BRAS, INSERTS, AND UNDERWIRES, AND METHODS OF FORMING SUCH BRAS, INSERTS, AND UNDERWIRES

Abstract

An insert configured to modify an appearance of a breast comprises a flexible bladder comprising a gelatinous elastomer and a flowable material disposed within the flexible bladder. A bra may comprise at least one insert and a shell configured to cover the breast and the at least one insert. An underwire comprises an elongated body comprising an elastomeric material having a Shore A durometer hardness of about 1 or greater. A shell may be connected to the underwire and configured to cover a breast. A method of forming a bra comprises forming an underwire and securing the underwire to a shell. Another method of forming a bra comprises forming a flexible bladder comprising a gelatinous elastomer, disposing a flowable material within the flexible bladder to form an insert, and securing the insert to a shell.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/402,562, filed Sep. 1, 2010, entitled “Brassiere Elements,” the disclosure of which is incorporated herein by reference in its entirety.

FIELD

Embodiments of the disclosure relate generally to elements of brassieres, and to methods of making and using such elements. Some, but not all, embodiments of these elements comprise gelatinous elastomers.

BACKGROUND

Brassieres (hereafter “bras”) are articles of clothing. Bras may be independent articles or may be built into other articles of clothing. For example, bras may be articles of underclothing, swim suits, corsets, t-shirts, or dresses. Bras may be intended to perform one or more of the following functions: cover, support, shape, disguise the shape of, and/or elevate the breast(s) of the wearer. Improvements in covering, supporting, shaping, disguising of the shape of, and/or elevating the breast(s) may be desirable. Furthermore, it would be desirable to improve the comfort of the bra wearer, protect the skin of the bra wearer, and make the bra less noticeable to others or to the wearer.

BRIEF SUMMARY

In some embodiments, the present disclosure includes a bra comprising at least one insert configured to modify an appearance of a breast and a shell configured to cover the breast and the at least one insert. The insert comprises a flexible bladder comprising a gelatinous elastomer and a flowable material disposed within the flexible bladder.

In other embodiments, the disclosure includes an insert configured to modify an appearance of a breast, the insert comprising a flexible bladder comprising a gelatinous elastomer and a flowable material disposed within the flexible bladder.

In some embodiments, a bra comprises an underwire comprising an elastomeric material having a Shore A durometer hardness of about 1 or greater and a shell connected to the underwire and configured to cover at least one breast.

In other embodiments of the disclosure, an underwire for a bra comprises an elongated body comprising an elastomeric material having a Shore A durometer hardness of about 1 or greater.

In certain embodiments, a method of forming a bra comprises forming an underwire comprising an elastomeric material and securing the underwire to a shell configured to cover at least one breast. The elastomeric material has a Shore A durometer hardness of about 1 or greater.

In other embodiments, a method of forming a bra comprises forming a flexible bladder comprising a gelatinous elastomer, disposing a flowable material within the flexible bladder to form an insert configured to modify an appearance of a breast, and securing the insert to a shell configured to cover the breast.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of this disclosure may be more readily ascertained from the following description of example embodiments of the disclosure provided with reference to the accompanying drawings, in which:

FIG. 1 is a simplified drawing illustrating a bra;

FIGS. 2 through 4 are simplified cross-sections illustrating materials that may be used to form bra cups;

FIGS. 5 through 7 are simplified top view drawings illustrating underwires;

FIGS. 8 through 13 are simplified cross-sections illustrating underwires coupled to bra cups;

FIGS. 14 and 15 are simplified cross-sections illustrating inserts coupled to bra cups;

FIG. 16 is a simplified top view illustrating an insert;

FIG. 17 is a simplified cross-section illustrating materials that may be used to form straps; and

FIGS. 18 and 19 are simplified perspective views illustrating clasps.

DETAILED DESCRIPTION

As used in this disclosure and the claims, the term “bra” means and includes any article of clothing configured for covering and/or supporting a wearer's breasts. Though the figures show and the disclosure describes a women's undergarment, commonly referred to as a “brassiere,” the embodiments herein may be used in other garments, such as sports bras, swimwear, bikini tops, camisoles, lingerie, clothing with built-in-bras or other breast supports, etc. Such garments may or may not be worn under other clothing.

As used herein, the term “elastomeric polymer” means and includes a polymer capable of returning to its original shape after deformation. In other words, an elastomeric polymer is a polymer having elastic properties. Elastomeric polymers may also be referred to as “elastomers” in the art. Elastomeric polymers include homopolymers (polymers having a single chemical unit repeated) and copolymers (polymers having two or more chemical units). Elastomeric polymers may have linear or ring architecture. The polymer backbone may or may not be branched.

As used herein, the term “elastomeric material” means and includes any material having elastomeric properties. Elastomeric materials may include elastomeric polymers, as well as mixtures of elastomeric polymers and other substances.

As used herein, the term “plasticizer” means and includes a substance added to another material (e.g., to an elastomeric polymer) to increase a workability of the material. For example, a plasticizer may increase the flexibility or softness of the material. Plasticizers may include hydrocarbon fluids, such as mineral oils. Hydrocarbon plasticizers may be aromatic or aliphatic.

As used herein, the term “gelatinous elastomer” means and includes a mixture of an elastomeric polymer and a plasticizer that when deformed in compression comes back to its original shape, that under tension can be stretched to many times its original size but still comes back to its original size and shape, that is rubbery in feel but can deform to the shape of an object applying a deforming pressure better than typical rubber materials, and that has a durometer hardness lower than typical rubber materials. Gelatinous elastomers are, by definition, elastomeric materials. Gelatinous elastomers are described, for example, in U.S. Pat. No. 5,749,111, issued May 12, 1998 and titled “Gelatinous Cushions with Buckling Columns;” U.S. Pat. No. 6,026,527, issued Feb. 22, 2000 and titled “Gelatinous Cushions with Buckling Columns;” U.S. Pat. No. 5,994,450, issued Nov. 30, 1999 and titled “Gelatinous Elastomer and Methods of Making and Using the Same and Articles Made Therefrom;” and U.S. Pat. No. 6,797,765, issued Sep. 28, 2004 and titled “Gelatinous Elastomer,” the disclosure of each of which is are incorporated herein in its entirety by this reference. For example, gelatinous elastomers have a Shore A durometer hardness of less than 1 up to about 50, whereas typical rubber materials have a Shore A durometer hardness of from about 55 to 100. The term “elastomeric gel” may be used synonymously with “gelatinous elastomer” in the art.

As used herein, the term “flexible bladder” means and includes a material that can adapt under pressure to the shape of an object in contact therewith and that defines an enclosed volume. Flexible bladders generally include sewn or woven fabrics, plastics such as thermally welded plastic films, which may include polyurethane, polyethylene or polyvinyl chloride, or another material that is flexible. A flexible bladder may also be formed of a gelatinous elastomer.

As used herein, the phrase “melt mass-flow rate” (MFR) means a melt mass-flow rate as determined according to ISO 1133 (“Plastics-Determination of the Melt Mass-Flow Rate (MFR) and the Melt Volume-Flow Rate (MVR) of Thermoplastics,” International Organization for Standardization, Geneva, Switzerland, 2005) when tested at 230° C. with a 2.16 kg mass.

As used herein, the term “gel putty” means and includes a mixture of an elastomeric polymer and a plasticizer, a volume of which may be rejoined and healed after being parted. As used herein, “healing” means and includes becoming a unified or integrated mass. Two portions of gel putty that are placed adjacent one another may become a single mass, and the boundary between the two portions may become obscured. When a force is applied on the single mass, the mass may part in a different location than the boundary between the original two portions. Gel putties are described in more detail in U.S. patent application Ser. No. 13/098,182, titled “Gel Putties, Articles Comprising Same, and Methods of Forming Such Gel Putties and Articles,” filed Apr. 29, 2011, the disclosure of which is incorporated herein in its entirety by reference.

The illustrations presented herein are not actual views of any particular material or device, but are merely idealized representations employed to describe embodiments of the present disclosure. Elements common between figures may retain the same numerical designation.

