GARMENT HAVING PERFORATED SYNTHETIC SUPPORTS

Abstract

Vented support structures for garments and garments with vented support structures are described. The support structures are made of silicone or soft plastic. The support structures include one or more openings that allow the body heat of the wearer to pass through the support structure. The support structures are placed in the garment in a region that is required to provide support to the wearer and is prone to perspiration. A method of making such support structures, which includes forming holes in a cured silicone support structure either before the silicone is cured or thereafter is also described.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of filing date of U.S. Provisional Application No. 63/021,469, filed on May 7, 2020, the disclosure of which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

Women's garments configured to be worn on the upper torso have features that accommodate the female anatomy, such as the bosom. The female figure is highly variable and most such garments are mass produced. The fact that no one style or fit suits all women in a given size category forces women to shop for particular sizes and particular fits among scores of garments, each with their own particular style and fit that may or may not work for a particular individual. Women are often required to sacrifice comfort for the fit and look that they desire.

Garment supports present other issues for the wearer. Supports are often constructed of solid materials, such as hard plastic or metal. Solid materials can be the source of discomfort for a wearer for a variety of reasons. Hard plastic or metal supports can be rigid and poke the wearer. Metal supports can set off metal detectors. Rigid, solid supports can be visible through layers of fabric, which creates an undesirable appearance. Rigid, solid supports also make garments difficult to fold and store. Rigid, solid supports can kink, break or twist in a manner that distorts the garment. When rigid supports, such as wires, bend or twist, the garment is rendered at best uncomfortable and at worst unusable.

Consequently, garments with solid supports that control, reduce or minimize discomfort to the wearer continue to be sought.

BRIEF SUMMARY OF THE INVENTION

Described herein is a garment with at least one support made of solid, non-rigid material. Non-rigid, as use herein, means that the support will not break when deformed. Also, when a stress is applied to the support causing it to change shape, the support will not retain that shape when the stress is removed (unlike a wire, which, when bent, will remain bent without additional stress being applied to the wire). The support can be placed in the garment such that it supports a region of the wearer's anatomy that benefits from such support. Typically, such regions are the breast, stomach, waist and back. Supports for a woman's breasts in a garment such as a bra or brassiere garment and garments having a brassiere or bra portion are well known.

Described herein is a garment support made of a solid material (e.g. silicone) that is at least somewhat flexible and is also perforated. Perforation is provided to allow the body heat of the wearer to escape through the solid support. The extent of perforation is largely a matter of design choice. The perforations are referred to as holes or vents herein because they allow the body heat of the wearer to escape or vent through the solid support. However, there is no requirement that the holes or vents be round. The holes or vents can be of any geometric configuration such as square, rectangular, slitted (straight or curved), channels (straight or curved), provided the support can accommodate such geometries and retain its ability to function as a garment support. Channels are thinner portions of the support that are adjacent thicker portions. Channels are not required to extend through the thickness of the supports. As such, channels form a side vent as opposed to a through vent.

The support is selected for its structural characteristics. Such characteristics include flexibility, resilience, etc. The support structure is constructed to have a shape and size consistent with its placement in the garment and the support it is required to provide. In one embodiment, the garment is a bra that has a cup portion with cups that receive the breasts of the wearer. The cups are affixed to the body portion of the garment. The body portion of the garment has features that allow the garment to be fitted onto the wearer. Such features include, but are not limited to, straps, clasps, elastic fabric, etc. Such features secure the garment on the wearer. The garment can be configured in a variety of fits and styles that are well known to those skilled in the art. Not all fits and styles are described herein and the styles and fits disclosed are by way of example and are not to be considered as limiting in any way.

Unlike typical support structures, the support structures with vents, perforations, holes, passages, etc. provide a surface that allows the body heat of the wearer to escape through the support structure. This reduces or even eliminates perspiration induced by the amount of body heat trapped by the support structure.

The support structures contemplated herein are shaped structures made of a synthetic material (silicone, soft plastic, etc.). The support structure has a shape or contour adapted for its purpose in the garment. The support structures are bendable, twistable, etc. in response to an applied force. In one aspect, the support structures are resilient (i.e. the support structure can be deformed, but returns to its particular shape or contour when the applied force is removed). In another aspect, the support structure is both elastic and resilient. In yet another aspect, the support structure is inelastic (i.e. it resists stretching), in that it cannot be stretched, but it is also flexible and/or resilient.

