GB2499617A

GB2499617A - Improvements in or relating to bras

Info

Publication number: GB2499617A
Application number: GB1203050.8A
Authority: GB
Inventors: Lisa Mulube
Original assignee: Marks and Spencer PLC
Current assignee: Marks and Spencer PLC
Priority date: 2012-02-22
Filing date: 2012-02-22
Publication date: 2013-08-28
Also published as: GB201203050D0

Abstract

A garment for at least partially supporting the bust of a user omprises a cup region 2 having a lower edge 22 and a cradle region 3 below at least a part of the lower edge, the cup region and cradle region comprising inner 14 and outer 13 layers of material which are bonded to one another, a support element (8, figure 2), formed from a polymer material, held between the inner and outer layers and extending along at least a part of the lower edge, and a region of a support material 12, having an elasticity that is significantly less than that of the inner or outer layer of material, held between said layers and extending along an outer portion of the cup region lying, in use, furthest from the wearer's sternum. The support element is preferably formed from a silicon polymer and may vary in width or depth or both over its length. A layer of stiffening material (21, figure 4) may be provided between the layers over at least a part of the cradle region. The garment may be a bra. Also disclosed is a method of forming the garment of the invention.

Description

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Title: IMPROVEMENTS IN OR RELATING TO BRAS Description of Invention

The present invention relates to bras, and in particular to non-underwired bras, and methods of manufacture thereof.

Underwired bras are very popular, and a large proportion of currently-available bras include underwiring. This is particularly the case for shape-enhancing bras (as opposed to more functional garments such as sports bras and nursing bras), and also larger-sized bras.

Underwiring is popular because the wires provide strong structural elements which can be used for support to help provide a desired shape. However, many women find that underwired bras can be uncomfortable, particularly if worn for long periods. In addition, the use of underwired bras is sometimes discouraged, for instance during pregnancy or nursing.

It is an object of the present invention to seek to alleviate some or all of the above problems.

Accordingly, one aspect of the present invention provides a garment for at least partially supporting the bust of a user, the garment comprising: a cup region, the cup region having a lower edge and a cradle region below at least a part of the lower edge, the cup region and cradle region comprising inner and outer layers of material which are bonded to one another, a support element, formed from a polymer material, extending along at least a part of the lower edge of the cup region, but not extending into the cup region itself, the support element being held between the inner and outer layers of material; and a region of a support material, having an elasticity that is significantly less

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than that of the inner or outer layer of material, the support material being held between the inner and outer layers of material and extending along an outer portion of the cup region, which lies, in use of the garment, furthest from the wearer's sternum.

Advantageously, the support material is attached to the support element.

Preferably, the cup region comprises a high point, which is adapted to be attached to a shoulder strap of the garment, and wherein the support material extends to, or near to, the high point.

Conveniently, the support material does not cover the peak of the cup region.

Advantageously, a layer of a stiffening material is provided between the inner and outer layers of material over at least a part of the cradle region

Preferably, the support element is moulded.

Conveniently, the support element is formed from a silicone polymer.

Advantageously, the width and/or depth of the support element varies over its length.

Preferably, the width and/or depth of the support element is greater in a region at or near one end of the support element.

Conveniently, the inner layer of material is substantially unitary and does not comprise any seams or joins.

Advantageously, the garment is a bra.

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Another aspect of the present invention provides a method of forming a garment for at least partially supporting the bust of a user, the method comprising the steps of: providing inner and outer layers of material which define a cup region having a lower edge and a cradle region below at least a part of the lower edge; providing a support element formed from a polymer material; placing the support element between the inner and outer layers of material so that the support element extends along at least a part of the lower edge of the cup region, but does not extend into the cup region itself; providing a region of a support material having an elasticity that is significantly less than that of the inner or outer layer of material; placing the support material between the inner and outer layers of material so that it extends along an outer portion of the cup region which lies, in use, of the garment, further from the wearer's sternum; and bonding the inner and outer layers of material together, so that the support element and support material are held in place between the inner and outer layers of material.

Advantageously, the method further comprises the step of attaching the support material to the support element.

Preferably, the cup region comprises a high point, which is adapted to be attached to a shoulder strap of the garment, further comprising the step of placing the support material between the inner and outer layers of materials that the support material extends to, or near to, the high point.

Conveniently, the step of placing the support material between the inner and outer layers of material comprises placing the support material so that it does not cover the peak of the cup region.

Advantageously, the method further comprises the step of providing a layer of stiffening material between the inner and outer layers of the material of at least a part of the cradle region.

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Preferably, the method further comprises the step of moulding the support element.

Conveniently, the method further comprises the step forming the support element from a silicone polymer.

Conveniently, the garment is a bra.

