pocket space of the first breast covering portion <NUM>. Similar to the pad insert <NUM> and the bra <NUM>, having the perimeter shapes of the pad insert <NUM> and the pocket space of the first breast covering portion <NUM> be substantially the same, positioning the pad insert <NUM> within the pocket space such that the perimeter shapes align or correspond, and configuring the perimeter shapes of each to include multiple edges including linear and concave edges helps to lock the pad insert <NUM> into place once positioned within the pocket space of the first breast covering portion <NUM>. Although not shown, a pad insert that is the mirror image of the pad insert <NUM> may be removably inserted into the pocket space of the second breast covering portion <NUM> and aligned similar to that described for the pad insert <NUM>.

<FIG> depicts a cross-section of the first breast covering portion <NUM> of the bra <NUM> taken along cut line <NUM>-<NUM>. A cross-section of the first breast covering portion <NUM> of the bra <NUM> would be similar. As shown in <FIG>, the pad insert <NUM> is positioned within a pocket space <NUM> between the first layer of material <NUM> and the second layer of material <NUM>. It is contemplated herein that the pad insert <NUM> is not affixed to the first layer of material <NUM> or the second layer of material <NUM> such that it can be inserted and removed from the pocket space <NUM>.

<FIG> depict two example back views of either the bra <NUM> or the bra <NUM>. Using the bra <NUM> as an example, <FIG> depicts a construction where the shoulder straps <NUM> remain separate as they extend over, for instance, a back of a wearer before joining a back portion <NUM> of the bra <NUM>. The underband <NUM> extends from the lower edge of the back portion <NUM>. In <FIG>, the shoulder straps <NUM> join together at a central back area before joining a back portion <NUM> of the bra <NUM>. The underband <NUM> extends from the lower edge of the back portion <NUM>. These are just two example configurations and multiple different shoulder strap and back configurations are contemplated herein.

<FIG> illustrates an example wearer <NUM> wearing the bra <NUM> and removably inserting the pad insert <NUM> into the pocket space of the first breast covering portion <NUM>. As shown, the pad insert <NUM> is inserted by way of the pocket opening formed by the lateral concave edge <NUM> of the first breast covering portion <NUM>. The perimeter edges of the pad insert <NUM> are aligned with the edges of the pocket space of the first breast covering portion <NUM> to lock the pad insert <NUM> into place and prevent shifting and rotating during wear and wash. The pad insert <NUM> may be removably inserted when additional modesty and/or support is desired. The pad insert <NUM> may be removed by way of the pocket opening formed by the lateral concave edge <NUM> of the first breast covering portion <NUM> when no longer needed.

<FIG> illustrates an example wearer <NUM> wearing the bra <NUM> and removably inserting the pad insert <NUM> into the pocket space of the first breast covering portion <NUM>. As shown, the pad insert <NUM> is inserted by way of the pocket opening formed by the second upper concave edge <NUM> of the first breast covering portion <NUM> although it is contemplated herein that the pad insert <NUM> may be inserted by way of one of the other cutouts of the second layer of material <NUM>. The perimeter edges of the pad insert <NUM> are aligned with the edges of the pocket space of the first breast covering portion <NUM> to lock the pad insert <NUM> into place and prevent shifting and rotating during wear and wash. The pad insert <NUM> may be removably inserted when additional modesty and/or support is desired. The pad insert <NUM> may be removed by way of the pocket opening formed by the second upper concave edge <NUM> of the first breast covering portion <NUM> when no longer needed.

<FIG> depicts a one-piece pad insert <NUM>. The one-piece pad insert <NUM> is configured to simultaneously cover both a right breast and a left breast of a wearer as well as the space between the right breast and the left breast when positioned within a pocket space of a bra such as the bra <NUM>. The one-piece pad insert <NUM> includes a right side portion <NUM> and a left side portion <NUM> that integrally extend from one another and comprise a unitary construction. The right side portion <NUM> is configured to cover the right breast of the wearer, and the left side portion is configured to cover the left breast of the wearer. Similar to the pad insert <NUM>, the one-piece pad insert <NUM> may be formed from a foam material having a uniform thickness and having a plurality of apertures <NUM> extending through a thickness of the one-piece pad insert <NUM>. The one-piece pad insert <NUM> may further include a mesh material <NUM> laminated to a first surface of the one-piece pad insert <NUM> as shown, to a second opposite surface of the one-piece pad insert <NUM>, or to both the first surface and the second surface of the one-piece pad insert <NUM>.

