Patent ID: 12201166

DETAILED DESCRIPTION

The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. 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 or 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.

Aspects herein are 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 that includes one or more concave edges and one or more linear edges. In one example aspect, the one or more concave edges are separated by the 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 (25 degrees Celsius or 298.15 K and 1 bar) and is in a resting (e.g., un-stretched) state.

FIG.1depicts a view of a first surface110of an example pad insert100. The pad insert100is configured for a left breast covering portion of a bra such as the bra shown inFIG.3. A pad insert for the right breast covering portion of the bra shown inFIG.3would be the mirror image of the pad insert100. In example aspects, the pad insert100may be formed of a foam material such as, for example, a polyurethane foam although other foam materials are contemplated herein. The pad insert100may be formed through an injection molding process and may optionally be formed to include a plurality of apertures112that extend through the pad insert100from the first surface110to an opposite second surface (not shown). The plurality of apertures112help to improve the permeability, breathability, and flexibility of the pad insert100. They also help to make the pad insert100lightweight. Although the plurality of apertures112are shown as ovoid in shape, other shapes are contemplated herein such as circles, triangles, squares, and the like. The pad insert100may have a uniform thickness throughout ranging from about 1 mm to about 7 mm, or from about 2 mm to about 5 mm. As used herein, the term “about” means within ±10% of an indicated value. It is also contemplated herein that the pad insert100may have a non-uniform thickness with some areas of the pad insert100being thicker than other areas.

In example aspects, a mesh fabric114is laminated to the first surface110of the pad insert100, to the second surface of the pad insert100, or to both the first surface110and the second surface of the pad insert100. The mesh fabric114may help to protect the integrity of the pad insert100during wash and wear. In further example aspects, the edges of the pad insert100may be flattened by, for instance, a pressing process, to create a smoother aesthetic when the pad insert100is positioned within a pocket space of a bra.

The pad insert100has a perimeter shape referenced generally by the numeral116. The perimeter shape116generally includes concave edge and linear edges. In one example aspect, the concave edges are separated by one or more linear edges. The perimeter shape116includes at least a medial concave edge118and a lateral concave edge120positioned opposite the medial concave edge118. The pad insert100includes additional edges such as a lower linear edge122that directly extends horizontally from the medial concave edge118. The pad insert100may additionally include a medial linear edge124that directly extends upward from the medial concave edge118. The pad insert100also includes an upper concave edge126opposite the lower linear edge122and directly extending from the medial linear edge124. An upper lateral edge128that may be linear or concave, extends directly between the upper concave edge126and the lateral concave edge120. In addition, the pad insert100includes a lower lateral linear edge130that extends directly between the lateral concave edge120and the lower linear edge122.

The combination of the different edges described above forms a number of interior obtuse angles and interior acute angles. For example, the pad insert100may include at least obtuse angle132formed between the lateral concave edge120and the upper lateral edge128, and obtuse angle134formed between the medial concave edge118and the medial linear edge124. The pad insert100may also include at least acute angle136formed between the upper lateral edge128and the upper concave edge126. The perimeter shape116described for the pad insert100creates a unique shape similar to, for example, a jigsaw piece which allows the pad insert100to lock into place when inserted into a pocket space of a breast covering portion as described below.

FIG.2depicts a view of a first surface210of another example pad insert200. The pad insert200is configured for a left breast covering portion of a bra such as the bra shown inFIG.4. A pad insert for the right breast covering portion of the bra shown inFIG.4would be the mirror image of the pad insert200. Similar to the pad insert100, the pad insert200may comprise a perforated foam material having an optional plurality of apertures212that extend through the pad insert200from the first surface210to an opposite second surface (not shown). The plurality of apertures212help to improve the permeability, breathability, and flexibility of the pad insert100. They also help to make the pad insert200lightweight. Although the plurality of apertures212are shown as ovoid in shape, other shapes are contemplated herein such as circles, triangles, squares, and the like. The pad insert200may have a uniform thickness throughout ranging from about 1 mm to about 7 mm, or from about 2 mm to about 5 mm. It is also contemplated herein that the pad insert200may have a non-uniform thickness with some areas of the pad insert200being thicker than other areas.

In example aspects, a mesh fabric214is laminated to the first surface210of the pad insert200, to the second surface of the pad insert200, or to both the first surface210and the second surface of the pad insert200. The mesh fabric214may help to protect the integrity of the pad insert200during wash and wear. In further example aspects, the edges of the pad insert200may be flattened by, for instance, a pressing process, to create a smoother aesthetic when the pad insert200is positioned within a pocket space of a bra.

