Gel-Cushioned Support Component Channel for a Brassiere

Abstract

The present disclosure is of a support component channel for a bra and methods for producing the support component channel and attaching it to a bra. The support component channel comprises a gel tube, an underwire tunnel casing, and a cover fabric. The gel tube provides cushion between the support component and the wearer's chest, thereby providing comfort despite the geometry and materials of the support component. The gel tube, underwire tunnel casing, and cover fabric can be sewn to one another simultaneously to being attached to the bra, prior to being attached to the bra, or can be attached to the bra in stages, according to different methods of production. The methods allow for both sides of the support component channel to be sewn to the bra simultaneously.

Description

FIELD

The present disclosure relates generally to brassieres. More specifically, the present disclosure relates to support components (such as tunnel casings and underwires) for brassieres.

BACKGROUND

Brassieres (bras) are often uncomfortable for a wearer due to the geometry and materials of components that provide support and shape to the bra, such as a tunnel casing and/or an underwire. Further, bras with underwires are often uncomfortable for a wearer due to the hard and sharp edges of metal or resin underwires. It is therefore desirable to cushion the support components of the bra such that the cushion lies between the support component and the wearer's chest. However, current methods do not allow for easy and efficient manufacturing of a bra that incorporates both a cushion and a support component.

SUMMARY

The present disclosure is of a support component channel for a bra and methods for producing the support component channel and attaching it to a bra. The support component channel comprises a gel tube, an underwire tunnel casing, and a cover fabric. The gel tube provides cushion between the support component and the wearer's chest, thereby providing comfort despite the geometry and materials of the support component. The gel tube, underwire tunnel casing, and cover fabric can be sewn to one another simultaneously to being attached to the bra, prior to being attached to the bra, or can be attached to the bra in stages, according to different methods of production. The methods allow for both side edges of the support component channel to be sewn to the bra simultaneously.

The present disclosure is of a support component channel for a bra. The channel comprises a gel tube having a first side and a second side. An underwire tunnel casing is adjacent the first side of the gel tube and is co-extensive in length with the gel tube. A cover fabric is adjacent the second side of the gel tube and is co-extensive in length with the gel tube. Side edges of the cover fabric are folded over respective side edges of the gel tube to cover the gel tube.

A method of creating a bra having a support component channel is also disclosed. The method comprises providing a gel tube having a first side and a second side. The method further comprises providing an underwire tunnel casing co-extensive in length with the gel tube and placing the tunnel casing adjacent the first side of the gel tube. The method further comprises providing a cover fabric co-extensive in length with the gel tube and placing the cover fabric adjacent the second side of the gel tube. The method further comprises covering the gel tube with side edges of the cover fabric that are folded over respective side edges of the gel tube, and attaching the tunnel casing, gel tube, and cover fabric to the bra cup.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a bra cup comprising a support component channel of the present disclosure;

FIG. 2 is a cross sectional view of the support component channel of the present disclosure taken along the line 2-2 of FIG. 1;

FIG. 3 is a perspective, cross-sectional view of the support component channel of the present disclosure;

FIG. 4 is a perspective, cross-sectional view of an alternative embodiment of the support component channel of the present disclosure;

FIG. 5 is a cross sectional view of the support component channel of FIG. 3 with an underwire;

FIG. 6 is a back view of the support component channel of FIG. 3;

FIG. 7 is a flow chart depicting one method of creating a bra having a support component channel; and

FIG. 8 is a flow chart depicting an alternative method of creating a bra having a support component channel.

DETAILED DESCRIPTION

In the present description, certain terms have been used for brevity, clearness and understanding. No unnecessary limitations are to be applied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The different configurations and methods described herein may be used alone or in combination with other configurations and methods. Various equivalents, alternatives and modifications are possible within the scope of the appended claims. Each limitation in the appended claims is intended to invoke interpretation under 35 U.S.C. §112, sixth paragraph, only if the terms “means for” or “step for” are explicitly recited in the respective limitation.