A bra 100 is shown in FIG. 1. The bra 100 includes cups 102 (a portion or portions that cover the breasts), one or more straps 104, and one or more bands 105. The straps 104 may be configured to wrap over the shoulders and the bands 105 may be configured to wrap around the torso to the back of the wearer. The straps 104 and/or bands 105 may have one or more clasps 106 and/or clasp receiving mechanisms 107 to secure the straps 104 and/or bands 105 together. The clasp receiving mechanisms may be integral to the strap 104 or band 105 (e.g., a loop of the material of the strap 104 or band 105). In other embodiments (not shown), straps 104 or bands 105 may be permanently affixed to one another, or a single band 105 may be affixed to the cups 102, such that clasps 106 are unnecessary. The bra 100 may have a connector 108 to secure the cups 102 to one another. The connector 108 may include a strap 104 and/or a clasp 106 and clasp receiving mechanism 107. The cups 102 may alternatively be attached directly to one another (not shown) without a distinct connector 108. In some embodiments (not shown), the bra 100 may include a one-piece shell that covers both breasts and includes the cups 102. The bra 100 may include an underwire 110 along or below the cups 102 to provide additional support for and/or shaping of the breasts.

The cup 102 of the bra 100 may be a shell formed by layering a polyurethane cushioning foam between two fabrics. The assembly may be compressed with heat at or near the degradation temperature of the foam. The heat may fuse the foam into fabrics that are on either side of the foam, producing a permanently compressed, firmer foam and foam-infused fabric.

In some embodiments of the present disclosure, a different material may be substituted for the foam to form a more natural-feeling bra cup. For example, a cup 102 may be a shell formed from a flexible material 122 fused, sewn, or quilted to a fabric 124, as shown in FIGS. 2 through 4. The flexible material 122 may be an elastomeric polymer, a gelatinous elastomer, or other flexible material. The fabric 124 may be attached to one side (FIG. 2) or both sides (FIG. 3) of the flexible material 122 and/or within the flexible material 122 (FIG. 4). The flexible material 122 may be, for example, a material having a durometer hardness of about 1 or lower on the Shore A scale, a material having a durometer hardness of about 1 to about 10 on the Shore A scale, a material having a durometer hardness of about 10 to about 25 on the Shore A scale, or a material having a durometer hardness of about 25 or higher on the Shore A scale (e.g., about 25 to about 100). Such ranges may be referred to using respective terms such as “very soft,” “soft,” “medium,” and “firm.”

Gelatinous elastomers that may be used to form a cup 102 (FIG. 1) or a component of a cup 102 may comprise up to about 30 parts by weight of a plasticizer to one part of an elastomeric polymer. The plasticizer may include, for example, a hydrocarbon fluid, such as mineral oil. For example, a plasticizer may include aromatic-free food-grade white paraffinic mineral oils, such as those sold by Sonneborn, Inc., of Mahwah, N.J., under the trade names BLANDOL® and CARNATION®. The plasticizer may include any other material that at least partially associates with a mid-block of the elastomeric polymer.

The elastomeric polymer may include, for example, an elastomeric block copolymer such as a triblock copolymer, a diblock copolymer, a branched copolymer (e.g., a star copolymer), etc. Elastomeric polymers may include A-B-A triblock copolymers such as styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS). Elastomeric polymers may have densities from about 0.7 g/cm³ to about 1.5 g/cm³. For example, an elastomeric polymer in some embodiments may have a density from about 0.8 g/cm³ to about 1.0 g/cm³, or more particularly, about 0.9 g/cm³. The elastomeric polymer may have a melt mass-flow rate (MFR) in a range below about 100 g/10 min or below about 2 g/10 min. The elastomeric polymer may have a tensile strength at yield, as determined according to ISO 37 (“Rubber, Vulcanized or Thermoplastic-Determination of Tensile Stress-Strain Properties,” International Organization for Standardization, Geneva, Switzerland, 2005) or ASTM Standard D412 (“Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers,” ASTM Intl, West Conshohocken, Pa., 2006), from about 1 MPa (145 psi) to about 30 MPa (4350 psi). For example, an elastomeric polymer in some embodiments may have a tensile strength at yield from about 5 MPa (725 psi) to about 20 MPa (2900 psi). The elastomeric polymer may have a tensile elongation at break, tested according to ISO 37, from about 200% to about 1000%. For example, an elastomeric polymer in some embodiments may have a tensile elongation at break from about 400% to about 800%. In some embodiments, the elastomeric polymer may have a styrene (e.g., polystyrene) content from about 10 wt % to about 70 wt %, or from about 10 wt % to about 40 wt %. In further embodiments, elastomeric polymers may have a styrene content from about 20 wt % to about 35 wt %. For example, A-B-A triblock copolymers are currently commercially available from Kuraray America, Inc., of Houston, Tex., under the trade name SEPTON® 4055, and from Kraton Polymers, LLC, of Houston, Tex., under the trade name KRATON® G1651. In these examples, the “A” blocks are styrene. Elastomeric polymers other than styrene-based copolymers may also be used, such as elastomeric polymers that are thermoplastic in nature or that can be solvated by plasticizers. Elastomeric polymers may have a molecular weight (MW) of about 180,000 g/mol or higher, a MW from about 80,000 to about 180,000 g/mol, or a MW of about 80,000 g/mol or lower. Such ranges may be referred to using terms such as “high,” “medium,” and “low,” respectively.

A gelatinous elastomer may be formed by mixing the elastomeric polymer and the plasticizer by any means through which heat and agitation or shearing may be applied. For example, the elastomeric polymer and the plasticizer may be mixed in a heated stirring pot or a heated extrusion screw. In some embodiments, the agitation or shearing may provide energy to heat the materials as mixing occurs (i.e., a separate heat source may not be necessary).

A gelatinous elastomer may optionally include a filler. Fillers may be solid and may or may not contain voids. Voids, if present, may be filled with gases, liquids, phase change materials, or any other substance. Fillers may be spherical or any other appropriate shape. Fillers may include, for example, talc, silica (e.g., fumed silica), hollow or solid microspheres (i.e., approximately spherical particles having a mean diameter of less than about 1,000 microns), or pearlite. Gelatinous elastomers comprising fillers may exhibit different properties (e.g., density, viscosity, modulus of elasticity, shrinkage, thermal conductivity, heat capacity, etc.) than gelatinous elastomers not comprising fillers. Properties of the gelatinous elastomer may vary based on the quantity and type of fillers. Fillers may have bulk densities, for example, of 3 g/cm³ or lower, about 1 g/cm³ or lower, about 0.5 g/cm³ or lower, about 0.2 g/cm³ or lower, or even about 0.1 g/cm³ or lower. For example, fillers may have a bulk density of about 0.015 g/cm³, such as the ultra-light hollow acrylic microspheres currently available from Eka Chemicals AB, of Sundsvall, Sweden, under the trade name EXPANCEL®. Gelatinous elastomers may include up to about 85 wt % fillers. For instance, a gelatinous elastomer may include about 1 wt % to about 50 wt % filler, or from about 20 wt % to about 33 wt % filler. The filler may include, by way of example, but not limitation, EXPANCEL® 909 DET 80d15 hollow acrylic microspheres.

A gelatinous elastomer may optionally include one or more antioxidants. Antioxidants may reduce the effects of thermal degradation during processing or may improve long-term stability. Antioxidants include, for example, octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate, commercially available as IRGANOX® 1076, from BASF Corp., of Iselin, N.J. The use of antioxidants in mixtures of plasticizers and polymers is described in U.S. Pat. No. 5,994,450, the disclosure of which has been previously incorporated herein by reference. Gelatinous elastomers may include up to about 20 wt % antioxidants. For instance, the non-filler portion of a gelatinous elastomer may include about 0.5 wt % of an antioxidant, melt-blended together in an injection molding screw or by any other means of blending.

An example of a gelatinous elastomer includes one part A-B-A triblock copolymer (e.g., SEEPS, such as SEPTON® 4055 or SEBS, such as KRATON® G1651) and 12 parts of a white food grade paraffinic mineral oil, free of aromatic content and having a kinematic viscosity at 100° F. of from about 10.8 mm²/s to about 13.6 mm²/s (e.g., CARNATION® mineral oil). An antioxidant (e.g., IRGANOX® 1076) may be combined with this mixture so that the combination includes 0.5 wt % antioxidant. A filler (e.g., EXPANCEL® 909 DET 80d15 hollow acrylic microspheres) may be added to the combination such that the final gelatinous elastomer comprises 30 wt % filler.

