LIGHT WEIGHT UPPER-BODY SUPPORT GARMENT WITH MODESTY AND CLEAN AESTHETIC

Abstract

An upper-body support garment that provides improved modesty and that can also be lighter weight, more sustainable, more comfortable, and/or include a desired aesthetic. The upper-body support garment can include a front portion having a laminate with one or more foam layers. The laminate layers are shaped and tailored to impart modesty to desired locations of the support garment without adding unnecessary bulk. The laminate can be integrated into a construction with flatter seams that can provide a desired aesthetic, be less likely to create skin irritations, and mitigate or eliminate visible pad lines.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY CLAIM

This non-provisional patent application claims priority to co-pending U.S. provisional patent app. No. 63/541,671, filed on Sep. 29, 2023, and titled “Light Weight Upper-Body Support Garment with Modesty and Clean Aesthetic,” the contents of which is incorporated herein by reference in the entirety.

BACKGROUND

Upper-body support garments (e.g., bras) can be configured to perform a variety of different functions, such as support, comfort, and modesty. In some examples, a material (or combinations of materials) might provide only some of these functions, and it can be challenging to achieve a desired balance of all of (or at least most of) these functions.

BRIEF DESCRIPTION OF THE DRAWINGS

Subject matter of this disclosure can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating principles of some examples.

FIG. 1 illustrates a perspective view of an example upper-body support garment in accordance with examples herein.

FIG. 2 illustrates a side view of the outer-facing side of the front portion of the upper-body support garment of FIG. 1, in accordance with examples herein.

FIG. 3 illustrates a side view of the outer facing side of the back portion of the upper-body support garment of FIG. 1, in accordance with examples herein.

FIGS. 4A-D illustrate side views of the inner-facing side of several examples of the front portion of the upper-body support garment of FIG. 1, in accordance with examples herein.

FIGS. 5A-D illustrate cross-sectional views of several examples of the modesty layer of the upper-body support garment of FIG. 1, in accordance with examples herein.

FIG. 6 illustrates a perspective view of press components and materials that may be used to form the modesty layer of the upper-body support garment of FIG. 1, in accordance with examples herein.

FIG. 7 illustrates a cross-sectional view of the press components and materials of FIG. 6.

FIG. 8 depicts a flow diagram illustrating an example method for manufacturing an example upper-body support garment in accordance with examples herein.

DETAILED DESCRIPTION

This disclosure is related to an upper-body support garment that provides improved modesty and that can also be lighter weight, more sustainable, more comfortable, and/or include a desired aesthetic. For example, the upper-body support garment can include a front portion having a laminate with one or more foam layers. In at least some instances, the foam layers are shaped and tailored to impart modesty to desired locations of the support garment without adding unnecessary bulk. In addition, the one or more foam layers can be integrated into a construction with flatter seams that can provide a desired aesthetic and that can be less likely to create skin irritations (e.g., hot spots). Furthermore, the foam layers can be integrated without creating pad lines in the front of the support garment.

In contrast to examples of the present disclosure, conventional support garments configured to impart modesty are often bulky, heavy weight, and lack breathability That is, in conventional support garments, some material layers can be effective at providing modesty (e.g., reducing the likelihood of visible nipple protrusion), but often, conventional material layers can be less comfortable and/or can be harder to incorporate into a bra construction, based on their thickness, density, and/or rigidity. In addition, in at least some conventional bra constructions, material layers are affixed to one another along seams, and material layers that are thicker (e.g., to obscure nipple protrusion) can create thicker seams that are more likely to themselves visibly protrude and that can be uncomfortable (e.g., due to chaffing or other skin irritation). In addition, in some conventional constructions, discrete pads are integrated into the front panel, such that the pads (e.g., pad outlines) are often visible on the outside of the support garment.

In some examples of the present disclosure, the upper-body support garment can include a modesty layer formed by a laminate that includes one or more thinner peripheral regions, which can contribute to flatter seams when attached to other parts of the upper-body support garment, and one or more thicker central regions configured to obscure nipple protrusion. For example, the laminate can include a foam sheet arranged between two stretch liners, which can be compressed to, and retained at, a smaller thickness in the peripheral regions, while remaining uncompressed and loftier in a central region.

The laminate can, in some instances, be combined with other material layers. For example, an upper-body support garment can include a multi-layer construction that includes the laminate combined with one or more additional material layers (e.g., a knit layer, a woven layer, a nonwoven layer, etc.), to further obscure nipple protrusion (e.g., based on the loftier central region), while avoiding bulky, thick seams based on the smaller thickness around the periphery.