FIG. 1 depicts a bra cup 10 with an support component channel 12. This view of the bra cup 10 shows the inside face 14 of the bra cup 10, which is the face that contacts a wearer's skin. A first side 16 of the support component channel 12 contacts the wearer's skin, while a second side 18 of the support component channel 12 faces away from the wearer's chest. The first side 16 of the support component channel 12 comprises a gel tube and a layer of cover fabric 20 (FIG. 2), as will be described further herein below. The second side 18 of the support component channel 12 comprises an underwire tunnel casing 24 (FIG. 2) and a layer of cover fabric 20 (FIG. 2) as will also be described further herein below.

FIG. 2 is a cross-section of the support component channel 12 taken along the line 2-2 of FIG. 1. In FIG. 2, the support component channel 12 comprises a cover fabric 20 surrounding a gel tube 22 and an underwire tunnel casing 24. In the embodiment shown, the gel tube 22 has an outer membrane 26 surrounding an inner gel cushion 28. In another embodiment, the gel tube 22 has only a gel cushion 28 and no outer membrane 26. The tunnel casing 24 has a tunnel 30 running though the length thereof. The tunnel casing 24 can be made of nylon, polyester, cotton, or any other fabric suitable for washing and wear. The cover fabric 20 has side edges 32a, 32b that are aligned adjacent one another along the length of the tunnel casing 24 as shown in FIG. 3. The cover fabric 20 can be made of nylon, polyester, cotton, or any other fabric suitable for washing and wear. The cover fabric 20 can be made of fabric that is plush or brushed, or can be made of microfiber in order to add softness and provide comfort against the wearer's skin. The cover fabric 20 is made of a material that allows stretch across the width of the tunnel casing 24, which creates a smooth outer surface of the channel 12 that is comfortable against the wearer's skin.

In the embodiment shown in FIGS. 2 and 3, the gel cushion 28 of the gel tube 22 has a cross-sectional shape of an oval. However, it is to be understood that the gel cushion could take other shapes besides an oval, such as an ellipse, a rectangle, a circle, or any other shape that provides adequate cushion between the support component and the wearer's skin. The oval can have a major axis dimension between about 0.1 millimeters to about 10 millimeters and a minor axis dimension between about 0.1 millimeters to about 10 millimeters. In another embodiment, the major axis dimension is between 4 millimeters and 5 millimeters and the minor axis dimension is between about 3 millimeters and 4 millimeters. In another embodiment, the major axis dimension is 4.8 millimeters and the minor axis dimension is between 3.5 to 4 millimeters. In one embodiment, the gel cushion 28 comprises a silicone gel; however, the gel cushion 28 could also be made of silicon and its compounds combined with an open-cell gel foam. In other embodiments, the cushion is not made of a gel, but comprises a flexible cushioning tube that provides comfort and protection despite the geometry and materials of the support component. For example, the cushioning tube could be rubber, an elastomeric polymer, or a gelatinous elastomer. The cushioning tube could be a flexible membrane filled with water, air, gas, mineral oil, vegetable oil, silicone fluid, gel putty, glycerin, cotton, nylon, polyester, or short fibers of glass, polyamide, or rayon.

If provided, the outer membrane 26 is made of a material that prevents leakage of the gel cushion 28 material onto the cover fabric 20 and bra cup 10. In the embodiments shown in the Figures, the outer membrane 26 does not add significant bulk or shape to the assembled support component channel 12, but is merely a sleeve that protects the fabric of the bra cup 10 from the gel cushion 28 material. In one embodiment, the outer membrane 26 comprises thermoplastic polyurethane (TPU); however, the outer membrane 26 could also comprise any thermoplastic polymer that is compatible with the material of the gel cushion 28. For example, the outer membrane 26 could comprise polyvinyl chloride (PVC), emulsion polyvinyl chloride (EPVC) or polyurethane (PU). In another embodiment, the gel cushion 28 is made of a material that does not leak, and no outer membrane 26 is needed.

FIG. 3 shows a perspective cross-sectional view of the support component channel 12. From FIG. 3 it can be seen that the gel tube 22 has a first side 34 and a second side 36. The cover fabric 20 is adjacent the second side 36 of the gel tube 22 and is co-extensive in length L with the gel tube 22. The tunnel casing 24 is adjacent the first side 34 of the gel tube 22 and is co-extensive in length L with the gel tube 22. The side edges 32a, 32b of the cover fabric 20 are folded over respective side edges 38a, 38b of the tunnel casing 24 and are folded over the gel tube 22 to cover both the tunnel casing 24 and the gel tube 22.