To form a cup 102 for a bra 100, flexible material 122 may be injection molded or otherwise provided into a cavity that is of the dimensions of the desired cup 102. One or more pieces of fabric 124 may optionally be placed into the cavity before providing the flexible material 122 in the cavity. For example, two pieces of fabric 124 may be placed on opposing sides of a mold (not shown).

The flexible material 122 may fuse into or onto any layers of fabric 124 so that the layers are on the exterior of, or within, the flexible material 122. The fabric 124 that is beyond the borders of the flexible material 122, if any, may easily be sewn into or onto other items such as a strap 104, a band 105, a connector 108, or another cup 102. In some embodiments, one or more fibers may pass through a portion of the flexible material 122 to attach the flexible material 122 directly to other items.

The flexible material 122 may be allowed to cool and may at least partially solidify within the mold. The assembly of the flexible material 122 may be removed from the mold, along with any fabric 124 attached thereto.

A filler, if optionally used, may include a material that is or may be expanded to increase its specific volume. A filler may be heated to a temperature at which its specific volume is higher than its specific volume at a reference temperature. For example, microspheres may have a liquid blowing agent disposed inside a shell. When heated, the shell may soften and the blowing agent may turn from liquid to gas, enlarging the shell. The shell may remain expanded, and may therefore retain its higher specific volume, even after it cools. The filler may pre-expanded and added to a mixture of ingredients before or after melting, or may be added in a partially expanded or unexpanded form. If added in a partially expanded or unexpanded form, the filler may expand when the mixture is heated to a blowing temperature of the filler (i.e., a temperature at which the specific volume of the filler increases). Expanding the filler when the mixture is heated may raise pressure of the flexible material 122 and may provide a force to fill the cavity and/or any fabrics 124. The use of microspheres may be desirable in some embodiments because microspheres may promote filling the cavity and because the microspheres may reduce the weight of the flexible material 122, (which may be desirable characteristics for some bras). However, the addition of microspheres may stiffen the flexible material 122 (increase its durometer hardness), and stiffening effects should be considered when selecting a formulation for the flexible material 122. For some applications, it may be advantageous to start with a lower durometer (softer) formulation of flexible material 122 so that any stiffening effect of the filler yields the desired final modulus of elasticity.

In some embodiments, the fabric 124 may be breathable to limit or reduce sweating of the breast and the surrounding area of skin. To maintain the breathability of the fabric 124, the flexible material 122 may, in some embodiments, fuse only partially through the fabric 124. By way of non-limiting example, spacer fabrics or breathable elastic knit fabrics may be fused to an inner side of the cup 102. Breathability may also be increased by using a mold having features configured to form holes through the flexible material 122 and/or the fabric 124, thus retaining some breathability of the fabric 124. Such holes may allow vapor and heat to escape from the skin while the bra 100 is worn. In some embodiments, holes may be formed (e.g., punched, drilled, etc.) through the flexible material 122 and/or the fabric 124 in a post-molding procedure.

In one example, the flexible material 122 may be formed by the principles and in the configurations described in U.S. Pat. No. 5,749,111 and U.S. Pat. No. 6,026,527, the disclosures of each of which have been previously incorporated herein by reference. For instance, hollow breathable buckling columns may be formed of a flexible material 122.

In another example, the flexible material 122 may be formed by the principles and in the configurations described in U.S. patent application Ser. No. 12/287,057, filed Oct. 3, 2008 and titled “Ribbed Gel,” which is hereby incorporated herein in its entirety by reference. As an illustration of one embodiment, and not by way of limitation, the flexible material 122 may comprise two layers of spaced-apart ribs, each formed of an elastomeric polymer, gelatinous elastomer, or other flexible material. One rib may be disposed atop the other, with the ribs in the top layer running at an angle to the ribs in the bottom layer, and the two layers being integral at the points where the ribs intersect.

As shown in FIG. 1, some bras may include an underwire 110 in the form of a metal (e.g., steel or nickel titanium) or a plastic wire or strip. Underwires may have hard plastic coatings such as nylon (polyamide) on each end, and may be encased in a fabric sleeve. An underwire may be located at the bottom and/or sides of a bra cup. An underwire may be configured to be disposed underneath and supporting one or both breasts of the bra wearer. A bra may have two underwires—one configured to be disposed under each breast. Underwires may provide shaping to the bra cup or the breast and/or alter the shape of the breast by shaping the bra cup along the line of the underwire. For example, an underwire may make one breast appear to be approximately the same size as the other breast (even if it is not the same size), and/or may give a more attractive or desirable shape to one or both breasts. Underwires may provide support of the breasts. Such support may be especially valuable for relatively large breasts and for breasts in motion due to walking, running, or other activity. Underwires may help lift and/or separate the breasts, such as by promoting a “push-up” effect of some bras to increase cleavage.

Underwires of the present disclosure may be used to alleviate or prevent conditions that may be associated with metal underwires, such as pain, infection, and allergic reactions to the metal. Underwires of the present disclosure may also be used to avoid inconvenience associated with metal underwires, such as extra scrutiny at security checkpoints (e.g., metal detectors in airports, courthouses, prisons, etc.) Underwires of the present disclosure may be used to alleviate or lessen discomfort due to stress points on the skin of the wearer associated with the underwire's geometry and rigidity. Underwires of the present disclosure may avoid irritation or injury associated with a metal underwire's piercing through its encapsulation and poking the skin of the wearer. Conventional plastic underwires, though avoiding some of the problems of metal underwires, generally do not provide the same support and rigidity offered by metal underwires.

As shown in FIG. 5, an underwire 150 may include a rigid elongated member 152 encapsulated by a coating 154. The coating 154 may include, for example, a gelatinous elastomer or other elastomeric material. The rigid elongated member 152 may include a metal, a plastic, or another material more rigid than the material of the coating 154. The underwire 150 may run along the bottom and side of one or both bra cups, such as underwire 110 shown in FIG. 1.

The rigid elongated member 152 may be completely encapsulated, as shown in FIG. 5. In some embodiments, shown in FIG. 6, an underwire 160 may include rigid elongated member 152 covered by a coating 154 only at the end portions 162, 164 of the rigid elongated member 152. The coating 154 may cushion the bra wearer from the rigidity of the rigid elongated member 152. Should the underwire 150, 160 break through the fabric of the bra 100, the coating 154 may prevent the rigid elongated member 152 from abrading, piercing, contusing, bruising, or otherwise irritating the skin of the wearer. The rigid elongated member 152 may be of any cross-sectional shape and may vary in cross-sectional shape along its length. The rigid elongated member 152 may be solid or may have perforations 166 therethrough in such a way that the coating 154 may be continuous from one side, such as a front side, of the rigid elongated member 152 through the perforations 166 to the other side (not visible) of the rigid elongated member 152, so as to secure the coating 154 to the rigid elongated member 152.

In one example, the coating 154 may be a gelatinous elastomer comprising up to 25 parts by weight of a plasticizer to one part of an elastomeric polymer. The plasticizer may include, for example, a hydrocarbon fluid, as described above. The elastomeric polymer may include, for example, an elastomeric block copolymer such as a triblock copolymer, a diblock copolymer, a branched copolymer (e.g., a star copolymer), etc., as described above. For example, the elastomer may include an oil-absorbing elastomer which forms a gelatinous elastomer or elastomer having a tensile strength of at least 15 pounds per square inch.

An example of a gelatinous elastomer that may be used to form a coating 154 includes one part A-B-A triblock copolymer (e.g., SEEPS, such as SEPTON® 4055) and six parts by weight white food grade paraffinic mineral oil free of aromatic content and having a kinematic viscosity at 100° F. of from about 10.8 mm²/s to about 13.6 mm²/s (e.g., CARNATION® mineral oil).

The coating 154 may be injection molded partially or completely around the rigid elongated member 152. The thickness of the coating 154 on or around the rigid elongated member 152 may vary along the length of the rigid elongated member 152, and may be thicker around the end portions 162, 164 of the rigid elongated member 152 to increase comfort and/or decrease the likelihood of injury. The cross-section of the coating 154 may be of any shape, and the cross-sectional shape of the coating 154 may vary along the length of the rigid elongated member 152. For example, the coating 154 may have a uniform thickness around the rigid elongated member 152, or may be thicker near one side of the rigid elongated member 152. The coating 154 may further comprise a filler, such as microspheres, described above. The filler may be expandable. The expandable filler, if optionally used, may be pre-expanded and added to a mixture used to form the coating 154, or may be added to the mixture in unexpanded form and allowed to expand when the mixture is heated, such as to a blowing temperature of the filler. If the filler is added to the mixture used to form the coating 154 in unexpanded form, the coating 154 may be pressurized into a cavity and/or fabric into which the underwire is molded or placed.