Further similar to the pad insert <NUM>, each of the right side portion <NUM> and the left side portion <NUM> of the one-piece pad insert <NUM> includes a medial concave edge <NUM> and a lateral concave edge <NUM> opposite the medial concave edge <NUM>. As described below, the one-piece pad insert <NUM> includes additional edges that extend from the medial concave edge <NUM> and the lateral concave edge <NUM> to form a perimeter shape of the one-piece pad insert <NUM>. For example, both the right side portion <NUM> and the left side portion <NUM> of the one-piece pad insert <NUM> include an upper concave edge <NUM> and a lower linear edge <NUM> opposite the upper concave edge <NUM>. In example aspects, the lower linear edge <NUM> directly extends from the medial concave edge <NUM> of each of the right side portion <NUM> and the left side portion <NUM>. Additional edges for each of the right side portion <NUM> and the left side portion <NUM> of the one-piece pad insert <NUM> may further include upper lateral edge <NUM> extending between the lateral concave edge <NUM> and the upper concave edge <NUM>, and lower lateral edge <NUM> extending between the lateral concave edge <NUM> and the lower linear edge <NUM>. The one-piece pad insert <NUM> may also include two or more obtuse angles such as obtuse angle <NUM> that is formed by the intersection of the upper lateral edge <NUM> and the lateral concave edge <NUM> for each of the right side portion <NUM> and the left side portion <NUM>. The one-piece pad insert <NUM> may also include two or more acute angles such as acute angle <NUM> that is formed by the intersection of the upper concave edge <NUM> and the upper lateral edge <NUM> for each of the right side portion <NUM> and the left side portion <NUM>.

In example aspects, the one-piece pad insert <NUM> may be used in the bra <NUM>. In this example, the pocket space formed between the first layer of material <NUM> and the second layer of material <NUM> may comprise a continuous pocket space extending between the left arm opening <NUM> and the right arm opening <NUM> and across the central region <NUM> of the bra <NUM>. For example, the one-piece pad insert <NUM> may be inserted into the bra <NUM> by way of one of the lateral cutouts <NUM> located on either the right side and/or the left side of the bra <NUM>. Similar to what was described for the pad insert <NUM>, the different edges of the one-piece pad insert <NUM> align with the different edges of the pocket space. For instance, for each of the right side portion <NUM> and the left side portion <NUM> of the one-piece pad insert <NUM>, the medial concave edge <NUM> of the one-piece pad insert <NUM> is aligned with the medial concave edges <NUM> of the pocket space, and the lateral concave edge <NUM> of the one-piece pad insert <NUM> is aligned with the lateral concave edges <NUM> of the pocket space. The lower linear edge <NUM> of the one-piece pad insert <NUM> is aligned with the lower edge <NUM> of the front portion <NUM> of the bra <NUM> and is further aligned with the upper edge of the underband <NUM>, and the upper concave edge <NUM> of the one-piece pad insert <NUM> is aligned with the neckline edge <NUM> of the front portion <NUM> of the bra <NUM>. The lower lateral edge <NUM> of the one-piece pad insert <NUM> is aligned with the lateral side edges <NUM> of the pocket space, and the upper lateral edge <NUM> of the one-piece pad insert <NUM> is aligned with the lateral upper edge <NUM> of the pocket space.

As shown, the perimeter shape of the one-piece pad insert <NUM> is substantially the same as the perimeter shape of the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM>. Having the perimeter shape of the one-piece pad insert <NUM> and the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM> be substantially the same, positioning the one-piece pad insert <NUM> within the pocket space such that the perimeter shapes align or correspond, and configuring the perimeter shapes of each to include multiple edges including linear and concave edges helps to lock the one-piece pad insert <NUM> into place once positioned within the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM>.