In one embodiment, the support structures are placed beneath a cup portion of a bra garment. In some embodiments, the garments have an edge finish. Typically, the edge of the garment is finished with a band of material. In a bra garment, for example, the band extends on the body portion of the garment such that it forms a substantially continuous band at least beneath the cup portion. In certain embodiments, the band will extend substantially around the garment when the garment is being worn (i.e. beginning from the backside of the garment, around the front side of the garment and terminating in the back). In these embodiments, the band may be interrupted, for example by a fastening portion of the garment. The fastening portion, as used herein, is the portion of the garment that is brought together so that it can be secured by the wearer with fasteners (e.g. zippers, clasps, etc.) when worn. The fastening portion can be any conventional fastener for such garments. Non-limiting examples include hooks, snaps, buttons, zippers, Velcro®, etc. Also, contemplated herein are garments that are not fastened together to be worn. The wearer dons such garments by either stepping into them or pulling such garments on over their head. In those embodiments where the garment does not need to be fastened together to be worn, the band is a substantially continuous band formed at least beneath the cup portion and, in some embodiments, extending around the garment.

The support structures can be disposed in a casing, but this is not required. Casing, as used herein, refers to the support structure being covered by fabric so that it is not on the outside of the garment or in contact with the wearer when the garment is worn. Such casings are typically fabric, but can be other materials (e.g., a foam or silicone coating, etc.). Since the support structures are porous, thereby providing vents that allow body heat to escape therethrough, any casing will be selected so that the venting is not significantly impeded. In one aspect the casing is a fabric with a weave that does not impede venting. In another aspect, the casing can be a wicking fabric or have a wickable finish. In yet another aspect the casing can have corresponding holes to ensure that body heat that vents through holes in the support structure is not trapped by the casing. In some embodiments, the support structure is covered by the outer fabric of the garment but the support structure is in direct contact with the wearer (i.e., there is no fabric being interposed between the wearer and the and the support structure.

In an embodiment where the support structure is provided in a bra garment, the support structure is positioned relative to the cup portion such that it proximately follows the contour of the cups, although it might be placed a distance from the cups and is therefore not required to be placed immediately adjacent to the cups. In this regard, the support structures have an approximately arcuate shape. The support structure can be positioned to provide an anchor point or region to the garment, but this is not a requirement. In such embodiments, the support structure is at least partially attached to a portion of the garment that does not stretch as much or have as much give as the body fabric of the garment. For example, in a bra, the support will have an arcuate shape roughly following a contour of the cup portion of the garment. In those embodiments where the support structure has a proximately arcuate shape, the portion of the support structure that forms the anchor region is about at the midpoint of the arc (i.e., proximate to or at the apex of the arc of the support). Anchor, as used herein, is a defined region of the band that does not stretch or “stretches less” than other portions of the band when the garment is subjected to tension. Similarly, the position of the support structure affixed to the band to form the anchor does not adjust or change relative to the band portion to which it is affixed when the garment is subjected to tensions, stress and strain. The anchor provides stability to the garment when worn.

On other portions of the garment, the support structure does not anchor the garment and, as a result, the support structure position can “float” in response to the garment stretch. As used herein, “float” does not mean complete and unrestricted movement of the support structure relative to the garment on which or in which it is disposed. Rather “float” means that the support structure does not significantly impede the stretch ability of the fabric to which the support structure is adjacent or attached and that the support structure position will respond to stresses, strains and tensions to which the garment is subjected when worn. In this manner, the support structure and the fabric adjacent the support structure respond differently to stresses, strains and tensions to which the garment is subjected when worn.

“Body fabric” as used herein is the base fabric of the garment to which the other garment components (e.g. the cups, the straps, the band, the support structure, etc.) are attached to assemble the garment. The body fabric can be a single layer of material or multiple layers of materials. Each layer of material is conventionally referred to as a ply, with multiple layers of material being referred to as multi-ply herein.

The support structure is affixed to the garment in any conventional manner such as sewing or gluing. The support structure is typically disposed between layers of fabric, such as the outer surface of the garment and the inner surface thereof, which is in contact with the wearer when the garment is worn. As noted above, since the support structure has holes or passages therein that vent the body heat from the wearer, any fabric covering the support structures will not impede such venting. Disposing the support structure in fabric or in a casing protects the support structure, and also prevents the support structure from being in direct contact with the wearer, which can cause discomfort or irritation.