A further aspect of the present invention provides a garment for at least partially supporting the bust of a user, the garment comprising: a cup region, the cup region having a lower edge and a cradle region below at least a part of the lower edge, the cup region and cradle region comprising inner and outer layers of material which are bonded to one another, and a support element, formed from a polymer material, extending along at least a part of the lower edge of the cup region, but not extending into the cup region itself, the support element being held between the inner and outer layers of material.

Another aspect of the present invention provides a garment for at least partially supporting the bust of a user, the garment comprising: a cup region, the cup region having a lower edge, the cup region comprising inner and outer layers of material which are bonded to one another, and a support element, formed from a polymer material, extending along at least a part of the lower edge of the cup region, but not extending into the cup region itself, the support element being held between the inner and outer layers of material.

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In order that the present invention may be more readily understood, embodiments thereof will now be described, now way of example, with reference to the company drawings, in which:

Figure 1 is a schematic view of a part of a bra embodying the present invention;

Figures 2 and 3 show a support element for use with the present invention; and

Figure 4 shows a cutaway view through the bra of figure 1.

Referring firstly to figure 1, a portion 1 of a bra embodying the present invention is shown.

The portion 1 includes a cup region 2, which is shaped to receive and hold a breast of a wearer (in the orientation shown in figure 1, the left breast). Immediately beneath the cup region is a cradle region 3, which is preferably generally planar and adapted to lie substantially flat against the chest of the wearer, in the region immediately below the wearer's bust. The cradle region 3 surrounds a lower edge 22 of the cup region 2.

The cradle region 3 has an inner edge 5 which will, when the bra is worn, lie on or near the sternum of the wearer. The inner edge 5 will, in a finished article, be connected directly or indirectly to, or be formed integrally with, the cradle region associated with the opposing cup of the bra.

The cradle region 3 also has an outer edge 6 which will, in use, lie in the region generally under the armpit of the wearer. The outer edge 6 will, in a finished article, be directly or indirectly attached to, or formed integrally with, a

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back strap of the bra. It should be noted, however, that the invention may also be used with backless bras of various designs.

In the embodiments shown in figure 1, the outer edge 6 of the cradle region 3 is wider than the inner edge 5 thereof.

The cup region 3 extends to a high point 4. In a finished bra, the high point 4 will be connected directly or indirectly to, or formed integrally with, a shoulder strap of the bra. Embodiments of the invention may also be used with strapless bras, however, and in this case the upper edge 7 of the cup region 2 will extend across from the inner edge 5 to the outer edge 6 of the cradle region 3, following a suitable line.

The construction of the portion 1 of the bra will be discussed in more detail below.

The portion 1 is formed from inner and outer layers of material. In preferred embodiments of the invention the inner and outer layers are formed from a foam material, in particular polyurethane (PU) foam. The inner and outer layers may, however, be made from any other suitable material, and the skilled person will understand which materials will be appropriate for this purpose.

In preferred embodiments the inner surface of the inner layer or material (i.e. the layer that will, primarily, lie against the body of the wearer) is formed from a soft, smooth material. In preferred embodiments, at least the inner layer of material of the portion 1 is a single, integral sheet of material, having substantially no seams or joins therein that would lie against the body of the wearer. Still more preferably, both the inner and outer layers are formed as single, integral sheets of material.

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As the first step in the manufacturing process, the inner and outer layers of material are cut to a correct, or approximately correct, shape.

A support element 8 is provided, as shown schematically in figure 2. The support element 8 generally comprises an elongate, curved element which generally corresponds in shape to the shape of the join between the lower edge 22 of the cup region 2 and the upper edge of the cradle region 3. The support element 8 may therefore generally take the shape of a lopsided "U".

The support element 8 is formed from a material which is resilient, and which will return to its initial shape after deformation. However, the support element 8 is formed from a material which is softer and less rigid than the metal wires used in underwired bras. Preferably the support element 8 is formed from a polymer material, most preferably from a silicone polymer material.

Figure 3 shows an enlarged cross-sectional view of the support element 8. In the embodiments shown, the support element 8 has a generally planar inner side 9, which will, in use, face the body of the wearer. On the outer side 10 of the support element 8, a bulge 11 is provided, and this may give the support element 8 a substantially "D" shape in cross-section. This shape allows the support element 8 to be relatively deep (in the direction passing from the inner side 9 to the outer side 10), thus increasing the strength of the support element 8, whilst retaining a high level of comfort for the wearer.

The support element 8 is preferably at least partially surrounded by protective fabric. In some embodiments inner and outer layers of fabric may be placed against the inner and outer sides 9, 10 of the support element 8. Alternatively, a single layer of fabric may be wrapped all the way around the support element 8. Adhesive is then applied to outer surfaces of the protective fabric. The support element 8 is then placed on the inner layer of material, so that it lies substantially along, or is just underneath, at least a part of the join

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between the lower edge 22 of the cup region 2 and the cradle region 3, but preferably does not extend into the cup region 2 itself. It will therefore be understood that the support element 8 occupies generally the same location as a wire of a conventional underwired bra.