One advantage of a conventional steel bra underwire 110 is stiffness. Such stiffness may provide support, shaping, lifting, etc., of the breasts. Materials with a lower modulus of elasticity having the same dimensions may not provide sufficient support, shaping, lifting, etc. A firm elastomer or a firm gelatinous elastomer may be designed with geometries that may combine the stiffness of a steel underwire of standard size and shape with the comfort, safety, and convenience of plastic.

An underwire 170, as shown in FIG. 7, may be a rigid elongated member without a coating. The underwire 170 may be formed of an elastomer or a gelatinous elastomer. Such an underwire 170 without metal or a coating may be more comfortable, safe, and/or natural-feeling than conventional underwires or coated underwires 150, 160. In one embodiment, a gelatinous elastomer or other elastomeric material may be used as the underwire 170 without another more rigid material. To achieve an appropriate stiffness, the geometry of the underwire 170 may be modified from the geometry of conventional underwires. For example, a cross-section of the underwire 170 generally perpendicular to a major axis thereof may have any shape, such as circular, rectangular, triangular, etc. A person having ordinary skill in the art will recognize that underwires 170 with different cross-sectional shapes will have different stiffnesses. Furthermore, stiffness may be varied by varying the cross-sectional shape or cross-sectional dimensions along the length of the underwire 170. In some embodiments, cross-sectional dimensions (e.g., width, diameter, etc.) may be larger than dimensions of conventional metal or otherwise rigid underwires. In some embodiments, an underwire 170 may have a cross-sectional area of greater than about 10 mm² or larger, about 20 mm² or larger, or even about 30 mm² or larger.

For example, FIG. 8 shows a cross-sectional view of a cup 102 including an underwire 180 having a cross-section with such an increased dimension. The underwire 180 is approximately flat, spreading its support over a larger area of the cup 102, and therefore over a larger area of the breast of the wearer. By way of example, the underwire 180 may have a width W of about 5 mm or larger, about 10 mm or larger, or even about 20 mm or larger.

FIG. 9 shows a cross-sectional view of a cup 102 including another underwire 190 having a cross-section with an increased dimension. The underwire 190 has a portion of greater thickness 192 surrounded by portions of lesser thickness 194. The portion of greater thickness 192 may provide stiffness, and the portions of lesser thickness 194 may spread the support over a larger area of the cup 102 than conventional underwires. By way of example, the portion of greater thickness 192 may have a thickness T of about 2 mm or larger, about 4 mm or larger, or even about 6 mm or larger.

The underwires 180 and 190 may have greater static moments of inertia about a centerline of the underwires 180 and 190 than conventional underwires. Even though the material of underwires 180 and 190 may be less rigid than steel, the overall stiffness of the underwires 180 and 190 within the bra may be greater than the stiffness of a conventional steel underwire. That is, the loss in stiffness due to exchanging steel for an elastomeric material or gelatinous elastomer may be overcome by changing the geometry (size and/or shape) of the underwire 180 or underwire 190.

Underwires 170, 180, and 190 may be less likely to break through the fabric of the cups 102 to which they are attached than conventional underwires because the fabric surrounding the underwires 170, 180, and 190 may not be stressed as highly as the fabric surrounding conventional underwires. Underwires 170, 180, and 190 formed of an elastomer or gelatinous elastomer may be, in comparison with conventional underwires, less likely to abrade, pierce, bruise, contuse, or otherwise irritate the skin.

The underwires 170, 180, and 190 may be of any cross-sectional shape and may vary in cross-sectional shape along their length. The underwires 170, 180, and 190 may be solid or may be perforated in such a way as to promote breathability. The underwires 170, 180, and 190 may be sewn in or melt-fused in to the cup 102 or to fabric proximate the cup 102.

An underwire 170, 180, or 190 may be formed by injection molding an elastomer or gelatinous elastomer into a mold or die. In some embodiments, fabric material of the bra 100 (FIG. 1) may be inserted into the mold before the underwire 170, 180, or 190 is formed. In such embodiments, the material of the underwire 170, 180, or 190 may fuse into the fibers of the fabric material of the bra 100. In other embodiments, a pre-form of the underwire 170, 180, or 190 may be placed into a mold proximate one or more fabrics. Heat and/or pressure may be applied to the assembly in the mold to fuse the pre-form to the fabric. For example, a profile extrusion (e.g., a profile extrusion having a circular cross-section) may be cut to length to fit a cup 102. Other profile extrusions may be cut to fit cups 102 of different sizes.

An underwire 170, 180, or 190 may include a gelatinous elastomer comprising up to 12 parts by weight of a plasticizer to one part of an elastomeric polymer, and may form a material having a durometer hardness of about Shore A 1 or greater, such as from about Shore A 1 to about Shore D 100. For example, an underwire 170, 180, and 190 may include one part A-B-A triblock copolymer (e.g., SEEPS, such as SEPTON® 4055) and one and one-half parts by weight white food grade paraffinic mineral oil free of aromatic content and having a kinematic viscosity at 100° F. of from about 10.8 mm²/s to about 13.6 mm²/s (e.g., CARNATION® mineral oil). Such a mixture may form a gelatinous elastomer having a durometer hardness of about Shore A 40.

An underwire 170, 180, or 190 may optionally include a filler, such as a plurality of microspheres or a plurality of short fibers such as glass or polyamide or rayon fibers. The filler may further stiffen the material of the underwire 170, 180, or 190, which may be desirable in some applications. Expandable filler may be pre-expanded and added to a mixture used to form the underwire 170, 180, or 190, or may be added to the mixture in unexpanded form and allowed to expand when the mixture is heated, such as to a blowing temperature of the filler. If the filler is added to the mixture used to form the underwire 170, 180, or 190 in unexpanded form, the underwire 170, 180, or 190 may be pressurized by expansion of the filler via heating into a cavity and/or fabric into which the underwire is molded or placed.

As shown in FIG. 10, an underwire 200 may be configured as a leaf spring. The underwire 200 may include a plurality of layers 202 of material (e.g., metal or plastic) that support each other in a progressive manner and therefore support the breast within the cup 102. The layers 202 may be bonded together and may each have an arc shape. The underwire 200 may have a low profile to limit or prevent detection of the underwire by others (note that the figures, including FIG. 10, are not necessarily drawn to scale). The underwire 200 may respond progressively to loading forces. This progressive response may provide soft support as a load is applied. The underwire 200 may dimensionally taper toward its edges, and such tapering may reduce discomfort of the user.

As shown in FIG. 11, an underwire 210 may be formed of a single, continuous material having a first thickness in a center 212 of the underwire 210, and a smaller thickness at edges 214. For example, the underwire 210 may be tapered out toward the edges 214. Thus, the underwire 210 may have a shape similar to the shape of the underwire 200 shown in FIG. 10, but may be formed of a single piece of support material (e.g., metal or rigid plastic). A load on the underwire 210 may be spread more broadly than a load on a conventional underwire. Cross-sectional widening, even with thinning edges, may increase the static moment of inertia of the underwire, which may allow a material having a lower modulus of elasticity than conventional underwires (e.g., plastic or elastomeric material) to achieve an acceptable overall in-bra stiffness. For example, a plastic underwire 210 may have a stiffness similar to the stiffness of a metal underwire in typical configurations that have lower static moment of inertia, even though the plastic has a lower modulus of elasticity than the metal.

In the underwires 190, 200, and 210 shown in FIGS. 9 through 11, the thinner portion of the underwire 190, 200, 210 may be disposed on one side of the thickest portion of the underwire 190, 200, 210 (see FIG. 9), or may be disposed on both sides of the underwire 190, 200, 210 (see FIGS. 10 and 11). In other words, a cross-section of the underwire 190, 200, 210 may thin in one direction or in both directions. The thinning may be gradual (see FIG. 11) or may be step-wise in one or more steps (see FIG. 10). In any of these non-limiting examples, the underwire 190, 200, 210, may be sewn through the thinner portions to secure the underwire 190, 200, 210 to fabric of the cup 102 (i.e., one or more threads or fibers may pass through a portion of the underwire 190, 200, 210 and a portion of the fabric of the cup 102).