The fabric selected for the body fabric of the garment can be virtually any fabric suitable for garments. In those aspects where the garment is a brassier, bra or any garment that incorporates a bra portion (including foundations, shapewear, swimwear, activewear, sundresses, etc.), the fabric is selected for that particular type of garment. Suitable fabrics for bras, foundations, shapewear, swimwear, etc. typically have some stretch. The stretch is typically in all directions although fabrics that have limited or no stretch in some directions and a greater amount of stretch in other directions are contemplated as suitable. Direction, as used herein, is relative to the plane of the fabric.

In one aspect, the garment is a bra. As noted above, a bra has cups that fit over the wearer's breasts. The cups in the cup portion of the garment can be any conventional material. In one example, the cup is a molded fabric that, through the molding process, has a predefined stretch such that the cup retains its molded shape. Garments with cut and sewn-in cups or fiber fill foam cups are also contemplated. The cups can also be single ply or multi-ply. The garments described herein provide the wearer with a natural feeling lift that provides both confidence and comfort. While cups are typically associated with undergarments or foundation garments such as bras, the fact is that any garment contemplated herein will include a cup portion for fit and function.

In terms of the garments described herein, the garment can be any type of garment that would benefit from adding a support structure thereto for improved fit and comfort. Garments that have support structures such as those disclosed herein have a number of advantages. Since the support structures are thin and flexible, the support structures, which are disposed in the garment interior, are not visible to others and provide unnoticeable support to the wearer. Because such supports are flexible, they do not poke the wearer. Because the supports are made of synthetic material, they will not set off a metal detector (unlike conventional metal support structures). Synthetic materials hold up well even after the garment is washed multiple times, and do not need to be washed separately (depending on the garment fabric), and, because rigid supports are lacking in the garments described herein, the garments do not twist in the wash. Also, the supports dry easily, so that garments with slow to dry regions, such as swimsuits, dry quicker. Also, because the supports are light and flexible, they store easily, because they can be compressed to a small size. Because they lack rigid support structures, garments with such supports do not get hung up on other garments. Garments with such support structures are less bulky, are lighter weight and therefor pack and ship easily and less expensively.

The support structures described herein are used in any garment that uses such support structures. For example, support structures such the back stays are described in U.S. Pat. No. 9,648,911, which is entitled, “Garment with Back Stays for Enhanced Fit,” the disclosure of which is incorporated by reference herein.

The support structures described herein are comfortable because they are flexible but provide support. The flexibility also allows the support structures to adapt to the wearer. Because the support structures are flexible, they offer more comfortable support than rigid structures such as metal wires, which can kink or break. Because the support structures are light, they easily remain affixed to the garment even after multiple washings. The support structures resist distortion. The support structure materials have surfaces with a high coefficient of friction, so they stay in place when worn and do not readily shift position when worn.

In one aspect a garment having the support structures described herein includes a structure for supporting a woman's breasts and can be a brassiere or bra, an undergarment or shapewear garment that incorporates a bra or brassiere portion (for example, a camisole, body brief, long line bra, etc.) or a more conventional garment that incorporates a bra or brassiere portion (e.g. a sundress). Activewear garments such as swimwear or other sports or exercise garments that incorporate a bra or brassiere portion to provide the wearer with support and confidence during their selected activity are also contemplated. Garments with a support structure that support a wearer's abdomen, waist, or back are also contemplated.

A method for fabricating a garment is also described herein. The method includes forming a support structure for a garment. Forming one or more holes or vents in the support structure, where the hole density will allow at least a portion of the body heat generated by the wearer in the region of the body over which the support structure will be placed to escape through the one or more passages in the support structure. In one aspect, the support structure is made of silicone. After the support structure is fabricated, it is placed on the location of the garment where support is required and affixed to the garment in that location. In those aspects where the support structure is placed in a casing, the casing is selected so that the venting is not significantly impeded. In one aspect the casing is a fabric with a weave that does not impede venting. In another aspect, the casing can be a wicking fabric or have a wickable finish. In yet another aspect the casing has holes or passages that are provided in the casing that correspond to the holes or vents in the support structure. If the support structure is placed between layers of fabric in the garment, the fabric is selected so that the venting is not significantly impeded. In one aspect the fabric has a weave that does not impede venting. In another aspect, the fabric can be a wicking fabric or have a wickable finish. In yet another aspect the fabric may have holes or vents that correspond to the holes or passages in the support structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a bra or bra portion of a larger garment with vented, solid supports according to one embodiment of the present invention.