A region of support fabric 12 is provided. The support fabric 12 is formed from a material which is flexible, but is significantly less elastic than the upper and lower layers of material that form the portion 1 of the bra. In preferred embodiments the support fabric 12 comprises a knitted or woven fabric, and is also preferably formed from polyester. The region of support fabric 12 has a lower edge 13 which corresponds generally in shape to the region of the support element 8 that lies nearest the outer edge 6 of the portion 1. The remainder of the region support fabric 12 is generally shaped to cover an outer part of the cup region 2 (i.e. a part of the cup region 2 which, in use, will lie furthest from the user's sternum), extending up to the high point 4 of the cup region 2. In the depicted example, the shape of the support fabric can be seen in figure 1.

The region of support fabric 12 is also placed on the inner layer of material, so that the lower edge 13 thereof lies on or near the support element 8. In preferred embodiments of the invention, the support fabric 12 is bonded at or near its lower edge 13 to the support element 8. Preferably, the support fabric lies outwardly of the central point of the cup region 2 (i.e. the "peak" of the cup).

As an optional further step, a region of relatively stiff material is placed over the cradle region 3 of the inner layer of material. The relatively stiff material may, for instance, comprise highly compressed silicone, or may be another material entirely such as plastic, card or a stiff woven fabric. The relatively stiff material may be knitted or woven polyester, as is the case for the support fabric 12.

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The outer sheet of material is then placed over the inner sheet of material, and over the support element 8, support fabric 12, and the region of stiffening material (if used). The inner and outer layers of fabric are then placed between inner and outer moulding elements, which are generally in the shape of a breast of approximately the appropriate size for the bra - it is envisaged that at least each different cup size of bra will have a template for the correct shape for the upper and lower layers of material, the support element 8 and region of support fabric 12, and also a mould of an appropriate size and shape.

The components are bonded together as they are moulded, for instance through the presence of an adhesive which is provided on the inner surfaces of the layers of material. In preferred embodiments the adhesive is a heat-activated adhesive, so that components can be handled and assembled with relative ease prior to the moulding process.

Figure 4 shows a schematic cut-away view of the portion 1, taken along the line indicated by reference letter L in figure 1. This view shows the upper and lower layers of material 13, 14. In a first region 15, corresponding to the majority of the cup region 2, the upper and lower layers 13, 14 are bonded directly to one another.

In a second region 16, the support fabric 12 is bonded in position between the upper and lower layers 13, 14.

In a third region 17 the support element 8 is surrounded by upper and lower layers 18, 19 of protective fabric, and held in place between the upper and lower layers 13, 14 of material. In this example the support fabric 12 is attached to the support element 8.

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In a fourth region 20, corresponding to the cradle region 3, a layer of stiffening material 21 is bonded in place between the upper and lower layers 13, 14.

During the moulding process, the cradle region 3 may be placed under a higher level of compression than the cup region 2. This will help the cradle region 3 to be of a relatively high stiffness, to provide additional support. This higher level of compression may be in addition to, or instead of, the use of a stiffening material in the cradle region 3. It will be understood that this may be achieved by reducing the distance between the inner and outer moulding elements in the cradle region 3, as compared to the distance between the moulding elements for other parts of the portion 1 of the bra.

The region of the support fabric 12 may also be placed under a higher level of compression than the remainder of the cup region 2, and this will help to provide additional stiffness and support for the outer side of the cup region 2.

In preferred embodiments of the invention, the support element 8 is held in place with respect to the inner and outer layers of material 13, 14 solely through adhesive, and/or fusion of components during the moulding process, and without the use of stitching. This will increase the smoothness and comfort of the inner surface of the bra.

Once the moulding process has been completed, the portion 1 is ready to be attached to other components to form a finished bra. Straps and other fasteners may be added, as well as decorative elements such as lace trim, as will be understood by those skilled in the art.

The combination of the support element and support fabric will allow the bra to produce styles and shapes similar to those that can be achieved using underwiring, in particular for larger cup sizes. The support element 8 will provide a structural member to allow a desired shape to be created, and the

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support fabric will reduce the "give" on the outer side of the cup region, thus encouraging the wearer's bust to be lifted and to be directed forward rather than outwards. The bra overall will, however, be softer and more comfortable than conventional underwired bras, and the layer immediately opposing the skin of the wearer can be substantially smooth. The bra will therefore be more comfortable, particularly when worn for prolonged periods.

If the support element 8 is formed from a polymer material, the support element 8 can be moulded, and this gives increased flexibility in selecting the shape and form of the support element 8, compared to the wires used in conventional underwired bras. For instance, the thickness and/or depth of the support element 8 may be increased in regions where the greatest strain is likely to be placed on the support element 8, for instance in the regions around one or both of the ends of the support element 8. The support element 8 can be thinner in other regions, however, thus reducing the overall size, cost and bulkiness of the bra.