The pad insert200has a perimeter shape referenced generally by the numeral216. Similar to the pad insert100, the perimeter shape216generally comprises concave edges and linear edges. In one example aspect, the concave edges are separated by one or more linear edges. The perimeter shape216includes at least a medial concave edge218and a lateral concave edge220positioned opposite the medial concave edge218. The pad insert200includes additional edges such as a lower linear edge222that directly extends horizontally between the medial concave edge218and the lateral concave edge220. The pad insert200may additionally include a medial linear edge224that directly extends upward from the medial concave edge218. The pad insert200may also include a first upper concave edge226that directly extends from the medial linear edge224and a second upper concave edge228. The first upper concave edge226and the second upper concave edge228are connected by an upper linear edge230. The pad insert200further includes a lateral linear edge232that directly extends upward from the lateral concave edge220. Edge234, which may be linear or concave, joins the lateral linear edge232to the second upper concave edge228to complete the perimeter shape216of the pad insert200.

The combination of the different edges described above forms a number of interior obtuse angles and interior acute angles. For example, the pad insert200may include at least obtuse angle236formed between the lower linear edge222and the medial concave edge218, obtuse angle238formed between the first upper concave edge226and the upper linear edge230, obtuse angle240formed between the second upper concave edge228and the edge234, obtuse angle242formed between the lateral linear edge232and the lateral concave edge220, and obtuse angle244formed between the lateral concave edge220and the lower linear edge222. The pad insert200may also include at least acute angle246formed between the upper linear edge230and the second upper concave edge228. Similar to the pad insert100, the perimeter shape216described for the pad insert200creates a unique shape which allows the pad insert200to lock into place when inserted into a pocket space of a breast covering portion as described below.

FIG.3depicts a view of an outer-facing surface of a front portion310of an example support garment in the form of a bra300having the pad insert100removably positioned within a pocket space of one of the breast covering portions of the bra300. In addition to the front portion310, the bra300includes first and second shoulder straps312configured to extend over shoulders of a wearer when the bra300is in an as-worn configuration. The bra300also includes an underband314extending from a lower edge311of the front portion310, where the underband314is configured to encircle a torso area of the wearer when the bra300is in the as-worn configuration. In example aspects, the underband314may comprise a separate panel piece having a top edge that is affixed by seaming, bonding, and the like to the lower edge311of the front portion310. In another example, the underband314may comprise a seamless extension of the front portion310.

The front portion310includes a first breast covering portion316and a second breast covering portion318separated from the first breast covering portion316by a central region320of the bra300where the central region320is configured to be positioned overlying a sternum area of a wearer when the bra300is worn. The first breast covering portion316is configured to substantially cover a left breast of the wearer when the bra300is in the as-worn configuration and generally extends from a left arm opening317to the central region320and from a neckline edge319of the bra300to the lower edge311of the front portion310. Similarly, the second breast covering portion318is configured to substantially cover a right breast of the wearer when the bra300is in the as-worn configuration and generally extends from a right arm opening321to the central region320and from the neckline edge319of the bra300to the lower edge311of the front portion310.

In example aspects, the front portion310of the bra300is formed from a first layer of material322that forms an innermost layer of both the first breast covering portion316and the second breast covering portion318, and a second layer of material324that forms an outermost layer of both the first breast covering portion316and the second breast covering portion318. It is contemplated herein, that the first layer of material322may be unaffixed from the second layer of material324except for one or more perimeter edges to form a space between the first and second layers of material322and324. The space may comprise a pocket space into which the pad insert100is removably positioned.

In example aspects, both the first layer of material322and the second layer of material324may comprise a knit mesh material such as a warp knit mesh. Use of a mesh material contributes to the lightweight nature of the bra300and also makes the bra300permeable and breathable all of which contribute to wearer comfort. As well, the first layer of material322and the second layer of material324may include one or more elastic yarns to impart stretch and recovery properties to the first and second layers of material322and324making the bra300easier to don, doff, and wear. For example, the first and second layers of material322and324may comprise about 85% nylon and 15% elastane, about 90% nylon and 10% elastane, or about 92% nylon and 8% elastane. Use of nylon yarns with their high abrasion resistance, contributes to the durability of the bra300. 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 material322and the second layer of material324may comprise a layer of material that extends continuously from the left arm opening317across the central region320to the right arm opening321and from the neckline edge319to the lower edge311of the front portion310. In this example, the first layer of material322and the second layer of material324may optionally be vertically joined together using stitching, bonding, and the like at the central region320to better define a pocket space as described below. In other example aspects, one or more of the first layer of material322and the second layer of material324may comprise a first panel piece that extends from, for example, the left arm opening317to the central region320and from the neckline edge319to the lower edge311of the front portion310, and a second panel piece that extends from the right arm opening321to the central region320and from the neckline edge319to the lower edge311of the front portion310. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.