In some examples, the laminate is easily customizable to include various silhouettes or shapes, which can be based on the fit and style of the upper-body support garment. For example, a generic laminate blank can be configured to include a compressed region that forms a periphery around a non-compressed region, and the compressed region of the generic laminate blank can include a size and shape configured to accommodate a variety of different sizes and shapes. For instance, a pattern can then be cut out from the generic laminate blank to form a pattern piece for incorporation into an upper-body support garment.

In some examples, the laminate can be combined with one or more additional structures for additional functionality. For example, one or more additional foam layers (e.g., shaved foam), additional lamination layers, or printing may also be applied to the laminate in the compressed regions, the non-compressed regions, or both. In addition, different types of bonding may be used to maintain the desired thickness or loft of the laminate in particular areas while taking into account these additional structures or processes.

Examples of this disclosure can include a modesty layer (e.g., for a support garment) that includes a laminate having at least one central region with a thickness that is greater than the surrounding peripheral region, with the central region or regions providing improved coverage against nipple protrusion showing through the modesty layer and the outer surface of the bra. The modesty layer described herein includes a laminate with a foam layer in between two stretch layers of material. In an example, the modesty layer is configured to provide coverage to both breasts of a wearer. The laminate is compressed in the peripheral region around the central regions so that the thickness of the peripheral region is less than that of the central region. This reduced thickness can provide advantages such as contributing to flatter seams when the modesty layer is attached to other parts of the bra or other upper-body support garment, while the thicker central regions provide improved modesty coverage to prevent excess nipple protrusion and visibility of the nipples. Moreover, having the modesty layer sized and configured to cover both breasts results in a unique and pleasing aesthetic for the bra when worn. In some examples, the stretch layer may comprise a waterproof material to prevent excess sweat or other moisture from saturating the modesty layer.

In another example, an upper-body support garment using the modesty layer may further improve its modesty coverage by having another layer of material disposed between the modesty layer and the outer material layer of the bra. In some examples, this additional inner layer may be a film that is bonded to the central regions of the modesty layer laminate. In other examples, the inner layer can include a film or textile layer that covers the central regions and peripheral regions of the modesty layer. This additional inner layer may also be, for example, in the form of flocking that is adhered to the central regions of the modesty layer during manufacturing. The flocking may be of a material that provide not only additional loft and opacity to the central regions of modesty layer but may also improve softness to the touch of the outer surface of the bra. In another example, to maximize opacity and nipple protrusion the additional inner layer may include a hard insert made of plastic or other stiff opaque material that may be shaped to provide a smooth contour to the outer surface of the bra.

Although the term “bra” and “support garment” are used herein, it is contemplated that the terms may apply to other types of support garments such as tank tops, camisoles with built-in support, swimming suit tops, body suits, and other styles or types of support garments used to support breast tissue. Example support garments may include bras as that term is known in the art (sport bras, conventional bras, and the like), camisoles, swimwear, or other garments with built-in support.

Additionally, positional terms as used herein to describe the bra or upper-body support garment such as “anterior,” “posterior,” “front,” “back,” “upper,” “lower,” “bottom,” “inner-facing surface,” “outer-facing surface,” and the like are with respect to the garment being worn as intended and as shown and described herein by a wearer standing in an upright position.

The term “seam” as used herein generally refers to an area where two or more separate components, e.g., textile or fabric portions, are joined together at or adjacent to their edges by, for instance, stitching, bonding, welding, adhesives and the like. For the purposes of this discussion, a seam is considered to be a visible interface, joining point, or transition point between the edges of two portions of material. In many cases, the edges of the two portions may be overlapped and bonded together or stitched. In contrast, “seamless” is considered to include transition points between different portions of material that would not be visible to a user of the bra and that do not include significant edge overlapping or stitching. A unitary portion of a layer without transition points is considered to be seamless.

The term “laminate” as used herein generally refers to a structure formed from layers of material bonded together. The layers may be joined via adhesive, bonding, fusing, or other methods. The term “stretch layer” as used herein generally refers to a textile layer of the laminate that exhibits at least some amount of stretch (i.e., elasticity) in at least one dimension. As used herein, “about” includes +/−10% of a given value.

Referring to FIGS. 1-3, a bra 100 associated with examples of the present disclosure is depicted. The bra 100 generally includes a front portion 110, a back portion 130, an underband or rib band 150, and shoulder straps 160. The bra 100 also has a neck hole 170, arm holes 172, and torso opening 174.

The front portion 110 is configured to cover the wearer's chest and provide support, comfort, modesty, and the like. In at least some examples, the front portion 110 of the bra 100 can include one or more textile layers, which can include an outer layer 112 and one or more inner layers (not shown in FIGS. 1-3) that can be combined with the outer layer 112. Examples of the one or more inner layers are depicted in association with FIGS. 4A-B and 5A-E and are described in association with those figures below.