<FIG> depicts a second example one-piece pad insert <NUM>. The one-piece pad insert <NUM> is configured to simultaneously cover both a right breast and a left breast of a wearer as well as the space between the right breast and the left breast when positioned within a pocket space of a bra such as the bra <NUM>. The one-piece pad insert <NUM> includes a right side portion <NUM> configured to cover the right breast of the wearer and a left side portion <NUM> configured to cover the left breast of the wearer that integrally extend from one another and comprise a unitary construction. The one-piece pad insert <NUM> may be formed from a foam material having a uniform thickness and having a plurality of apertures <NUM> extending through a thickness of the one-piece pad insert <NUM>. The one-piece pad insert <NUM> may further include a mesh material <NUM> laminated on a first surface of the one-piece pad insert <NUM> as shown, a second opposite surface of the one-piece pad insert <NUM>, or both the first surface and the second surface of the one-piece pad insert <NUM>.

Further similar to the pad insert <NUM>, each of the right side portion <NUM> and the left side portion <NUM> of the one-piece pad insert <NUM> includes a medial concave edge <NUM> and a lateral concave edge <NUM> opposite the medial concave edge <NUM>. As described below, the one-piece pad insert <NUM> includes additional edges that extend from the medial concave edge <NUM> and the lateral concave edge <NUM> to form a perimeter shape of the one-piece pad insert <NUM>. For example, both the right side portion <NUM> and the left side portion <NUM> of the one-piece pad insert <NUM> include a lower linear edge <NUM> that directly extends horizontally between the medial concave edge <NUM> and the lateral concave edge <NUM>. Both the right side portion <NUM> and the left side portion <NUM> of the one-piece pad insert <NUM> may additionally a first upper concave edge <NUM> and a second upper concave edge <NUM>. The first upper concave edge <NUM> and the second upper concave edge <NUM> are connected by an upper linear edge <NUM>. Both of the right side portion <NUM> and the left side portion <NUM> of the one-piece pad insert <NUM> further includes a lateral linear edge <NUM> that directly extends upward from the lateral concave edge <NUM>. Edge <NUM>, which may be linear or concave, joins the lateral linear edge <NUM> to the second upper concave edge <NUM> to complete the perimeter shape of the one-piece pad insert <NUM>. The one-piece pad insert <NUM> may also include two or more obtuse angles such as obtuse angle <NUM> that is formed by the intersection of the first upper concave edge <NUM> and the upper linear edge <NUM> for each of the right side portion <NUM> and the left side portion <NUM>. The one-piece pad insert <NUM> may also include two or more acute angles such as acute angle <NUM> that is formed by the intersection of the second upper concave edge <NUM> and the upper linear edge <NUM> for each of the right side portion <NUM> and the left side portion <NUM>.

In example aspects, the one-piece pad insert <NUM> may be used in the bra <NUM>. In this example, the pocket space formed between the first layer of material <NUM> and the second layer of material <NUM> may comprise a continuous pocket space extending between the left arm opening <NUM> and the right arm opening <NUM> and across the central region <NUM> of the bra <NUM>. For example, the one-piece pad insert <NUM> may be inserted into the bra <NUM> by way of one of the upper lateral cutouts <NUM> located on either of the right side and/or the left side of the bra <NUM>. Similar to what was described for the one-piece pad insert <NUM>, the different edges of the one-piece pad insert <NUM> align with the different edges of the pocket space. For instance, for each of the right side portion <NUM> and the left side portion <NUM> of the one-piece pad insert <NUM>, the medial concave edge <NUM> of the one-piece pad insert <NUM> is aligned with the medial concave edge <NUM> of the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM>, the lateral concave edge <NUM> of the one-piece pad insert <NUM> is aligned with the lateral concave edge <NUM> of the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM>, and the lower linear edge <NUM> of the one-piece pad insert <NUM> is aligned with the lower edge <NUM> of the front portion <NUM> of the bra <NUM> and is further aligned with an upper edge of the underband <NUM>. As well, the lateral linear edge <NUM> is aligned with the lateral side edge <NUM> of the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM>. Additionally, the first upper concave edge <NUM> of the one-piece pad insert <NUM> is aligned with the first upper concave edge <NUM> of the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM>, the second upper concave edge <NUM> of the one-piece pad insert <NUM> is aligned with the second upper concave edge <NUM> of the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM>, and the upper linear edge <NUM> of the one-piece pad insert <NUM> is aligned with the neckline edge <NUM> of the front portion <NUM> of the bra <NUM>. Lastly, the edge <NUM> of the one-piece pad insert <NUM> is aligned with the edge <NUM> of the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM>.