In some embodiments, a surface of an underwire 180, 190, 200, or 210 may be roughened such that it grips the fabric of the cup 102 and reduces or eliminates migration within the fabric (e.g., may help hold the underwire 180, 190, 200, or 210 in place). For example, the surface of the underwire 180, 190, 200, or 210 that is away from the bra wearer's skin may include textures, grabbers, and/or teeth, which may be formed by molding, machining, or any other method.

As shown in FIG. 12, an underwire 220 may have material in two or more planes that integrally intersect. The material of the underwire 220 may be configured to increase its stiffness or the support it provides. The underwire 220 may have a cross-section similar to an I-beam, angle iron, or any other shape. A person having ordinary skill in the art will recognize that members having non-rectangular cross-sections may have a higher stiffness than the same amount of material in a member having a rectangular cross-section. Underwires 220 having various cross-sectional shapes may be extruded, injection molded, welded, formed from metal sheets, or made by other means known in the art.

As shown in FIG. 13, an underwire 230 may have a hollow cross-section. Though shown in FIG. 13 as a square tube with a square void, the underwire 230 may have any shape (e.g., circular, rectangular, triangular, generally flat, etc.), and may have an opening of any shape. The cross-section may be constant along the length of the underwire 230 or may vary. The void within the underwire 230 may have open or closed ends. The underwire 230 may be extruded or made by other means known in the art. The underwire 230 may be made from an elastomeric material, a gelatinous elastomer, or other flexible material. In some embodiments, the underwire 230 may be metal.

FIGS. 14 through 16 show embodiments of inserts 240 and 250 that may be placed within a bra cup 102 to make the breast appear larger and/or to lift or shape the breast in a comfortable way. Such inserts 240, 250 may be referred to in the art as “cookies” or space-filling members. Each bra cup 102 of a bra 100 (FIG. 1) may have the same size and shape of inserts 240, 250, or inserts 240, 250 may have differing sizes and shapes to aid in creating an appearance that both of a user's breasts are the same size and shape, when in fact they are not. Inserts 240, 250 may comprise foam, layers of fabric, natural or synthetic fibers, and/or bladders (e.g. plastic-film bladders filled with fluid such as air and/or mineral oil). Inserts 240, 250 may be permanently or semi-permanently molded, fused, sewn, or quilted into or onto the cup 102, as shown in FIGS. 14 and 15. For example, inserts 240, 250 may be secured between an outer layer 242 and an inner layer 244 of the cup 102 as shown in FIGS. 14 and 15. Alternatively, inserts 240, 250 may be placed in the cup 102 without permanent attachment, such as by the wearer prior to putting on the bra 100. In some embodiments, the insert 240, 250 may not be attached at all, or may have a non-permanent attachment mechanism such as hook-and-loop fasteners. The inserts 240, 250 may have a feel similar to the feel of a human breast.

FIG. 14 shows an insert 240 having a continuous mass of homogeneous material. The material used to form an insert 240 may be elastic. For example, the material used to form the insert 240, when formed into a cylindrical test sample having a diameter of 0.25 inch (6.35 mm), may stretch to at least five times its length prior to failure (e.g., breakage). A test sample of the material having a diameter of 0.25 inch (6.35 mm) and a length of 3 inches (76.2 mm) may stretch to a length of 15 inches (381 mm) before failure. The firmness of an insert 240 may be tailored based on the particular application and user preference. For example, an insert 240 may be made from soft, medium, or firm elastomer or gelatinous elastomer.

An example of a material that may be used to form an insert 240 is a gelatinous elastomer including one part A-B-A triblock copolymer (e.g., SEEPS, such as SEPTON® 4055), 12 parts of a white food grade paraffinic mineral oil free of aromatic content (e.g., CARNATION® mineral oil), and a sufficient amount of filler (e.g., EXPANCEL® 909 DET 80d15 hollow acrylic microspheres) to further increase the volume by 50%.

In some embodiments, as shown in FIG. 15, an insert 250 may include a flexible bladder 251 defining a cavity 252. The bladder 251 may fully encapsulate a flowable material 254 within the cavity 252. The flowable material 254 may include one or more of air, gas, water, mineral oil, vegetable oil, silicone fluid, gel putty, glycerin, cross-linked viscoelastic glycerin (e.g., glycerin cross-linked with a flocculant, such as MAGNAFLOC®, available from Ciba Specialty Chemicals Water Treatment, Inc., of Suffolk, Va.), or cocamide diethanolamine (cocamide DEA). In some embodiments, the flowable material 254 may include polymer-thickened water with or without cross-linkers (e.g., a flocculant, such as MAGNAFLOC® or a borate). The polymer may be, for example, propylene glycol, poly(vinyl) alcohol, super-absorbent polymer, starch, gum (e.g., xanthan gum, guar gum, etc.), mineral oil with dissolved elastomer, lubricated microspheres, or other lubricated particles. The flowable material 254 may include combinations of one or more flowable materials. The flowable material 254 may be of a type that will not permeate, bleed through, or react with the material of the bladder 251. Flowable materials 254 that permeate, bleed through, or react with material of the bladder 251 may cause degradation of the insert 250 and/or the flowable materials 254 therein. For example, a gelatinous elastomer bladder 251 may absorb mineral oil contained therein, changing the properties of either or both components and allowing the mineral oil to bleed through the gelatinous elastomer.

FIG. 16 shows a top view of the insert 250, without the cup 102. The insert 250 may have a hollow flat-elliptical shape, flat-circular shape, or any other shape, flat or otherwise. The shape of the insert 250 may be typical of the shape of inserts known in the art, and may be configured to cover all or a portion of a breast. The shape of the insert 250 may be selected or tailored for a specific bra wearer. The insert may be formed by methods known in the art for forming bodies of elastomers or gelatinous elastomers, such as injection molding, extruding, dip molding, slush molding, etc. For example, a material (e.g., an elastomer or a gelatinous elastomer) may be applied to a mold and allowed to solidify or harden, forming the bladder 251. The bladder 251 may be filled with flowable material 254 (not shown in FIG. 16), such as through a port 256. The port 256 may be sealed after the bladder 251 is filled with flowable material 254 so that the flowable material 254 remains in the bladder 251, and so that other materials cannot enter the bladder 251.

An example of a material that may be used to form a bladder 251 is a gelatinous elastomer including one part A-B-A triblock copolymer (e.g., SEEPS, such as SEPTON® 4055 or SEBS, such as KRATON® G1651), six parts of a white food grade paraffinic mineral oil free of aromatic content (e.g., CARNATION® mineral oil), and 0.04 parts antioxidant (e.g., IRGANOX® 1076).

An insert 250 comprising a bladder 251 encapsulating a flowable material 254 (FIG. 15) may have an elastomer or gelatinous elastomer having a different firmness than the firmness of a homogeneous insert 240 (FIG. 14), yet may provide the same function and/or feel as a homogeneous insert 240. For example, the insert 250 may be firmer or softer than the insert 240. In general, the elastomeric polymer component of a gelatinous elastomer material of an insert 250 comprising a bladder 251 encapsulating a flowable material 254 need not be as soft as a homogeneous insert 240 to provide similar function and feel.

In one example of an insert 250, the bladder 251 comprises a gelatinous elastomer, and the flowable material 254 comprises a gel putty as described in U.S. patent application Ser. No. 13/098,182, titled “Gel Putties, Articles Comprising Same, and Methods of Forming Such Gel Putties and Articles,” filed Apr. 29, 2011, previously incorporated herein by reference. In another example of an insert 250, the bladder 251 comprises a gelatinous elastomer, and the flowable material 254 comprises a fluid made from about 96% by weight glycerin and about 4% by weight flocculant (e.g., MAGNAFLOC®) heat-blended together. That fluid is mixed with filler (e.g., EXPANCEL® 909 DET 80d15 hollow acrylic microspheres) to create a flowable material with a bulk specific gravity of from about 0.30 to about 0.50.