It is contemplated herein that the first layer of material322and the second layer of material324may have different perimeter shapes. For example, as shown inFIG.3, the second layer of material324includes a cutout326at the lower edge311of the front portion310and positioned generally at the central region320of the bra300where the cutout326extends upward into both the first breast covering portion316and the second breast covering portion318. In example aspects, the first layer of material322may also optionally include a cutout having edges coincident with the cutout326. Thus, a wearer's skin surface may be exposed in the area of the cutout326. The second layer of material324may also include lateral cutouts328adjacent to the left and right arm openings317and321. In this location, the first layer of material322may extend up to and partially form or define the left and right arm openings317and321. In example aspects, the lateral cutouts328may comprise pocket openings in communication with the space between the first layer of material322and the second layer of material324.

Each of the first breast covering portion316and the second breast covering portion318includes a pocket space formed between the first layer of material322and the second layer of material324. The respective pocket spaces of the first and second breast covering portions316and318have 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 portion316, the pocket space is defined by a medial concave edge330formed by the cutout326and a lateral concave edge332opposite the medial concave edge330formed by the lateral cutout328. In example aspects, the lateral concave edge332forms a pocket opening to the pocket space. The perimeter shape of the pocket space includes additional edges such as the lower edge311of the front portion310where the lower edge311directly extends horizontally from the medial concave edge330, the neckline edge319, and a lateral side edge334that extends between the lateral concave edge332and the lower edge311. The one or more additional edges may also include a medial linear edge336that extends between the medial concave edge330and the neckline edge319, and a lateral upper edge338that extends from the lateral concave edge332and may form an edge of the shoulder strap312. One or more of the edges described above may be formed by affixing together the first layer of material322and the second layer of material324. It is contemplated herein that the lateral concave edge332formed by the lateral cutout328of the second layer of material324is not affixed to the inner layer of material322so as to form the opening to the pocket space.

The pad insert100is shown removably positioned within the pocket space of the first breast covering portion316. It is shown in dashed lines to indicate that it is positioned between the first layer of material322and the second layer of material324. When inserted, and as shown inFIG.3, the medial concave edge118of the pad insert100is aligned with the medial concave edge330of the pocket space, and the lateral concave edge120of the pad insert100is aligned with the lateral concave edge332of the pocket space. The lower linear edge122of the pad insert100is aligned with the lower edge311of the front portion310of the bra300and is further aligned with an upper edge of the underband314, and the upper concave edge126of the pad insert100is aligned with the neckline edge319of the front portion310of the bra300. The lower lateral linear edge130of the pad insert100is aligned with the lateral side edge334of the pocket space, the medial linear edge124of the pad insert100is aligned with the medial linear edge336of the pocket space, and the upper lateral edge128of the pad insert100is aligned with the lateral upper edge338of the pocket space.

As shown, the perimeter shape116of the pad insert100is substantially the same as the perimeter shape of the pocket space of the first breast covering portion316. 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 insert100so the pad insert100can be positioned within the pocket space without buckling or folding. Having the perimeter shapes of the pad insert100and the pocket space of the first breast covering portion316be substantially the same, positioning the pad insert100within 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 insert100into place once positioned within the pocket space of the first breast covering portion316. Although not shown, a pad insert that is the mirror image of the pad insert100may be removably inserted into the pocket space of the second breast covering portion318and aligned similar to that described for the pad insert100.

FIG.4depicts a view of an outer-facing surface of a front portion410of an example support garment in the form of a bra400having the pad insert200removably positioned within a pocket space of one of the breast covering portions of the bra400. In addition to the front portion410, the bra400includes first and second shoulder straps412configured to extend over shoulders of a wearer when the bra400is in an as-worn configuration. The bra400also includes an underband414extending from a lower edge411of the front portion410, where the underband414is configured to encircle a torso area of the wearer when the bra400is in the as-worn configuration. In example aspects, the underband414may comprise a separate panel piece that is affixed by seaming, bonding, and the like to the lower edge411of the front portion410. In another example, the underband414may comprise a seamless extension of the front portion410.