FIG. 2 illustrates a shapewear garment having a bra or bra portion with vented solid supports shown in phantom according to a second embodiment.

FIG. 3 illustrates a sundress with a bra or bra portion with vented support structures shown in phantom according to a third embodiment.

FIG. 4 illustrates a swimsuit with a bra or bra portion with vented support structures shown in phantom according to a fourth embodiment.

FIG. 5 is a perspective view of one embodiment of a support contemplated herein.

FIG. 6 is a back view of an alternative garment with support structures as described herein placed in the back thereof.

DETAILED DESCRIPTION

An embodiment of the present invention is illustrated in FIG. 1. Illustrated as a bra or brassiere, the illustrated embodiment can be incorporated into a larger garment. The garment 100 has two cups 110. The cups 110 are assembled with and supported by the body fabric 120. The garment is illustrated in a front view with the cups projecting from the page. The garment is illustrated as having portions 130 illustrated as straps, but straps are optional. The openings 140 fit around the arms and shoulders of the wearer. The mechanism by which the garment 100 is secured on the wearer is not illustrated. Typically, the body of the garment extends around the wearer's torso and the ends of the body of the garment terminate adjacent each other in the mid shoulder region of the wearer's back where the ends of the garment are fastened together to secure the garment onto the wearer. However, the securement mechanism is not absolutely required to be in any one location although garment design and function may drive a particular placement. The portions of the garment that extend beneath the arms and around to the back of the wearer where they are fastened (referred to as bra wings in the context of those garments), are portions 150. In FIG. 1 portions 150 and 130 are also formed from the body fabric. In some embodiments, cups 110 are molded body fabric, whereby the body fabric is shaped to form the cups. In other embodiments, the cups 110 are foam cups or other cups incorporated into the garment by attaching the cups to the body fabric 120 of the garment by sewing, gluing, etc. The garment supports the cups and secures them on the wearer. In this manner, the cups can be integrated into the garment either by molding the body fabric to include cups or by attaching the cups to the body fabric. The cups can be single ply or multi-ply. In another embodiment, the garment is formed with the cups through molding of the cups into the body fabric. In some embodiments, the cups can have a foam middle layer with body fabric disposed on either side of the foam.

The body fabric of the garment illustrated in FIG. 1 can also be single ply or multi-ply. In one example, the garment may have a lace outer layer disposed on a layer of body fabric. An additional layer might be placed on the inner portion of the garment. In the context of garments, the inner portion is the portion closest to the wearer and the outer portion is furthest away from the wearer. The skilled person is aware of the many ways in which a garment such as a bra can be constructed, the fabric used and the number of fabric layers in the garment. These conventional aspects of garment design are not described in detail herein.

Bras or brassieres and garments that incorporate them are made using a variety of manufacturing techniques including sewing, gluing, etc. The bras or brassieres and the garments that incorporate the bras and brassieres described herein are not limited to any one manufacturing technique nor any one way of securing the garment components together.

The bra of FIG. 1 has a band 160 disposed on the garment body in a location beneath the cups 110. As noted above, the band 160 is made of a material that stretches to some degree. Put another way, pulling or applying tension on the band 160 causes the band to stretch. In FIG. 1, the band 160 is illustrated as the finished lower edge of the garment 100. However, in other embodiment the garment 100 may extend lower on the torso of the wearer such that the band 160 is placed in the illustrated location relative to the cups 110 but is not the finished lower edge of the garment. In some embodiments, the band 160 is a narrow elastic. However, the band 160 may be silicone or simply folded over fabric or some other fabric with sufficient stretch to perform the function of the band as described herein. In this manner, the band may be made using the same fabric that forms the body portion, but modified in some way to provide a different stretch than that of the body fabric. Modifications in the stretch of the portion of the body fabric that forms the band are achieved by, for example, folding the fabric on itself, depositing silicone or other adhesive on the portion of the body fabric, or other techniques for causing a change in the way a fabric stretches. Such techniques are well known to one skilled in the art. When the band is formed from the same piece of fabric used for the garment body fabric, the band is described herein as monolithic with the body portion. Indeed, the band material can be any conventional material used in garments provided that the band material stretches to some degree. Additional examples of stretchable material include spandex, elastane (Lycra), Lastex and Nylon. Certain synthetic fabrics and other materials may also be considered stretchable provided elastomeric fibers are disposed therein, such as denim with elastic fibers interwoven with cotton fibers. In contrast, some materials do not provide the described stretching function. For example, cotton, linen, silk, wool and leather are typically not considered to be stretchable. Nor are synthetic fabrics such as acetate, chiffon, organza and velvet typically viewed as stretchable materials. Typically, the ability of a material to stretch depends on whether the material has some elasticity. For example, when a fabric includes a plurality of fibers, at least some of those fibers are elastomeric if the fabric is to be stretchable. The degree to which the band will stretch is largely a matter of design choice.