In certain embodiments, the bra may include filler elements to enhance the overall shape and/or size of the wearer's bust. Filler elements of this type are usually positioned within the cup of the bra, adjacent the lower and outer side of each breast. The filler elements may, in some embodiments, be attached to, or formed integrally with, the support element. In such embodiments, however, the filler element is not to be interpreted as forming all or any part of the support element.

In the above discussion of the construction of the bra, it is stated that various components are placed on the inner layer of material 13, and the outer layer of material 14 is subsequently placed over the lower layer 13 and the components. However, the construction need not be carried out in this order, and the various elements of the bra may be assembled in any practical order and using any suitable method.

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Embodiments of the present invention will provide comfortable, practical and stylish garments that will provide a welcome alternative to underwired bras. The invention is not limited to bras, however, and may be applied equally to swimwear such as bikini tops and one-piece swimsuits, and tops which include "built-in" bras. The invention may be applied to any garment which is required to fulfil the function of at least partially supporting the bust of a user.

When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

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Claims

1. A garment for at least partially supporting the bust of a user, the garment comprising:

a cup region, the cup region having a lower edge and a cradle region below at least a part of the lower edge, the cup region and cradle region comprising inner and outer layers of material which are bonded to one another,

a support element, formed from a polymer material, extending along at least a part of the lower edge of the cup region, but not extending into the cup region itself, the support element being held between the inner and outer layers of material; and a region of a support material, having an elasticity that is significantly less than that of the inner or outer layer of material, the support material being held between the inner and outer layers of material and extending along an outer portion of the cup region, which lies, in use of the garment, furthest from the wearer's sternum.

2. A garment according to claim 1, wherein the support material is attached to the support element.

3. A garment according to claim 1 or 2 wherein the cup region comprises a high point, which is adapted to be attached to a shoulder strap of the garment, and wherein the support material extends to, or near to, the high point.

4. A garment according to any preceding claim wherein the support material does not cover the peak of the cup region.

5. A garment according to any preceding claim wherein a layer of a stiffening material is provided between the inner and outer layers of material over at least a part of the cradle region

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6. A garment according to any preceding claim wherein the support element is moulded.

7. A garment according to any preceding claim wherein the support element is formed from a silicone polymer.

8. A garment according to any preceding claim wherein the width and/or depth of the support element varies over its length.

9. A garment according to claim 8, wherein the width and/or depth of the support element is greater in a region at or near one end of the support element.

10. A garment according to any preceding claim wherein the inner layer of material is substantially unitary and does not comprise any seams or joins.

11. A garment according to any preceding claim, wherein the garment is a bra.

12. A method of forming a garment for at least partially supporting the bust of a user, the method comprising the steps of:

providing inner and outer layers of material which define a cup region having a lower edge and a cradle region below at least a part of the lower edge;

providing a support element formed from a polymer material;

placing the support element between the inner and outer layers of material so that the support element extends along at least a part of the lower edge of the cup region, but does not extend into the cup region itself;

providing a region of a support material having an elasticity that is significantly less than that of the inner or outer layer of material;

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placing the support material between the inner and outer layers of material so that it extends along an outer portion of the cup region which lies, in use, of the garment, further from the wearer's sternum; and bonding the inner and outer layers of material together, so that the support element and support material are held in place between the inner and outer layers of material.

13. A method according to claim 12, further comprising the step of attaching the support material to the support element.

14. A method according to claim 12 or 13, wherein the cup region comprises a high point, which is adapted to be attached to a shoulder strap of the garment, further comprising the step of placing the support material between the inner and outer layers of materials that the support material extends to, or near to, the high point.

15. A method according to any one of claims 12 to 15 wherein the step of placing the support material between the inner and outer layers of material comprises placing the support material so that it does not cover the peak of the cup region.

16. A method according to any one of claims 12 to 15, further comprising the step of providing a layer of stiffening material between the inner and outer layers of the material of at least a part of the cradle region.

17. A method according to any of claims 12 to 16, further comprising the step of moulding the support element.

18. A method according to any one of claims 12 to 17, further comprising the step forming the support element from a silicone polymer.

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19. A method according to any one of claims 12 to 18, wherein the width and/or depth of the support element varies over its length.

20. A method according to any one of claims 12 to 19, wherein the width and/or depth of the support element is greater in a region at or near one end of the support element.

21. A method according to one of claims 12 to 20, wherein the garment is a bra.

22. A bra substantially as hereinbefore described, with reference to the accompanying drawings.

23. A method substantially as hereinbefore described, with reference to the accompanying drawings.

24. Any novel feature or combination of features disclosed herein.