The front portion410includes a first breast covering portion416and a second breast covering portion418separated from the first breast covering portion416by a central region420of the bra400where the central region420is configured to overlie a sternum area of a wearer when the bra400is worn. The first breast covering portion416is configured to substantially cover a left breast of the wearer when the bra400is in the as-worn configuration and generally extends from a left arm opening417to the central region420and from a neckline edge419of the bra400to the lower edge411of the front portion410. Similarly, the second breast covering portion418is configured to substantially cover a right breast of the wearer when the bra400is in the as-worn configuration and generally extends from a right arm opening421to the central region420and from the neckline edge419of the bra400to the lower edge411of the front portion410.

Similar to the bra300, the front portion410of the bra400is formed from a first layer of material422that forms an innermost layer of both the first breast covering portion416and the second breast covering portion418, and a second layer of material424that forms an outermost layer of both the first breast covering portion416and the second breast covering portion418. It is contemplated herein, that the first layer of material422may be unaffixed from the second layer of material424except for one or more perimeter edges to form a space between the first and second layers of material422and424. The space may comprise a pocket space into which the pad insert200is removably positioned. The first layer of material422and the second layer of material424may comprise the same material construction as the first layer of material322and the second layer of material324of the bra300.

In some example aspects, one or more of the first layer of material422and the second layer of material424may comprise a layer of material that extends continuously from the left arm opening417across the central region420to the right arm opening421and from the neckline edge419to the lower edge411of the front portion410. In this example, the first layer of material422and the second layer of material424may optionally be vertically joined using stitching, bonding, and the like at the central region420to better define a pocket space as described below. In other example aspects, one or more of the first layer of material422and the second layer of material424may comprise a first panel piece that extends from, for example, the left arm opening417to the central region420and from the neckline edge419to the lower edge411of the front portion410, and a second panel piece that extends from the right arm opening421to the central region420and from the neckline edge419to the lower edge411of the front portion410. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.

As shown, the second layer of material424may have a different perimeter shape compared to the first layer of material424. For example, as shown inFIG.4, the second layer of material424may include cutout426at the lower edge411of the front portion410and positioned generally at the central region420of the bra400where the cutout426extends upward into the first breast covering portion416and the second breast covering portion418. The second layer of material424may also include lower lateral cutouts428adjacent to the lower edge411of the front portion410, upper lateral cutouts430positioned adjacent to and below the first and second shoulder straps412, and upper medial cutouts432positioned adjacent to the neckline edge419and the central region420. In example aspects, the upper lateral cutouts430may comprise pocket openings in communication with the space between the first layer of material422and the second layer of material424.

Each of the first breast covering portion416and the second breast covering portion418include a pocket space formed between the first layer of material422and the second layer of material424. The respective pocket spaces of the first and second breast covering portions416and418have 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 portion416, the pocket space is defined by a medial concave edge434formed by the cutout426and a lateral concave edge436opposite the medial concave edge434formed by the lower lateral cutout428. The perimeter shape of the pocket space includes additional edges such as the lower edge411of the front portion410where the lower edge411directly extends horizontally between the medial concave edge434and the lateral concave edge436, the neckline edge419, a lateral side edge438that directly extends upward from the lateral concave edge436, and a medial linear edge440that directly extends upward from the medial concave edge434. Additional edges include first upper concave edge442formed by the upper medial cutout432and second upper concave edge444formed by the upper lateral cutout430; the neckline edge419of the pocket space extends between the first upper concave edge442and the second upper concave edge444. The pocket space may include additional edge446that extends between the second upper concave edge444and the lateral side edge438. One or more of the edges described above may be formed by affixing together the first layer of material422and the second layer of material424. It is contemplated herein that the second upper concave edge444formed by the upper lateral cutout430of the second layer of material424is not affixed to the inner layer of material422so as to form the opening to the pocket space.