The band portion as illustrated extends laterally below the cup portion of the garment. As noted above, when the garment incorporates a bra or brassiere portion as part of a larger garment (e.g. a swimsuit, a camisole, a sundress), the band, if present, may still be disposed beneath the cups but not at the edge of the garment, since in these constructions the garment extends lower on the torso of the wearer and therefore the edge of the garment is removed from where the band is placed. Such garments are illustrated in FIGS. 2-4. The distance between the cups 110 and the band is largely a matter of design choice. However, in one aspect, the location of the band 160 is somewhat defined by the placement and trajectory of the support structures 170 on or in the garment since the support structures are affixed to the band at the anchor regions. As described elsewhere herein, the support structures described herein are not required to anchor the garment.

The support structures 170 are strips of a synthetic material such as silicone or soft plastic that provide support to the wearer. The placement of the support structures 170 is such that they are disposed on the body fabric 120. That placement is largely a matter of design choice. However, the vented support structures will typically be placed in garments in areas that require support and are susceptible to perspiration. One such region is the region under the breast. The support structures described herein that are placed under the breast provide what is referred to herein as a “natural lift” to the wearer. The natural lift provides the wearer with comfortable support that enhances the appearance of the wearer consistently when the garment is worn. Such consistent enhancement provides the wearer with both comfort and confidence. The support structures 170 are affixed to the garment 100 by any conventional technique for garment fabrication including, but not limited to, sewing or gluing.

The support structures 170 are illustrated with holes or vents 175. As described herein the holes or vents in the support structures allow the body heat of the wearer to escape through the support structures. The number of vents in the support structure is largely a matter of design choice, as is the size of the vents. The number of vents and the size of the vents are selected, keeping in mind the physical characteristics of the support itself. The size and number of holes is limited to ensure that the mechanical and structural properties of the support are not adversely affected, thereby rendering the support unsuitable for providing support.

Support materials each have a hardness and flexibility. Flexibility is influenced by the thickness and length of the support in addition to the inherent support material properties (hardness, resilience, etc.). Placing holes or vents in a support structure can also influence the flexibility of a support structure. The diameter of the holes and their distribution will also have an effect on the flexibility of a support structure, where for a given support made of a particular material and having a particular length and thickness, a support with holes will have more flexibility than a support without holes. Consequently, contemplated herein is a method wherein a support is selected that is made of a specific material and has a predetermined length and thickness. According to the method, a predetermined flexibility for the support structure is identified. Hole size, shape and distribution are then selected so that the support structure has the target predetermined flexibility. Holes of the selected size, shape and distribution are then placed in the support to provide a support with the desired flexibility. The holes or perforations can be introduced in any conventional manner such as by molding a support with holes or introducing holes into a preformed, solid support. The vents in the support structure can be of the same size or different sizes. For example, where the support structure spans different regions of the body of the wearer, the region of the body that perspires more can have more vents or vents of a larger size or some combination thereof. If follows that, if the support structure has a portion placed on a region of the body of a wearer that perspires less, fewer and/or smaller vents will suffice. As noted, before, placing more vents closer together or providing larger vents may make the support structure more flexible but can also reduce resilience.

In one example the support is made of silicone. In one aspect, the silicone is shaped into a support using a mold wherein a liquid silicone precursor is introduced into the mold and cured, thereby forming the support. The manufacture of the support structures described herein, made of the materials described herein, are well known to one skilled in the art and is not described in detail herein. Examples of suitable silicone elastomer materials are Smooth-Sil™ 945, Smooth-Sil™ 950, and Smooth-Sil™ 960, which have Shore A hardness of 45 A, 50 A and 60 A, respectively and cure at room temperature. Such materials can be obtained from Smooth-On, Macungie Pa. The vents can be formed either in the mold used to shape the support or can be formed in the support post-cure. The vent size is largely a matter of design choice, but a vent that does not provide a sufficiently sized passage my not permit the escape of sufficient body heat. In one embodiment that span of the vent is about ⅛ of an inch (0.125 inches; 3.175 mm) to about 5/32 of an inch (0.15625 inches; 3.969 mm). If the vents are circular, the vent radius is in the range of about 0.125 inches to about 0.15625 inches. The number of vents in a support structure and their spacing is largely a matter of design choice. However, too few vents, or vents spaced too far apart, may fail to significantly mitigate perspiration. In one aspect, the center to center spacing of two vents is at least twice the diameter of a vent. Center to center spacings that are at least three times the diameter of vent, at least four times the diameter of a vent, or at least five times the diameter of a vent are contemplated.