With further reference to FIG. 3, a method of creating a bra having a support component channel 12 will now be described. The method comprises providing a cover fabric 20. The width of the cover fabric 20 is enough such that its side edges 32a, 32b can be folded over a gel tube 22 and a tunnel casing 24. The gel tube 22 is then provided and is placed on top of the cover fabric 20, generally in the center of the cover fabric 20. The gel tube 22 and the cover fabric 20 are co-extensive in length L. The tunnel casing 24 is then placed on top of the gel tube 22, also generally centered on the cover fabric 20. The tunnel casing 24 is generally co-extensive in length L with the gel tube 22 and the cover fabric 20. The side edges 32a, 32b of the cover fabric 20 are thereafter folded over the side edges 38a, 38b of the tunnel casing 24, and the cover fabric 20 and side edges 38a, 38b of the tunnel casing 24 are sewn together. As shown in FIGS. 3 and 6, the cover fabric 20 and the tunnel casing 24 can be sewn together along seam allowances 40a, 40b. In the embodiment shown in FIG. 6, the side edges 32a, 32b of the cover fabric 20 do not meet and some of the tunnel casing 24 is left exposed. In other embodiments, the side edges 32a, 32b do meet and the tunnel casing 24 is not left exposed. Whether the tunnel casing 24 is left exposed depends on the width of the cover fabric 20 in relation to the thickness and width of the gel tube 22 and the tunnel casing 24.

FIG. 4 shows a perspective cross-sectional view of another embodiment of the support component channel 12. From FIG. 4 it can be seen that the gel tube 22 has a first side 34 and a second side 36. The cover fabric 20 is adjacent the second side 36 of the gel tube 22 and is co-extensive in length L with the gel tube 22. The tunnel casing 24 is adjacent the first side 34 of the gel tube 22 and is co-extensive in length L with the gel tube 22. The side edges 32a, 32b of the cover fabric 20 are folded over respective side edges 39a, 39b of the gel tube 22 to cover the gel tube 22, instead of being folded over the respective side edges 38a, 38b of the tunnel casing 24 as shown in FIG. 3.

With further reference to FIG. 4, a method of creating a bra having a support component channel 12 will now be described. The method comprises providing a cover fabric 20. The width of the cover fabric 20 is enough such that its side edges 32a, 32b can be folded over a gel tube 22. The gel tube 22 is then provided and is placed on top of the cover fabric 20, generally in the center of the cover fabric 20. The gel tube 22 and the cover fabric 20 are co-extensive in length L. The side edges 32a, 32b of the cover fabric 20 are thereafter folded over the side edges 39a, 39b of the gel tube 22. The tunnel casing 24 is then placed on top of the gel tube 22 and the folded side edges 32a, 32b of the cover fabric 20. The tunnel casing 24 is generally co-extensive in length L with the gel tube 22 and the cover fabric 20. The cover fabric 20, and side edges 38a, 38b of the tunnel casing 24 are then sewn together along seam allowances 40a, 40b.

When manufacturing the support component channel 12 of the present disclosure, it is possible to use a twin needle sewing machine. The present inventors have recognized that due to the substantially straight configuration of the tunnel casing 24 and gel tube 22 along their lengths L, as shown in FIGS. 3 and 4, it is possible to feed the components through a twin needle sewing machine and it is possible to sew both sides of the support component channel 12 to the bra cup 10 at the same time. As used herein, the term “substantially straight” covers embodiments of the tunnel casing 24 and gel tube 22 that have no curvature and embodiments of the tunnel casing 24 and gel tube 22 that are slightly curved or curved, yet are still able to be run through a twin needle sewing machine in accordance with the methods described herein. Two methods for attachment of the tunnel casing 24, gel tube 22 and cover fabric 20 to the bra cup 10 will now be described.