The pad insert200is shown removably positioned within the pocket space of the first breast covering portion416. It is shown in dashed lines to indicate that it is positioned between the first layer of material422and the second layer of material424. When inserted, and as shown inFIG.4, the medial concave edge218of the pad insert200is aligned with the medial concave edge434of the pocket space of the first breast covering portion416, the lateral concave edge220of the pad insert200is aligned with the lateral concave edge436of the pocket space of the first breast covering portion416, and the lower linear edge222of the pad insert200is aligned with the lower edge411of the front portion410of the bra400and is further aligned with an upper edge of the underband414. As well, the medial linear edge224of the pad insert200is aligned with the medial linear edge440of the pocket space of the first breast covering portion, and the lateral linear edge232is aligned with the lateral side edge438of the pocket space of the first breast covering portion416. Additionally, the first upper concave edge226of the pad insert200is aligned with the first upper concave edge442of the pocket space of the first breast covering portion416, the second upper concave edge228of the pad insert200is aligned with the second upper concave edge444of the pocket space of the first breast covering portion416, and the upper linear edge230of the pad insert200is aligned with the neckline edge419of the front portion410of the bra400. Lastly, the edge234of the pad insert200is aligned with the edge446of the pocket space of the first breast covering portion416.

As shown, the perimeter shape216of the pad insert200is substantially the same as the perimeter shape of the pocket space of the first breast covering portion416. Similar to the pad insert100and the bra300, having the perimeter shapes of the pad insert200and the pocket space of the first breast covering portion416be substantially the same, positioning the pad insert200within 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 insert200into place once positioned within the pocket space of the first breast covering portion416. Although not shown, a pad insert that is the mirror image of the pad insert200may be removably inserted into the pocket space of the second breast covering portion418and aligned similar to that described for the pad insert200.

FIG.5depicts a cross-section of the first breast covering portion316of the bra300taken along cut line5-5. A cross-section of the first breast covering portion416of the bra400would be similar. As shown inFIG.5, the pad insert100is positioned within a pocket space510between the first layer of material322and the second layer of material324. It is contemplated herein that the pad insert100is not affixed to the first layer of material322or the second layer of material324such that it can be inserted and removed from the pocket space510.

FIGS.6A and6Bdepict two example back views of either the bra300or the bra400. Using the bra300as an example,FIG.6Adepicts a construction where the shoulder straps312remain separate as they extend over, for instance, a back of a wearer before joining a back portion612of the bra300. The underband314extends from the lower edge of the back portion612. InFIG.6B, the shoulder straps312join together at a central back area before joining a back portion622of the bra300. The underband314extends from the lower edge of the back portion622. These are just two example configurations and multiple different shoulder strap and back configurations are contemplated herein.

FIG.7illustrates an example wearer710wearing the bra300and removably inserting the pad insert100into the pocket space of the first breast covering portion316. As shown, the pad insert100is inserted by way of the pocket opening formed by the lateral concave edge332of the first breast covering portion316. The perimeter edges of the pad insert100are aligned with the edges of the pocket space of the first breast covering portion316to lock the pad insert100into place and prevent shifting and rotating during wear and wash. The pad insert100may be removably inserted when additional modesty and/or support is desired. The pad insert100may be removed by way of the pocket opening formed by the lateral concave edge332of the first breast covering portion316when no longer needed.

FIG.8illustrates an example wearer810wearing the bra400and removably inserting the pad insert200into the pocket space of the first breast covering portion416. As shown, the pad insert200is inserted by way of the pocket opening formed by the second upper concave edge444of the first breast covering portion416although it is contemplated herein that the pad insert200may be inserted by way of one of the other cutouts of the second layer of material424. The perimeter edges of the pad insert200are aligned with the edges of the pocket space of the first breast covering portion416to lock the pad insert200into place and prevent shifting and rotating during wear and wash. The pad insert200may be removably inserted when additional modesty and/or support is desired. The pad insert200may be removed by way of the pocket opening formed by the second upper concave edge444of the first breast covering portion416when no longer needed.

FIG.9depicts a one-piece pad insert900. The one-piece pad insert900is 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 bra300. The one-piece pad insert900includes a right side portion910and a left side portion912that integrally extend from one another and comprise a unitary construction. The right side portion910is 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 insert100, the one-piece pad insert900may be formed from a foam material having a uniform thickness and having a plurality of apertures905extending through a thickness of the one-piece pad insert900. The one-piece pad insert900may further include a mesh material907laminated to a first surface of the one-piece pad insert900as shown, to a second opposite surface of the one-piece pad insert900, or to both the first surface and the second surface of the one-piece pad insert900.