As noted herein, vents can be of almost any configuration. The vents are not required to be round and can be of virtually any geometric shape. The vents can be slits through the thickness of the supports. The vents can be channels that vent through the side of the support. A support 570 illustrated in FIG. 5 has a mix of vents 575 through the support thickness and recessed channels 580 that vent through the side of the support 570. The recessed channels are placed on the inward (toward the wearer) side of the support. Although FIG. 5 illustrates a support with both through vents (perforations) and side vents (channels) this is not required. Supports with only one of the two types of vents are contemplated herein.

The support structures 170 are also fastened to the body fabric 120 by any conventional mechanism, examples of which are sewing and gluing. However, such fastening of the support structures 170 to the body fabric does not create an anchor. As noted herein, the support structure is typically elongate, flexible and/or resilient and has a relatively thin cross section. As such these supports typically flex more at their terminus than they do in their center. Such supports are lighter than conventional rigid supports made of metal or hard plastic. Although the support structures can be attached to the garment fabric using any suitable technique for attachment, gluing provides for a smoother looking garment when worn. The support structures 170 are typically enclosed in fabric or other materials, which are often referred to as casings. As noted herein, if a vented support structure is placed in a casing, the casing is selected so that the venting is not significantly impeded. In one aspect the casing is a fabric with a weave that does not impede venting. In another aspect, the casing can be a wicking fabric or have a wickable finish. In yet another aspect the casing has holes or openings are provided in the casing that approximately align with the vents in the support structures. This ensures that the body heat is vented through the support structure regardless of whether or not it is placed in a casing.

Support structures, as used herein, include support structures with and without casings or coatings. In one embodiment, the support structures 170 are silicone or soft plastic. The materials are at least one of pliable, flexible and resilient. The shape of the support structure is largely a matter of design choice but typically the support structures have a planar upper and lower surface (the lower surface being the surface affixed to the fabric). The width of the surface is typically greater than the thickness of the support. The support structure will flex in response to garment stress, strain, and tension and then release to its natural position when such tension, strain or stress is removed. The skilled person is aware of how garments with support structures are constructed. The way the support structures are incorporated into the garment is largely a matter of design choice. In some embodiments, the support structures are encased in fabric casings and disposed on the surface of the garment (i.e. the surface of the garment in contact with the wearer). In other embodiments, the support structures are disposed between garment layers (either in casings or not in casings). In such constructions, the support structures 170 are disposed either on the multi-ply or between plies of fabric such that the supports will not poke or pinch the wearer.

In the garment 110 of FIG. 1, the two support structures 170 are placed so that there is a space between them at 195 even at the portion on the garment in which they are most proximate to each other. This permits the support structures to move toward each other in response to tensions to which the garment 100 is subjected. This underscores a feature of the garment, i.e. that the portions of the support structures 170 that are not disposed on the less stretchable materials the form the garment (such as the band) do not form an anchor allowing the garment fabric to stretch and the position of the support structures 170 to adjust somewhat independently, which improves the fit, look and comfort of the wearer.

The support structures 170 follow proximately the contour of the cups 110 and are placed at a distance therefrom. In one embodiment, the support structure has an approximately arcuate shape. In a variant, to the extent a particular curved shape is not considered arcuate, such curved shapes are also contemplated for the support structure. The distance of the support structures 170 from the cups 110 is largely a matter of design choice. If a portion of the support structure 170 is to form an anchor, then a portion of each support structure is disposed on the band 160 with the support structures 170 extending onto the body fabric approximately conforming to the contour of the cup 110. As illustrated in FIG. 1, the support structures extend at least about halfway up on both sides of the cup, but this is not required. The support structures can extend further up the cup than illustrated and can extend less up the cup than illustrated. For example, sides of each support structure can extend less than or further up the cup than illustrated in FIG. 1. The extent to which the support structure extends is largely a matter of design choice. The support structure can extend above the cup and even further up the garment. However, if the portion of the support structures that terminate between the cups terminate in the region 195, this provides the wearer with better support. In a variant, an outer portion of a support structure can extend up the cup more than an inner portion, where the outer and inner portions both extend from the portion attached to the band but in opposite directions. In this way, a portion of the support structure closest to the arm opening extends to a further or lesser extent from the band than a portion of the support structure closest to the gore of the garment.