Straps 104 and bands 105 may be a source of discomfort, skin irritation, and/or injury. To alleviate such problems, a non-breathable solid gelatinous elastomer may be disposed in or on a strap 104 or band 105 (e.g., between the strap 104 and the wearer's shoulder or between the band 105 and the wearer's back). In some embodiments of the disclosure, a cushioning material may be incorporated within the strap 104 or band 105 and/or between the strap 104 or band 105 and the user, such as by the principles and in the configurations described in U.S. Pat. No. 5,749,111, U.S. Pat. No. 6,026,527, and U.S. patent application Ser. No. 12/287,057, the disclosures of each of which have been previously incorporated herein by reference. For instance, as shown in FIG. 17, a strap 104 and a band 105 may include a flexible material 172 and a fabric or elastic material 174. The flexible material 174 may include hollow breathable buckling columns, spaced-apart ribs, or other cushioning elements. The area cushioned by the flexible material 172 (e.g., the shoulders or torso) may experience lower peak pressures, and/or may have lower peak shear forces, than areas exposed to conventional straps and bands. Yet the strap 104 and the band 105 may maintain breathability.

The flexible material 172 may be sewn into or onto the fabric or elastic material 174, or may be molded into and fused to the fabric or elastic material 174. In some embodiments, the flexible material 172 may be molded in such a configuration (e.g., with slots molded therein) that the flexible material 172 may be threaded onto or clipped to the fabric or elastic material 174 of the strap 104 and the band 105. Some flexible materials 172 may naturally exhibit a high drag or friction force against fabric or elastic material 174, which may prevent or limit slippage of the strap 104 from the shoulder or band 105 from the torso of the wearer. Some flexible materials 172 may exhibit high tackiness, or may be formulated to increase tackiness, which tackiness may prevent or limit slippage of the strap 104 from the shoulder or the band 105 from the torso of the wearer. For example, tackiness of gelatinous elastomers may be increased by the use of higher MW plasticizers (e.g., by substituting 350 MW mineral oil for 70 MW mineral oil in a formulation), by the addition of resins, or by other known methods.

In some embodiments, holes may be molded into or punched through flexible material 172 and/or fabric or elastic material 174 of the strap 104 or band 105 to increase breathability. In other embodiments, the flexible material 172 may include a plastic-film bladder (including, but not limited to, a bladder made by radio-frequency-welding two layers of polyurethane film together) or a bladder made from an elastomer or gelatinous elastomer and filled with a solid or fluid cushioning material. For example, the bladder may be filled with lubricated microspheres, gel putty, or a mixture of glycerin, flocculant, and filler, as described above. A fluid cushioning may comprise, for example, a fluid made from 96% by weight glycerin and 4% by weight flocculant (e.g., MAGNAFLOC®) heat-blended together. That fluid may be mixed with filler (e.g., EXPANCEL® 909 DET 80d15 hollow acrylic microspheres) to create a flowable material with a bulk specific gravity of from about 0.30 to about 0.50. Examples of cushioning materials and related methods are described in U.S. Pat. No. 5,421,874, issued Jun. 6, 1995 and titled “Composite Microsphere and Lubricant Mixture;” U.S. Pat. No. 5,549,743, issued Aug. 27, 1996 and titled “Composite Microsphere and Lubricant Mixture;” U.S. Pat. No. 5,626,657, issued May 6, 1997 and titled “Composite Microsphere and Lubricant Mixture;” and U.S. Pat. No. 6,020,055, issued Feb. 1, 2000 and titled “Cushioning Media Including Lubricated Spherical Objects;” the disclosure of each of which is incorporated herein in its entirety by this reference. In embodiments in which the flexible material 172 includes a bladder, the bladder may be of any selected thickness, for example from 0.051 mm (0.002 in) thick to 7.62 mm (0.300 in) thick. Thicker films of a given material may be stronger than thinner films of that material, but may have a lower “hand” (i.e., the ability to deform around irregularities of a breast). For example, if the flexible material 172 comprises a polyurethane film, the average thickness of the polyurethane film may be between about 0.051 mm (0.002 in) and about 0.305 mm (0.012 in). If the flexible container 24 comprises a gelatinous elastomer, the average thickness of the gelatinous elastomer film may be between about 0.51 mm (0.020 in) and about 7.62 mm (0.300 in). Non-limiting general examples describing the use of fluid containers for cushioning are described in U.S. Pat. No. 5,592,706, issued Jan. 14, 1997 and titled “Cushioning Device Formed from Separate Reshapeable Cells,” the disclosure of which is incorporated herein in its entirety by this reference.

Straps 104 and bands 105 having flexible materials 172 described herein may improve pressure equalization on the body of the wearer (i.e., may limit the extremes of pressure by applying a lower, more uniform pressure over a larger area) and may lead to a reduction of shear pressures on the body. The features described herein may be used alone or in combination. Straps 104 and bands 105 as described herein may reduce the effect of impact or other loads relating to the pulling of the bra down on the shoulders or into the torso or back as the breasts move during walking, running, vehicle vibration, or any other cause of movement. The straps 104 and bands 105 may improve cushioning, shock absorption, and/or vibration attenuation properties of the bra 100.

A bra 100 may have one or more clasps 106 and/or clasp receiving mechanisms 107 as described herein. Though the clasp 106 and the clasp receiving mechanism 107 in FIG. 1 are shown as configured to connect the band 105 in the center of the back, clasps 106 and clasp receiving mechanisms 107 may connect straps 104 configured to go over the shoulders with the band 105 configured to go around the torso. A clasp 106 and a clasp receiving mechanism 107 may also be used to connect the two cups 102 together at the center of the wearer's chest. Typical clasps 106 and clasp receiving mechanisms 107 may include a hook and eye, and may be difficult for some wearers to attach and detach, especially when disposed on the wearer's back.

As shown in FIGS. 18 and 19, an attachment mechanism for the band 105 may include a clasp 106 and a clasp receiving mechanism 107 having a keyhole 260, each secured to a different portion of the band 105 by an attachment means 262 (e.g., stitching, fusing, etc.). The clasp receiving mechanisms 107 may be configured to receive the clasp 106 through the keyhole 260 and retain the clasp 106, securing the two portions of the band 105 together. The keyhole 260 may have a size and/or a shape similar to at least a portion of the clasp 106, such that at least a portion of the clasp 106 may be inserted into the keyhole 260 to fasten the band 105. Such clasp 106 and clasp receiving mechanisms 107 may be of any shape.

The clasp 106 may include a protrusion 264 from the band 105. The protrusion 264 may be supported by an undercut structure 266. In the embodiment shown in FIGS. 18 and 19, the protrusion 264 has the shape of a heart. The undercut structure 266 may have a linear dimension smaller than a linear dimension of the protrusion 264. In the embodiment shown in FIGS. 18 and 19, the undercut structure 266 has a cylindrical shape. The keyhole 260 may be a hole that at least partially matches the shape of the protrusion 264. The keyhole 260 may include an elongated portion 268 having a linear dimension smaller than the linear dimension of the protrusion 264. The elongated portion 268 may be a slot slightly larger than the undercut structure 266, in which the undercut structure 266 may slide, but through which the protrusion 264 may not pass. Thus, removal of the clasp 106 from the clasp receiving mechanism 107 may require sliding the clasp 106 until the protrusion 264 aligns with the similar shape of the keyhole 260, then pushing the protrusion through the keyhole 260.

In some embodiments, the keyhole 260 may have sufficient clearance for the protrusion 264 to pass through without deforming the keyhole 260 or the protrusion 264. In other embodiments, the protrusion 264 may have an interference fit with the keyhole 260, requiring the material of the clasp receiving mechanism 107 surrounding the keyhole 260 to flex as the clasp 106 is fastened and released. The keyhole 260 may slip over the protrusion 264 when pressure is applied. Once the protrusion 264 has passed through the keyhole 260, pulling each portion of the band 105 in opposite directions may cause the undercut structure 266 to slide in the slot and lock the clasp in place until the wearer wants to remove the garment.

The shape of the clasp 106, the clasp receiving mechanism 107, the protrusion 264, and the keyhole 260 may be designed for function and/or to enhance the look of the garment. In the embodiment shown in FIGS. 18 and 19, the protrusion 264 and the keyhole 260 each have the shape of a heart. The shapes of other objects may also be used, such as circles, squares, triangles, etc.