Further similar to the pad insert100, each of the right side portion910and the left side portion912of the one-piece pad insert900includes a medial concave edge914and a lateral concave edge916opposite the medial concave edge914. As described below, the one-piece pad insert900includes additional edges that extend from the medial concave edge914and the lateral concave edge916to form a perimeter shape of the one-piece pad insert900. For example, both the right side portion910and the left side portion912of the one-piece pad insert900include an upper concave edge918and a lower linear edge920opposite the upper concave edge918. In example aspects, the lower linear edge920directly extends from the medial concave edge914of each of the right side portion910and the left side portion912. Additional edges for each of the right side portion910and the left side portion912of the one-piece pad insert900may further include upper lateral edge922extending between the lateral concave edge916and the upper concave edge918, and lower lateral edge924extending between the lateral concave edge916and the lower linear edge920. The one-piece pad insert900may also include two or more obtuse angles such as obtuse angle926that is formed by the intersection of the upper lateral edge922and the lateral concave edge916for each of the right side portion910and the left side portion912. The one-piece pad insert900may also include two or more acute angles such as acute angle928that is formed by the intersection of the upper concave edge918and the upper lateral edge922for each of the right side portion910and the left side portion912.

In example aspects, the one-piece pad insert900may be used in the bra300. In this example, the pocket space formed between the first layer of material322and the second layer of material324may comprise a continuous pocket space extending between the left arm opening317and the right arm opening321and across the central region320of the bra300. For example, the one-piece pad insert900may be inserted into the bra300by way of one of the lateral cutouts328located on either the right side and/or the left side of the bra300. Similar to what was described for the pad insert100, the different edges of the one-piece pad insert900align with the different edges of the pocket space. For instance, for each of the right side portion910and the left side portion912of the one-piece pad insert900, the medial concave edge914of the one-piece pad insert900is aligned with the medial concave edges330of the pocket space, and the lateral concave edge916of the one-piece pad insert900is aligned with the lateral concave edges332of the pocket space. The lower linear edge920of the one-piece pad insert900is aligned with the lower edge311of the front portion310of the bra300and is further aligned with the upper edge of the underband314, and the upper concave edge918of the one-piece pad insert900is aligned with the neckline edge319of the front portion310of the bra300. The lower lateral edge924of the one-piece pad insert900is aligned with the lateral side edges334of the pocket space, and the upper lateral edge922of the one-piece pad insert900is aligned with the lateral upper edge338of the pocket space.

As shown, the perimeter shape of the one-piece pad insert900is substantially the same as the perimeter shape of the pocket space of the first breast covering portion316and the second breast covering portion318. Having the perimeter shape of the one-piece pad insert900and the pocket space of the first breast covering portion316and the second breast covering portion318be substantially the same, positioning the one-piece pad insert900within 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 insert900into place once positioned within the pocket space of the first breast covering portion316and the second breast covering portion318.

FIG.10depicts a second example one-piece pad insert1000. The one-piece pad insert1000is 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 bra400. The one-piece pad insert1000includes a right side portion1010configured to cover the right breast of the wearer and a left side portion1012configured to cover the left breast of the wearer that integrally extend from one another and comprise a unitary construction. The one-piece pad insert1000may be formed from a foam material having a uniform thickness and having a plurality of apertures1005extending through a thickness of the one-piece pad insert1000. The one-piece pad insert1000may further include a mesh material1007laminated on a first surface of the one-piece pad insert1000as shown, a second opposite surface of the one-piece pad insert1000, or both the first surface and the second surface of the one-piece pad insert1000.

Further similar to the pad insert100, each of the right side portion1010and the left side portion1012of the one-piece pad insert1000includes a medial concave edge1014and a lateral concave edge1016opposite the medial concave edge1014. As described below, the one-piece pad insert1000includes additional edges that extend from the medial concave edge1014and the lateral concave edge1016to form a perimeter shape of the one-piece pad insert1000. For example, both the right side portion1010and the left side portion1012of the one-piece pad insert1000include a lower linear edge1018that directly extends horizontally between the medial concave edge1014and the lateral concave edge1016. Both the right side portion1010and the left side portion1012of the one-piece pad insert1000may additionally a first upper concave edge1020and a second upper concave edge1022. The first upper concave edge1020and the second upper concave edge1022are connected by an upper linear edge1024. Both of the right side portion1010and the left side portion1012of the one-piece pad insert1000further includes a lateral linear edge1026that directly extends upward from the lateral concave edge1016. Edge1028, which may be linear or concave, joins the lateral linear edge1026to the second upper concave edge1022to complete the perimeter shape of the one-piece pad insert1000. The one-piece pad insert1000may also include two or more obtuse angles such as obtuse angle1030that is formed by the intersection of the first upper concave edge1020and the upper linear edge1024for each of the right side portion1010and the left side portion1012. The one-piece pad insert1000may also include two or more acute angles such as acute angle1032that is formed by the intersection of the second upper concave edge1022and the upper linear edge1024for each of the right side portion1010and the left side portion1012.