With reference to FIG. 7, one method of creating a bra having a support component channel 12 will be described. The method begins at 100. The method comprises providing a gel tube 22 having a first side 34 and a second side 36, as shown at 110. The method then comprises providing an underwire tunnel casing 24 coextensive in length with the gel tube 22 and placing the tunnel casing 24 adjacent the first side 34 of the gel tube 22, as shown at 120. The method then comprises providing a cover fabric 20 coextensive in length with the gel tube 22 and placing the cover fabric 20 adjacent the second side 36 of the gel tube 22, as shown at 130. The method then comprises covering the gel tube 22 with side edges 32a, 32b of the cover fabric 20 that are folded over respective side edges 39a, 39b of the gel tube 22, as shown at 140. Alternatively, the method then comprises covering both the tunnel casing 24 and the gel tube 22 with side edges 32a, 32b of the cover fabric 20 that are folded over respective side edges 38a, 38b of the tunnel casing 24 and gel tube 22. The method then comprises attaching the tunnel casing 24, gel tube 22, and cover fabric 20 to a brassiere cup 10, as shown at 150. The method ends at 160.

More specifically, the method of FIG. 7 can be performed with a twin needle sewing machine. In the method of FIG. 7, each of the gel tube 22, tunnel casing 24, and cover fabric 20 are sewn together prior to their attachment to the bra cup 10. In this embodiment, the gel tube 22 and tunnel casing 24 are fed through the top feed of a twin needle sewing machine, while the cover fabric 20 is fed through the bottom feed of the twin needle sewing machine. As the cover fabric 20 is fed through the bottom feed, the side edges 32a, 32b are folded inward around the gel tube 22 towards one another such that they cover the gel tube 22. Alternatively, as the cover fabric 20 is fed through the bottom feed, the side edges 32a, 32b are folded inward around the gel tube 22 and tunnel casing 24 towards one another such that they cover both the gel tube 22 and the tunnel casing 24. The cover fabric 20 is thereby sewn to the side edges 38a, 38b of the tunnel casing 24 along seam allowances 40a, 40b. These three assembled components (gel tube 22, tunnel casing 24, and cover fabric 20) are thereafter assembled to the bra cup 10 by sewing with a twin needle sewing machine such that the entire support component channel 12 is sewn to the bra cup 10 at the seam allowances 40a, 40b as a single unit. In another embodiment, the gel tube 22, tunnel casing 24, and cover fabric 20 are sewn together simultaneously to being attached to the bra cup 10, i.e., each of the four components 10, 20, 22, 24 are run through a twin needle sewing machine only once. In this embodiment, the cover fabric 20 is fed through a lowermost bottom feed of the sewing machine, the gel tube 22 is fed through an intermediate bottom feed of the sewing machine, the tunnel casing 24 is fed through an uppermost bottom feed of the sewing machine, and the bra cup 10 is fed through the top feed of the sewing machine. Preferably, the side of the support component channel 12 on which the side edges 32a, 32b of the cover fabric 20 appear (the second side 18 of the support component channel 12) is sewn to the bra cup 10 such that it is hidden against the fabric of the bra cup 10. The side of the support component channel 12 that is covered fully by the cover fabric 20 (the first side 16 of the support component channel 12) faces the wearer's skin. After the support component channel 12 has been sewn to the bra cup 10, an underwire 44 may be inserted into the tunnel 30 of the tunnel casing 24. Alternatively, no underwire 44 may be inserted into the tunnel 30.

With reference to FIG. 8, another method of creating a bra having a support component channel 12 will be described. The method begins at 200. The method comprises providing a cover fabric 20, as shown at 210. The method then comprises providing an underwire tunnel casing 24 and placing the tunnel casing 24 adjacent the cover fabric 20, as shown at 220. The method then comprises covering the tunnel casing 24 with side edges 32a, 32b of the cover fabric 20 that are folded over respective side edges 38a, 38b of the tunnel casing 24, as shown at 230. The method then comprises sewing the tunnel casing 24 and cover fabric 20 to one another along seam allowances 40a, 40b, as shown at 240. The method then comprises attaching the cover fabric 20 and tunnel casing 24 to the bra cup 10, as shown at 250. The method then comprises attaching the gel tube 22 to the bra cup 10, as shown at 260. The method ends at 270.