The clasp 106 and/or the clasp receiving mechanism 107 may be formed of an elastomeric material, such as by injection molding. The use of an elastomeric material may facilitate a secure lock between the clasp 106 and the clasp receiving mechanism 107 and/or improve the comfort of the wearer. Garments having a clasp 106 and clasp receiving mechanism 107 as disclosed herein may be produced more efficiently than garments having conventional clasps because the clasp 106 and clasp receiving mechanism 107 may be sewn to the band 105 or other material with little dexterity and with no special equipment requirements. For instance, the clasp 106 and the clasp receiving mechanism 107 may be sewn quickly into place with straight stitching. The clasp 106 and the clasp receiving mechanism 107 may each be a single piece, rather than many smaller pieces that need to be held in place individually. The clasp 106 and clasp receiving mechanism 107 may be easily and inexpensively injection molded in a family mold that allows for multiple pieces to be molded at the same time.

By way of example, and not limitation, the clasp 106 and the clasp receiving mechanism 107 may be molded from an elastomer having a durometer hardness of greater than Shore A 40. The drag and/or friction of the elastomer may promote formation of a secure connection between the clasp 106 and the clasp receiving mechanism 107 that is easily reversed when detaching the clasp 106 from the clasp receiving mechanism 107. In some embodiments, the clasp 106 may have a higher durometer hardness than the clasp receiving mechanism 107, such that the clasp 106 holds its shape under the pressures exerted in normal use, yet remains soft enough to increase the comfort of the user. The clasp receiving mechanism 107 may have a lower durometer hardness than the clasp 106 such that the keyhole 260 may deform as necessary to accept the protrusion 264.

Additional non-limiting example embodiments of the disclosure are described below.

Embodiment 1: A bra comprising at least one insert configured to modify an appearance of a breast and a shell configured to cover the breast and the at least one insert. The insert comprises a flexible bladder comprising a gelatinous elastomer and a flowable material disposed within the flexible bladder.

Embodiment 2: The bra of Embodiment 1, wherein the at least one insert is configured to increase an apparent size of the breast.

Embodiment 3: The bra of Embodiment 1 or Embodiment 2, wherein the at least one insert is configured to raise the breast.

Embodiment 4: The bra of any of Embodiments 1 through 3, wherein the flowable material comprises another gelatinous elastomer, the another gelatinous elastomer having a composition different from a composition of the gelatinous elastomer of the flexible bladder.

Embodiment 5: The bra of any of Embodiments 1 through 4, wherein the at least one insert is removably attached to the shell.

Embodiment 6: The bra of any of Embodiments 1 through 5, wherein the at least one insert comprises a first insert and a second insert, the second insert having at least one dimension different from the first insert.

Embodiment 7: The bra of any of Embodiments 1 through 6, wherein the flexible bladder comprises an A-B-A triblock copolymer.

Embodiment 8: The bra of Embodiment 7, wherein the A-B-A triblock copolymer comprises a material selected from the group consisting of styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS).

Embodiment 9: The bra of Embodiment 7, wherein the flexible bladder comprises a plasticizer, and wherein a ratio of the plasticizer to the A-B-A triblock copolymer by weight is in a range extending from about 1-to-1 to about 30-to-1.

Embodiment 10: The bra of any of Embodiments 1 through 9, wherein the flowable material comprises another gelatinous elastomer and a filler. The another gelatinous elastomer comprises about 96 wt % glycerin and about 4 wt % flocculant.

Embodiment 11: The bra of Embodiment 10, wherein the flowable material has a bulk specific gravity of from about 0.30 to about 0.50.

Embodiment 12: An insert configured to modify an appearance of a breast, the insert comprising a flexible bladder comprising a gelatinous elastomer and a flowable material disposed within the flexible bladder.

Embodiment 13: The insert of Embodiment 12, wherein the flowable material comprises a plurality of microspheres.

Embodiment 14: The insert of Embodiment 12 or Embodiment 13, wherein the flowable material comprises a fluid selected from the group consisting of air; a gas; water; mineral oil; vegetable oil; silicone fluid; gel putty; a mixture of glycerin and a flocculant; a mixture of glycerin, a flocculant, and a filler; and another gelatinous elastomer.

Embodiment 15: The insert of any of Embodiments 12 through 14, wherein the gelatinous elastomer of the flexible bladder is formulated to limit permeation by the flowable material.

Embodiment 16: The insert of any of Embodiments 12 through 15, wherein the gelatinous elastomer comprises an elastomeric polymer and a plasticizer mixed with the elastomeric polymer.

Embodiment 17: The insert of Embodiment 16, wherein the elastomeric polymer comprises a material having a melt mass-flow rate in a range of about 2 g/10 min or less.

Embodiment 18: The insert of Embodiment 16 or Embodiment 17, wherein a ratio of the plasticizer to the elastomeric polymer by weight is in a range extending from about 1-to-1 to about 30-to-1.

Embodiment 19: The insert of any of Embodiments 12 through 18, wherein the gelatinous elastomer comprises an antioxidant.

Embodiment 20: A bra, comprising an underwire comprising an elastomeric material having a Shore A durometer hardness of about 1 or greater and a shell connected to the underwire and configured to cover at least one breast.

Embodiment 21: The bra of Embodiment 20, wherein a first cross-section of the underwire generally perpendicular to a major axis of the underwire has a first area at a first position along a length of the underwire, and a second cross-section of the underwire generally perpendicular to the major axis of the underwire at a second position along a length of the underwire has a second area different from the first area.

Embodiment 22: The bra of Embodiment 20 or Embodiment 21, wherein a cross-section of the underwire generally perpendicular to a major axis of the underwire has an area of about 20 mm² or larger.

Embodiment 23: The bra of any of Embodiments 20 through 22, wherein the underwire has at least one tapered edge.

Embodiment 24: The bra of any of Embodiments 20 through 23, wherein the underwire is sewn to the shell.

Embodiment 25: The bra of any of Embodiments 20 through 24, wherein the elastomeric material has a Shore A durometer hardness of about 100 or less.

Embodiment 26: The bra of any of Embodiments 20 through 25, wherein the elastomeric material comprises an A-B-A triblock copolymer, and a plasticizer, wherein a ratio of the plasticizer to the A-B-A triblock copolymer by weight is in a range extending from about 0.5-to-1 to about 12-to-1.

Embodiment 27: The bra of Embodiment 26, wherein the A-B-A triblock copolymer comprises a material selected from the group consisting of styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS).

Embodiment 28: An underwire for a bra, comprising an elongated body comprising an elastomeric material having a Shore A durometer hardness of about 1 or greater.

Embodiment 29: The underwire of claim 28, wherein the elastomeric material has a Shore A durometer hardness of about 100 or less.

Embodiment 30: The underwire of Embodiment 28 or Embodiment 29, wherein the elastomeric material comprises an A-B-A triblock copolymer having a melt mass-flow rate in a range of about 2 g/10 min or less.

Embodiment 31: The underwire of any of Embodiments 28 through 30, wherein the elongated body further comprises a plasticizer, and wherein a ratio of the plasticizer to the elastomeric polymer by weight is in a range extending from about 0.5-to-1 to about 12-to-1.

Embodiment 32: The underwire of any of Embodiments 28 through 31, wherein a first cross-section of the elongated body generally perpendicular to a major axis of the elongated body has a first area, and a second cross-section of the elongated body generally perpendicular to the major axis of the elongated body has a second area different from the first area.

Embodiment 33: The underwire of any of Embodiments 28 through 32, wherein a cross-section of the elongated body generally perpendicular to a major axis of the elongated body has an area of about 20 mm² or larger.

Embodiment 34: The underwire of any of Embodiments 28 through 33, wherein the elongated body further comprises a plurality of microspheres.

Embodiment 35: A method of forming a bra, comprising forming an underwire comprising an elastomeric material, and securing the underwire to a shell configured to cover at least one breast. The elastomeric material has a Shore A durometer hardness of about 1 or greater.

Embodiment 36: The method of Embodiment 35, wherein forming an underwire comprising an elastomeric material comprises mixing an A-B-A triblock copolymer with a plasticizer, wherein a ratio of the plasticizer to the A-B-A triblock copolymer by weight is in a range extending from about 0.5-to-1 to about 12-to-1.

Embodiment 37: The method of Embodiment 35 or Embodiment 36, wherein forming an underwire comprises extruding the elastomeric material through a die.

Embodiment 38: The method of Embodiment 35 or Embodiment 36, wherein forming an underwire comprises injection molding the elastomeric polymer into a mold.

Embodiment 39: The method of any of Embodiments 35 through 38, wherein securing the underwire to the shell comprises passing a fiber through a portion of the underwire and through a portion of the shell.