In an alternative aspect, the garment in FIG. 1 has a control region 190. Such a control region may still have some give or stretch but not to the extent of other portions of the garment body (e.g. body fabric portions 120, 130, 150) that do not function as a control region. Such a control region (also referred to as a gore) are well known to one skilled in the art. The control region can be almost rigid, but has at least some ability to stretch in response to tensions, stress and strains to which the garment is subjected. A control region can be formed from one or more layers of fabric that are less stretchable than the body fabric. A control region can also be formed by applying adhesive or silicone to the fabric which reduces its ability to stretch. The control region is advantageous in that it keeps the cups aligned with respect to one another. This mitigates the risk of misalignment of the garment when worn. As a result, this control region can function as an anchor. Anchor and control regions, although contemplated herein, are optional and not required to be present in the garments with the breathable supports described herein.

FIG. 2 illustrates a second embodiment in which the garment 200 is a camisole or long line garment. The garment 200 has cups, 210, and support structures 270 with vents 275. Unlike the bra garment illustrated in FIG. 1, in this garment there is no band adjacent cups 210 and therefore the support structures 270 do not form an anchor. The cups 210, support structure 270 and vents 275 are illustrated in phantom because they are visible from the inside of the garment.

In those embodiments where the support structure includes a fabric casing, the support structure disposed in the casing is secured in the casing to prevent the support structure interior structure from migrating within the casing. This is accomplished by tacking the support structure in the casing. The fabric casings (not shown) can either be co-extensive with the support structures or extend beyond the terminus of the support structures. Extending the fabric casings may stabilize the support structures without restricting the ability of the support structures to adjust position as the garment shifts and stretches when worn. Support structures having an interior structure disposed in a casing are well known. Tacking interior structures in casings to retain the interior structure in the casing is also well known to one skilled in the art and not described in detail herein.

As illustrated in FIGS. 2, 3 and 4, support structures 270, 370 and 470, respectively, may extend even further up the garment. FIG. 3 illustrates a sun dress 300. The sun dress 300 has cups, 310, and support structures 370 with vents 375. Unlike the bra garment illustrated in FIG. 1, in this garment there is no band adjacent cups 310 and therefore the support structures 370 do not form an anchor. The cups 310, support structure 370 and vents 375 are illustrated in phantom because they are visible from the inside of the garment.

FIG. 4 illustrates a swimsuit 400. The swimsuit 400 has cups, 410, and support structures 470 with vents 475. Unlike the bra garment illustrated in FIG. 1, in this garment there is no band adjacent cups 410 and therefore the support structures 470 do not form an anchor. The cups 410, support structure 470 and vents 475 are illustrated in phantom because they are visible from the inside of the garment.

As noted above, the garment as described above can be a bra or brassiere, or a bra or brassiere portion of an undergarment or shapewear garment (camisoles, long line bra, body briefer; etc.) or active wear (e.g. swimwear). Other embodiments include the garment described above incorporated into a sun dress or other conventional garment. Examples of the garments enumerated above are non-limiting.

One alternative garment configuration is illustrated in FIG. 6. The garment illustrated is a strapless bra garment 600 incorporating both a cup or bra portion 610 and a torso portion 620. The back view of the garment 600 is illustrated. There is disposed on the torso portion two pairs of support structures 630, 630′ each pair spaced roughly equidistant from the wearer's spine. Pair 630 is nested within pair 630′. The supports 625 contain perforations 626 as described herein. The perforations can be distributed evenly or unevenly and they can be of the same size or different sizes. The number and size of the perforations can affect the flexibility of the support structure, with more perforations and/or larger perforations providing increased flexibility and less perforation and/or smaller perforations providing for less flexibility.

The torso portion has a gripper feature 640 disposed thereon near the lower portion of the garment that rests at the waist of the wearer. The silicone feature 640 prevents the garment 640 from riding up while the support structures 630, 630′ keep the garment 600 from slipping downward. The garment is configured to provide support to wearer through the midsection, so the garment fabric provides controlled stretch to provide support, smoothing and shape to the wearer.