As shown, the perimeter shape of the one-piece pad insert <NUM> is substantially the same as the perimeter shape of the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM>. Having the perimeter shapes of the one-piece pad insert <NUM> and the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM> be substantially the same, positioning the one-piece pad insert <NUM> within the pocket space such that the perimeter shapes align or correspond, and configuring the perimeter shapes of each to include multiple edges including linear and concave edges helps to lock the one-piece pad insert <NUM> into place once positioned within the pocket space of the first breast covering portion <NUM> and the second breast covering portion <NUM>.

<FIG> depicts a flow diagram of an example method <NUM> of manufacturing a pad insert, such as the pad insert <NUM>, the pad insert <NUM>, the one-piece pad insert <NUM>, and/or the one-piece pad insert <NUM> for use in a breast covering portion of a bra, such as the bra <NUM> or the bra <NUM>. At a step <NUM>, a pad insert is formed to have at least a medial concave edge such as the medial concave edge <NUM> of the pad insert <NUM>, the medial concave edge <NUM> of the pad insert <NUM>, the medial concave edge <NUM> of the one-piece pad insert <NUM>, or the medial concave edge <NUM> of the one-piece pad insert <NUM>. The step <NUM> also includes forming the pad insert to include a lateral concave edge such as the lateral concave edge <NUM> of the pad insert <NUM>, the lateral concave edge <NUM> of the pad insert <NUM>, the lateral concave edge <NUM> of the one-piece pad insert <NUM>, or the lateral concave edge <NUM> of the one-piece pad insert <NUM>. The step <NUM> may include forming additional edges to complete the perimeter shape of the pad insert.

In example aspects, the pad insert is formed by an injection molding process using a foam material such as a polyurethane foam material. The pad insert may be formed to include a plurality of apertures such as the plurality of apertures <NUM>, <NUM>, <NUM>, or <NUM> of the pad inserts <NUM>, <NUM>, <NUM> or <NUM> respectively. In another example aspect, the apertures may be formed in a post-formation step using laser cutting, die cutting, water jet cutting, and the like. It is further contemplated herein that a mesh material may be laminated to one or both surfaces of the pad insert to help protect the foam material of the pad insert during normal wear and wash. In example aspects, the edges of the pad insert may be flattened using a pressing process to create a smooth aesthetic when the pad insert is positioned within the pocket space of a breast covering portion of a bra.

Aspects of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative aspects will become apparent to those skilled in the art that do not depart from the scope of the invention as defined by the claims. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the invention as defined by the claims.

Claim 1:
A pad insert (<NUM>, <NUM>, <NUM>, <NUM>) for a breast covering portion (<NUM>, <NUM>, <NUM>, <NUM>) of a bra (<NUM>, <NUM>), the pad insert (<NUM>, <NUM>, <NUM>, <NUM>) comprising: a medial concave edge (<NUM>, <NUM>, <NUM>, <NUM>); a lateral concave edge (<NUM>, <NUM>, <NUM>, <NUM>) opposite the medial concave edge (<NUM>, <NUM>, <NUM>, <NUM>); and one or more additional edges (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) that extend from the medial concave edge (<NUM>, <NUM>, <NUM>, <NUM>) and the lateral concave edge (<NUM>, <NUM>, <NUM>, <NUM>) to form a perimeter shape (<NUM>, <NUM>) of the pad insert (<NUM>, <NUM>, <NUM>, <NUM>);
wherein the one or more additional edges (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) include an upper concave edge (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) the pad insert being characterised in that the one or more additional edges also include a lower linear edge (<NUM>, <NUM>, <NUM>, <NUM>) opposite the upper concave edge (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>).