More specifically, the method of FIG. 8 can be performed with a twin needle sewing machine. The cover fabric 20 is fed through the bottom feed of a twin needle sewing machine, while the tunnel casing 24 is fed through the top feed of the twin needle sewing machine. As the cover fabric passes through the bottom feed, the side edges 32a, 32b of the cover fabric 20 are folded inward around the side edges 38a, 38b of the tunnel casing 24 and are sewn along the seam allowances 40a, 40b to the respective side edges 38a, 38b of the tunnel casing 24. Next, the sewn tunnel casing 24 and cover fabric 20 are attached to the bra cup 10 also by using a twin needle sewing machine. The combination of the tunnel casing 24 and cover fabric 20 is sewn to the bra cup 10 along both of its side edges at once at the seam allowances 40a, 40b. In another embodiment, tunnel casing 24 and cover fabric 20 are sewn together simultaneously to being attached to the bra cup 10, i.e., each of the three components 10, 20, 24 are run through a twin needle sewing machine only once. In this embodiment, the cover fabric 20 is fed through a lowermost bottom feed of the sewing machine, the tunnel casing 24 is fed through an uppermost bottom feed of the sewing machine, and the bra cup 10 is fed through the top feed of the sewing machine. Preferably, the side of the support component channel 12 on which the side edges 32a, 32b of the cover fabric 20 appear (the second side 18 of the support component channel 12) is sewn to the bra cup 10 such that it is hidden against the fabric of the bra cup 10. The side of the support component channel 12 that is covered fully by the cover fabric 20 (the first side 16 of the support component channel 12) faces the wearer's skin.

After the tunnel casing 24 and cover fabric 20 are sewn to the bra cup 10, the gel tube 22 is inserted into a gap 42 (see FIGS. 2 and 5) between the tunnel casing 24 and cover fabric 20. Because the cover fabric 20 and tunnel casing 24 have already been sewn to the bra cup 10 and no longer have a straight shape, this is preferably done by using a curved needle that threads the gel tube 22 through the gap 42. After the gel tube 22 has been inserted into the gap 42, the underwire 44 may be inserted into the tunnel 30 in the tunnel casing 24. Alternatively, the underwire 44 may be inserted into the tunnel 30 prior to insertion of the gel tube 22. Alternatively, no underwire 44 may be inserted into the tunnel 30.

The method and apparatus described herein allow the support component channel 12 to be sewn to the bra cup 10 (prior to insertion of an underwire 44) with a twin needle sewing machine, due to the fact that the support component channel 12 is in a soft, malleable form. The support component channel 12 (assembled with or without the gel tube 22) also has a substantially straight configuration along its length L prior to it being sewn to the bra cup 10, which allows it to be sewn to the bra cup 10 with a twin needle sewing machine. Further, creating the gel tube 22 as a component separate from the underwire 44 (if an underwire 44 is used) minimizes the requirement for numerous mold blocks for each size and style of underwire, which are required when an underwire and a cushioning gel are molded together during production. The oval cross-sectional shape of the gel tube's 22 gel cushion 28 also provides comfort to the wearer as it protects the wearer from the hard metal or resin underwire 44 (if an underwire 44 is used), but at the same time, is dimensioned to allow the gel tube 22 to pass through a twin needle sewing machine. If included, the thermoplastic polyurethane (TPU) membrane 26 covers the gel cushion 28 and provides protection from oil leakage onto the finished bra cup 10. The fact that the side edges 32a, 32b of the cover fabric 20 are hidden against the fabric of the bra cup 10, combined with the soft and stretchy material of the cover fabric 20, provides comfort against the wearer's skin.

In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. The different configurations and method steps described herein may be used alone or in combination with other configurations and method steps. It is to be expected that various equivalents, alternatives, and modifications are possible within the scope of the appended claims. The claimed methods may be performed in various orders, and should be construed to cover various modifications understood by those having ordinary skill in the art. For example, the components described hereinabove may be assembled to one another in a multitude of combinations, orders, and ways, and the methods claimed herein are meant to cover such equivalent alternatives to the combinations, orders, and methods of assembly of such components.

Claims

1. A support component channel for a brassier, the channel comprising:

a gel tube having a first side and a second side;

an underwire tunnel casing adjacent the first side of the gel tube and coextensive in length with the gel tube; and

a cover fabric adjacent the second side of the gel tube and coextensive in length with the gel tube;

wherein side edges of the cover fabric are folded over respective side edges of the gel tube such that the cover fabric covers the gel tube.