A method for fabricating a garment is also described herein. The method includes forming a support structure for a garment. According to the method, one or more holes or vents is/are formed in the support structure. The holes or vents allow at least a portion of the body heat generated by the wearer in the region of the body over which the support structure will be placed to escape through the one or more passages in the support structure. The amount of body heat that will escape through the holes or vents is determined by the size of the vents, the number of the vents and the proximity of the vents to other vents. In one aspect, the support structure is made of silicone. After the support structure is fabricated, it is placed on the location of the garment where support is required and affixed to the garment in that location. In those aspects where the support structure is placed in a casing, holes or vents are provided in the casing that correspond to the holes or vents in the support structure. If the support structure is placed between layers of fabric in the garment, the fabric is selected so that the venting is not significantly impeded. In one aspect the fabric has a weave that does not impede venting. In another aspect, the fabric can be a wicking fabric or have a wickable finish. In yet another aspect the fabric has holes or vents that correspond to the holes or passages in the support structure.

While this invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. The preferred embodiments should be considered in descriptive sense only and not for purposes of limitation. Therefore, the scope of the invention is defined not by the detailed description of the invention but by the appended claims, and all differences within the scope will be construed as being comprised in the present invention. Those in the art will understand that a number of variations may be made in the disclosed embodiments, all without departing from the scope of the invention, which is defined solely by the appended claims.

Claims

1. A garment comprising:

a body portion including a body fabric,

a silicone or soft plastic support structure, attached to the body fabric, wherein the support structure has at least one vent formed therein, wherein the vent is configured to allow body heat from a wearer of the garment to pass through the vent, thereby causing the wearer to perspire less.

2. The garment of claim 1, wherein the garment is a bra or comprises a bra portion further comprising two arcuate support structures, each positioned on the garment proximate a contour of a respective cup in cup portion of the garment, wherein each arcuate support structure includes a first portion encompassing an apex of the arcuate support structure, and first and second termini, each extending from the apex portion.

3. The garment of claim 2, wherein the body fabric is a multi-ply fabric.

4. The garment of claim 3, wherein the arcuate support structures are disposed on the multi-ply fabric or between a first ply and a second ply.

5. The garment of claim 1, wherein the support structure is configured to respond to tensions to which the garment is subjected when worn without impeding the ability of the body fabric adjacent to the support structure to stretch.

6. The garment of claim 1, wherein the at least one vent is through a thickness of the support structure.

7. The garment of claim 1, wherein the at least one vent is through a side of the support structure.

8. A garment comprising:

a body portion including a body fabric;

a cup portion including two cups, the cup portion shaped from the body portion or attached to the body portion; and

two curved support structures each positioned on the garment proximate a contour of a respective cup in the cup portion, the curved support structures each constructed from silicone or soft plastic, the support structures comprising at least one vent, wherein the vent is configured to allow body heat from a wearer of the garment to pass through the vent, thereby causing the wearer to perspire less.

9. The garment of claim 8, wherein the body fabric is a multi-ply fabric.

10. The garment of claim 9, wherein the curved support structures are disposed on the multi-ply fabric or between a first ply and a second ply.

11. The garment of claim 8 wherein the garment is selected from the group consisting of a bra, a shapewear garment, a sundress and a swimsuit.

12. The garment of claim 8 wherein the at least one vent is through a thickness of the support structure.

13. The garment of claim 8 wherein the at least one vent is through a side of the support structure.

14. The garment of claim 13 wherein the curved support structures are made of silicone or a soft plastic.

15. A method for making a garment with a support structure comprising:

determining a size, shape, and flexibility of a support structure to be included with the garment;

based on the garment and the position in garment in which the support structure is to be placed;

selecting a size and placement of vents in the support structure;

obtaining s support structure of the determined size, shape and flexibility having vents with the selected size and placement therein; and

attaching the support structure to the garment.

16. The method of claim 15 wherein the support structure is at least one of pliable, flexible or resilient.

17. The method of claim 15 wherein the support structure is made of silicone or soft plastic.

18. The method of claim 15 wherein the garment is made of a multi-ply body fabric and the support structure is attached to the multi-ply body fabric.

19. The method of claim 18 wherein the support structure is place between two layer of the multi-ply body fabric.

20. The method of claim 15 wherein the vents are evenly distributed on the support structures.

21. The method of claim 15 wherein the vents have an uneven size distribution or uneven placement or both.