Embodiment 40: The method of any of Embodiments 35 through 39, wherein securing the underwire to the shell comprises heating at least one of the underwire and the shell to fuse the underwire to the shell.

Embodiment 41: A method of forming a bra, comprising forming a flexible bladder comprising a gelatinous elastomer, disposing a flowable material within the flexible bladder to form an insert configured to modify an appearance of a breast, and securing the insert to a shell configured to cover the breast.

Embodiment 42: The method of Embodiment 41, wherein forming a flexible bladder comprises combining an elastomeric polymer with a plasticizer, wherein a ratio of the plasticizer to the elastomeric polymer by weight is in a range extending from about 1-to-1 to about 30-to-1.

Embodiment 43: The method of Embodiment 41 or Embodiment 42, wherein securing the insert to the shell comprises disposing the insert between two portions of the shell and sewing the two portions together.

Embodiment 44: The method of Embodiment 41 or Embodiment 42, wherein securing the insert to the shell comprises removably affixing the insert to the shell.

Embodiments of the disclosure may be susceptible to various modifications and alternative forms. Specific embodiments have been shown in the drawings and described in detail herein to provide illustrative examples of embodiments of the disclosure. However, the disclosure is not limited to the particular forms disclosed herein. Rather, embodiments of the disclosure may include all modifications, equivalents, and alternatives falling within the scope of the disclosure as broadly defined herein. Furthermore, elements and features described herein in relation to some embodiments may be implemented in other embodiments of the disclosure, and may be combined with elements and features described herein in relation to other embodiments to provide yet further embodiments of the disclosure.

Claims

1. A bra, comprising: a shell configured to cover the breast and the at least one insert.

at least one insert configured to modify an appearance of a breast, the at least one insert comprising:

a flexible bladder comprising a gelatinous elastomer; and

a flowable material disposed within the flexible bladder; and

2. The bra of claim 1, wherein the at least one insert is configured to increase an apparent size of the breast.

3. The bra of claim 1, wherein the at least one insert is configured to raise the breast.

4. The bra of claim 1, wherein the flowable material comprises another gelatinous elastomer, the another gelatinous elastomer having a composition different from a composition of the gelatinous elastomer of the flexible bladder.

5. The bra of claim 1, wherein the at least one insert is removably attached to the shell.

6. The bra of claim 1, wherein the at least one insert comprises a first insert and a second insert, the second insert having at least one dimension different from the first insert.

7. The bra of claim 1, wherein the flexible bladder comprises an A-B-A triblock copolymer.

8. The bra of claim 7, wherein the A-B-A triblock copolymer comprises a material selected from the group consisting of styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS).

9. The bra of claim 7, wherein the flexible bladder comprises a plasticizer, and wherein a ratio of the plasticizer to the A-B-A triblock copolymer by weight is in a range extending from about 1-to-1 to about 30-to-1.

10. The bra of claim 1, wherein the flowable material comprises another gelatinous elastomer and a filler, the another gelatinous elastomer comprising:

about 96 wt % glycerin; and

about 4 wt % flocculant.

11. The bra of claim 10, wherein the flowable material has a bulk specific gravity of from about 0.30 to about 0.50.

12. An insert configured to modify an appearance of a breast, the insert comprising:

a flexible bladder comprising a gelatinous elastomer; and

a flowable material disposed within the flexible bladder.

13. The insert of claim 12, wherein the flowable material comprises a plurality of microspheres.

14. The insert of claim 12, wherein the flowable material comprises a fluid selected from the group consisting of air; a gas; water; mineral oil; vegetable oil; silicone fluid; gel putty; a mixture of glycerin and a flocculant; a mixture of glycerin, a flocculant, and a filler; and another gelatinous elastomer.

15. The insert of claim 12, wherein the gelatinous elastomer of the flexible bladder is formulated to limit permeation by the flowable material.

16. The insert of claim 12, wherein the gelatinous elastomer comprises:

an elastomeric polymer; and

a plasticizer mixed with the elastomeric polymer.

17. The insert of claim 16, wherein the elastomeric polymer comprises a material having a melt mass-flow rate in a range of about 2 g/10 min or less.

18. The insert of claim 16, wherein a ratio of the plasticizer to the elastomeric polymer by weight is in a range extending from about 1-to-1 to about 30-to-1.

19. The insert of claim 12, wherein the gelatinous elastomer comprises an antioxidant.

20. A bra, comprising:

an underwire comprising an elastomeric material having a Shore A durometer hardness of about 1 or greater; and

a shell connected to the underwire and configured to cover at least one breast.

21. The bra of claim 20, wherein a first cross-section of the underwire generally perpendicular to a major axis of the underwire has a first area at a first position along a length of the underwire, and a second cross-section of the underwire generally perpendicular to the major axis of the underwire at a second position along a length of the underwire has a second area different from the first area.

22. The bra of claim 20, wherein a cross-section of the underwire generally perpendicular to a major axis of the underwire has an area of about 20 mm2 or larger.

23. The bra of claim 20, wherein the underwire has at least one tapered edge.

24. The bra of claim 20, wherein the underwire is sewn to the shell.

25. The bra of claim 20, wherein the elastomeric material has a Shore A durometer hardness of about 100 or less.

26. The bra of claim 20, wherein the elastomeric material comprises an A-B-A triblock copolymer, and a plasticizer, and wherein a ratio of the plasticizer to the A-B-A triblock copolymer by weight is in a range extending from about 0.5-to-1 to about 12-to-1.

27. The bra of claim 26, wherein the A-B-A triblock copolymer comprises a material selected from the group consisting of styrene ethylene propylene styrene (SEPS), styrene ethylene butylene styrene (SEBS), and styrene ethylene ethylene propylene styrene (SEEPS).

28. An underwire for a bra, comprising:

an elongated body comprising an elastomeric material having a Shore A durometer hardness of about 1 or greater.

29. The underwire of claim 28, wherein the elastomeric material has a Shore A durometer hardness of about 100 or less.

30. The underwire of claim 28, wherein the elastomeric material comprises an A-B-A triblock copolymer having a melt mass-flow rate in a range of about 2 g/10 min or less.

31. The underwire of claim 28, wherein the elongated body further comprises a plasticizer, and wherein a ratio of the plasticizer to the elastomeric polymer by weight is in a range extending from about 0.5-to-1 to about 12-to-1.

32. The underwire of claim 28, wherein a first cross-section of the elongated body generally perpendicular to a major axis of the elongated body has a first area, and a second cross-section of the elongated body generally perpendicular to the major axis of the elongated body has a second area different from the first area.

33. The underwire of claim 28, wherein a cross-section of the elongated body generally perpendicular to a major axis of the elongated body has an area of about 20 mm2 or larger.

34. The underwire of claim 28, wherein the elongated body further comprises a plurality of microspheres.

35. A method of forming a bra, comprising:

forming an underwire comprising an elastomeric material, wherein the elastomeric material has a Shore A durometer hardness of about 1 or greater; and

securing the underwire to a shell configured to cover at least one breast.

36. The method of claim 35, wherein forming an underwire comprising an elastomeric material comprises mixing an A-B-A triblock copolymer with a plasticizer, wherein a ratio of the plasticizer to the A-B-A triblock copolymer by weight is in a range extending from about 0.5-to-1 to about 12-to-1.

37. The method of claim 35, wherein forming an underwire comprises extruding the elastomeric material through a die.

38. The method of claim 35, wherein forming an underwire comprises injection molding the elastomeric material into a mold.

39. The method of claim 35, wherein securing the underwire to the shell comprises passing a fiber through a portion of the underwire and through a portion of the shell.

40. The method of claim 35, wherein securing the underwire to the shell comprises heating at least one of the underwire and the shell to fuse the underwire to the shell.

41. A method of forming a bra, comprising:

forming a flexible bladder comprising a gelatinous elastomer;

disposing a flowable material within the flexible bladder to form an insert configured to modify an appearance of a breast; and

securing the insert to a shell configured to cover the breast.

42. The method of claim 41, wherein forming a flexible bladder comprises combining an elastomeric polymer with a plasticizer, wherein a ratio of the plasticizer to the elastomeric polymer by weight is in a range extending from about 1-to-1 to about 30-to-1.

43. The method of claim 41, wherein securing the insert to the shell comprises disposing the insert between two portions of the shell and sewing the two portions together.

44. The method of claim 41, wherein securing the insert to the shell comprises removably affixing the insert to the shell.