In example aspects, the one-piece pad insert1000may be used in the bra400. In this example, the pocket space formed between the first layer of material422and the second layer of material424may comprise a continuous pocket space extending between the left arm opening417and the right arm opening421and across the central region420of the bra400. For example, the one-piece pad insert1000may be inserted into the bra400by way of one of the upper lateral cutouts430located on either of the right side and/or the left side of the bra400. Similar to what was described for the one-piece pad insert900, the different edges of the one-piece pad insert1000align with the different edges of the pocket space. For instance, for each of the right side portion1010and the left side portion1012of the one-piece pad insert1000, the medial concave edge1014of the one-piece pad insert1000is aligned with the medial concave edge434of the pocket space of the first breast covering portion416and the second breast covering portion418, the lateral concave edge1016of the one-piece pad insert1000is aligned with the lateral concave edge436of the pocket space of the first breast covering portion416and the second breast covering portion418, and the lower linear edge1018of the one-piece pad insert1000is aligned with the lower edge411of the front portion410of the bra400and is further aligned with an upper edge of the underband414. As well, the lateral linear edge1026is aligned with the lateral side edge438of the pocket space of the first breast covering portion416and the second breast covering portion418. Additionally, the first upper concave edge1020of the one-piece pad insert1000is aligned with the first upper concave edge442of the pocket space of the first breast covering portion416and the second breast covering portion418, the second upper concave edge1022of the one-piece pad insert1000is aligned with the second upper concave edge444of the pocket space of the first breast covering portion416and the second breast covering portion418, and the upper linear edge1024of the one-piece pad insert1000is aligned with the neckline edge419of the front portion410of the bra400. Lastly, the edge1028of the one-piece pad insert1000is aligned with the edge446of the pocket space of the first breast covering portion416and the second breast covering portion418.

As shown, the perimeter shape of the one-piece pad insert1000is substantially the same as the perimeter shape of the pocket space of the first breast covering portion416and the second breast covering portion418. Having the perimeter shapes of the one-piece pad insert1000and the pocket space of the first breast covering portion416and the second breast covering portion418be substantially the same, positioning the one-piece pad insert1000within 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 insert1000into place once positioned within the pocket space of the first breast covering portion416and the second breast covering portion418.

FIG.11depicts a flow diagram of an example method1100of manufacturing a pad insert, such as the pad insert100, the pad insert200, the one-piece pad insert900, and/or the one-piece pad insert1000for use in a breast covering portion of a bra, such as the bra300or the bra400. At a step1110, a pad insert is formed to have at least a medial concave edge such as the medial concave edge118of the pad insert100, the medial concave edge218of the pad insert200, the medial concave edge914of the one-piece pad insert900, or the medial concave edge1014of the one-piece pad insert1000. The step1110also includes forming the pad insert to include a lateral concave edge such as the lateral concave edge120of the pad insert100, the lateral concave edge220of the pad insert200, the lateral concave edge916of the one-piece pad insert900, or the lateral concave edge1016of the one-piece pad insert1000. The step1110may 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 apertures112,212,905, or1005of the pad inserts100,200,900or1000respectively. 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.

The following clauses represent example aspects of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are illustrative in nature and are not limiting.

Clause 1. A pad insert for a breast covering portion of a bra, the pad insert comprising: a medial concave edge; a lateral concave edge opposite the medial concave edge; and one or more additional edges that extend from the medial concave edge and the lateral concave edge to form a perimeter shape for the pad insert.

Clause 2. The pad insert for the breast covering portion of the bra according to clause 1, wherein the one or more additional edges include an upper concave edge and a lower linear edge opposite the upper concave edge.

Clause 3. The pad insert for the breast covering portion of the bra according to clause 2, wherein the lower linear edge directly extends from the medial concave edge.

Clause 4. The pad insert for the breast covering portion of the bra according to any of clauses 1 through 3, wherein a medial linear edge directly extends from the medial concave edge.

Clause 5. The pad insert for the breast covering portion of the bra according to any of clauses 1 through 4, wherein the perimeter shape of the pad insert includes two or more obtuse angles.

Clause 6. The pad insert for the breast covering portion of the bra according to any of clauses 1 through 5, wherein the perimeter shape of the pad insert includes at least one acute angle.