2. The support component channel of claim 1, wherein each of the tunnel casing and gel tube are substantially straight along their respective lengths.

3. The support component of claim 1, wherein the side edges of the cover fabric are folded over respective side edges of the tunnel casing and gel tube such that the cover fabric covers both the tunnel casing and the gel tube.

4. The support component channel of claim 3, further comprising a gap between the tunnel casing and the cover fabric.

5. The support component channel of claim 1, wherein the gel tube comprises a gel cushion.

6. The support component channel of claim 5, wherein the gel cushion has a cross-sectional shape of an oval.

7. The support component channel of claim 6, wherein the oval has a major axis dimension between about 0.1 mm to about 10 mm and a minor axis dimension between about 0.1 mm to about 10 mm.

8. The support component channel of claim 5, wherein the gel cushion comprises a silicone gel.

9. The support component channel of claim 5, wherein the gel tube further comprises an outer membrane surrounding the gel cushion.

10. The support component channel of claim 9, wherein the outer membrane comprises thermoplastic polyurethane.

11. A method of creating a brassiere having a support component channel, the method comprising:

providing a gel tube having a first side and a second side;

providing an underwire tunnel casing coextensive in length with the gel tube;

placing the tunnel casing adjacent the first side of the gel tube;

providing a cover fabric coextensive in length with the gel tube;

placing the cover fabric adjacent the second side of the gel tube;

covering the gel tube with side edges of the cover fabric that are folded over respective side edges of the gel tube; and

attaching the tunnel casing, gel tube, and cover fabric to a brassiere cup.

12. The method of claim 11, wherein the step of attaching the tunnel casing, gel tube, and cover fabric to the brassiere cup comprises sewing along two seam allowances of the cover fabric simultaneously.

13. The method of claim 11, further comprising inserting an underwire into a tunnel in the tunnel casing.

14. The method of claim 11, further comprising covering both the tunnel casing and the gel tube with side edges of the cover fabric that are folded over respective side edges of the tunnel casing and gel tube.

15. The method of claim 14, further comprising sewing two seam allowances of the cover fabric to the respective side edges of the tunnel casing prior to attaching the tunnel casing, gel tube, and cover fabric to the brassiere cup.

16. The method of claim 15, wherein the step of sewing the seam allowances of the cover fabric to the respective side edges of the tunnel casing comprises sewing both seam allowances of the cover fabric simultaneously.

17. The method of claim 15, wherein the cover fabric and the tunnel casing are sewn together prior to providing the gel tube and placing the gel tube and the tunnel casing adjacent one another.

18. The method of claim 17, wherein the cover fabric and tunnel casing are attached to the brassiere cup prior to attaching the gel tube to the brassiere cup.

19. The method of claim 18, wherein the gel tube is attached to the brassiere cup by inserting it into a gap between the tunnel casing and the cover fabric.

20. The method of claim 15, wherein the cover fabric and the tunnel casing are sewn together after providing the gel tube and placing the gel tube and the tunnel casing adjacent one another.

21. The method of claim 20, wherein the cover fabric, tunnel casing, and gel tube are attached to the brassiere cup as a single unit.

22. The method of claim 20, wherein the cover fabric, tunnel casing, and gel tube are sewn together simultaneously to being attached to the bra cup.

23. A method of creating a brassiere having a support component channel, the method comprising:

providing a cushioning tube having a first side and a second side;

providing an underwire tunnel casing separate from the cushioning tube and coextensive in length with the cushioning tube;

placing the tunnel casing adjacent the first side of the cushioning tube;

providing a cover fabric coextensive in length with the cushioning tube;

placing the cover fabric adjacent the second side of the cushioning tube;

creating a support component channel by covering both the tunnel casing and the cushioning tube with side edges of the cover fabric that are folded over respective side edges of the tunnel casing and cushioning tube;

sewing the cover fabric to the tunnel casing by sewing along two seam allowances of the cover fabric simultaneously;

attaching the support component channel to a brassiere cup by sewing along the seam allowances of the cover fabric simultaneously; and

inserting an underwire into a tunnel in the tunnel casing after the support component channel has been attached to the brassiere cup.