Clause 7. The pad insert for the breast covering portion of the bra according to any of clauses 1 through 6, wherein the pad insert comprises a foam material with a plurality of apertures.

Clause 8. The pad insert for the breast covering portion of the bra according to any of clauses 1 through 7, wherein the pad insert further comprises a mesh material laminated to a first surface of the pad insert.

Clause 9. A bra system comprising: a bra comprising: a first breast covering portion formed by at least a first layer of material and a second layer of material in face-sharing contact with the first layer of material to define a pocket space therebetween, wherein the pocket space is defined by a perimeter shape comprising a medial concave edge, a lateral concave edge opposite the medial concave edge, and one or more additional edges that extend from the medial concave edge and the lateral concave edge, and a pocket opening in communication with the pocket space; and a pad insert removably positioned in the pocket space of the first breast covering portion, the pad insert comprising a medial concave edge, a lateral concave edge opposite the medial concave edge, and one or more additional edges that extend from the medial concave edge and the lateral concave edge, wherein the medial concave edge of the pad insert aligns with the medial concave edge of the pocket space and the lateral concave edge of the pad insert aligns with the lateral concave edge of the pocket space.

Clause 10. The bra system according to clause 9, wherein the one or more additional edges of the pad insert align with the one or more additional edges of the pocket space.

Clause 11. The bra system according to any of clauses 9 through 10, wherein the bra further comprises: a second breast covering portion that together with the first breast covering portion forms a front portion of the bra; a first shoulder strap extending from the first breast covering portion; and a second shoulder strap extending from the second breast covering portion.

Clause 12. The bra system according to any of clauses 9 through 11, wherein the one or more additional edges of the pad insert includes an upper concave edge and a lower linear edge opposite the upper concave edge.

Clause 13. The bra system according to clause 12, wherein the lower linear edge of the pad insert aligns with an edge of an underband extending from a lower edge of the bra.

Clause 14. The bra system according to any of clauses 12 through 13, wherein the lower linear edge of the pad insert directly extends from the medial concave edge of the pad insert.

Clause 15. The bra system according to any of clauses 9 through 14, wherein the first layer of material forms an innermost layer of the first breast covering portion, and wherein the first layer of material comprises a knit mesh construction.

Clause 16. The bra system according to any of clauses 9 through 15, wherein the second layer of material forms an outermost layer of the first breast covering portion, and wherein the second layer of material comprises a knit mesh construction.

Clause 17. The bra system according to any of clauses 9 through 16, wherein the pad insert comprises a foam material.

Clause 18. The bra system according to clause 17, wherein the foam material includes a plurality of apertures.

Clause 19. The bra system according to any of clauses 9 through 18, wherein the pad insert further comprises a mesh material laminated to a first surface of the pad insert.

Clause 20. A method of manufacturing a pad insert for use in a breast covering portion of a bra, the method comprising: forming the pad insert to include a medial concave edge, a lateral concave edge opposite the medial concave edge, and one or more additional edges that extend from the medial concave edge and the lateral concave edge.

Clause 21. A one-piece pad insert for a breast covering portion of a bra, the one-piece pad insert comprising a right side portion and a left side portion, wherein each of the right side portion and the left side portion includes: a medial concave edge; a lateral concave edge opposite the medial concave edge; and one or more additional edges that extend from the medial concave edge and the lateral concave edge to form a perimeter shape for the one-piece pad insert.

Clause 22. The one-piece pad insert for the breast covering portion of the bra according to clause 21, wherein the one or more additional edges include an upper concave edge and a lower linear edge opposite the upper concave edge.

Clause 23. The one-piece pad insert for the breast covering portion of the bra according to clause 22, wherein the lower linear edge directly extends from the medial concave edge.

Clause 24. The one-piece pad insert for the breast covering portion of the bra according to any of clauses 21 through 23, wherein the perimeter shape of the one-piece pad insert includes two or more obtuse angles.

Clause 25. The one-piece pad insert for the breast covering portion of the bra according to any of clauses 21 through 24, wherein the perimeter shape of the one-piece pad insert includes at least one acute angle.

Clause 26. The one-piece pad insert for the breast covering portion of the bra according to any of clauses 21 through 25, wherein the one-piece pad insert comprises a foam material with a plurality of apertures.

Clause 27. The one-piece pad insert for the breast covering portion of the bra according to any of clauses 21 through 26, wherein the one-piece pad insert further comprises a mesh material laminated to at least a first surface of the one-piece pad insert.

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 its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure.

It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.