In at least some examples, the outer layer 112 can include a single pattern piece that extends from the left side of the front portion 110 to the right side of the front portion 110, such that the outer-facing surface 114 is substantially seamless. In some examples, the outer layer 112 can include multiple pattern pieces that are seamed together to span across the front portion 110, from the left side to the right side. The outer layer 112 can include one or more types of textiles, such as knit, woven, nonwoven, spacer textile, films, foam pads, and the like. In some examples, the front portion 110 can include a single textile layer. In other examples, the front portion 110 can include multiple textile layers that are combined, such as a laminate, composite, etc.

The outer layer 112 of the bra 100 can include one or more yarns having various properties. In some instances, the yarns can include polyester, which as compared to some other materials can include lower moisture regain, which can facilitate the movement of moisture or perspiration away from a skin surface of a wearer to an outer-facing surface 114 of the bra 100 where the moisture or perspiration may evaporate. In some examples, the outer layer 112 can include an elastomeric yarn, such as elastane, which can provide a degree of stretch that can assist with donning and doffing the bra 100 and/or to provide a level of support. In at least some examples, one or more materials associated with the outer layer 112 can be based on cost, durability, colorfastness, resistance to odor, washability, and sustainability.

The back portion 130 of the bra 100, as shown in FIGS. 1 and 3 is configured to contact at least a portion of the wearer's back torso when the bra 100 is in an as-worn configuration. The back portion 130 of the bra 100 includes a main back panel 132 and a central column 134 that extends upward from the main back panel 132. The back portion 130, including the main back panel 132 and central column 134 may include a back layer 131 formed of the same material as that of the front portion outer layer 112. In other examples, the back layer 131 may be formed of a different material. For example, the material of the back layer 131 may be selected to have different stretch characteristics than that of the material used for the front portion outer layer 112. The material used to form the back layer 131 may include perforations to increase breathability, or may offer a different visual aesthetic (e.g., different color or surface texture).

Underband 150 is positioned along the bottom of the front portion 110 and the back portion 130 and encircles torso opening 174. In the example shown in FIG. 1, the underband 150 is a visible component of the bra 100 and the top edge 152 of the underband 150 is sewn to the bottom edges 116, 136 of front portion 110 and back portion 130 respectively along seam 154. In another example, the underband 150 is concealed and may be housed in a tunnel or sleeve formed along the bottom edges 116, 136 of the front portion 110 and the back portion 130. The material for underband 150 may be any type of material capable of being elastically stretched. In some examples, the material for the underband may be selected based on particular properties that may provide additional comfort, such as a textile made of fibers with a longer staple length or larger diameter.

In the example shown in FIG. 3, the edges of back portion 130 and front portion 110 are joined together along seams 120 using a bagged out stitching technique, which creates a cleaner aesthetic. In other examples, the front portion 110 and back portion 130 may be joined by other stitching or bonding techniques.

In the example of FIGS. 1-3, the front portion 110 and the back portion 130 are also joined together by straps 160. As seen in FIGS. 1-3, the pair of shoulder straps 160 extend from the upper part of the front portion 110 to the central column 134 of the back portion 130. More specifically, the shoulder straps 160 include front shoulder straps 162 which extend from the front portion 110, over the shoulders and transition to back shoulder straps 164 on the back portion 130 of bra 100, with the front shoulder straps 162 being joined to the back shoulder straps 164 along seams 166.

Back shoulder straps 162 extend downward from the seams 166 and join at the top of the central column 134. The central column 134 then extends downward and joins the top of main back panel 132. In the embodiment shown in FIGS. 1 and 3, it can be seen that this configuration of straps 160, central column 134 and main back panel 132 defines a racerback-style bra configuration. This style of bra may be advantageous in maintaining the positioning of the bra, and particularly the straps 160, on the wearer during times of increased physical activity, as the straps are less likely to slip along or down the shoulders toward the elbow. However, in other examples, any other bra configuration may be used, including but not limited to strapless, balconette, convertible, backless, plunge, push-up and t-shirt styles. Any and all examples, and any variation thereof, are contemplated as being within examples herein.

The shoulder straps may include one or more layers of material to impart different properties to the straps. For example, straps 160 of the upper-body support garment 100 shown in FIG. 1 may include an outer layer, a middle layer, and an inner layer. The outer layers of front straps 162 and back shoulder straps 164 may be integrally formed or of the same piece with the front portion outer layer 112 and back layer 131, respectively. The inner layer of the straps, which is the layer that touches the skin of the wearer, may be made from the same type of material as the outer layer or may be selected to enhance other properties, such as comfort against the skin. The middle layer may be formed from a material, such as a mesh material, that provide stability, structure and strength to the straps 160 while also allowing for breathability.

In the embodiments shown in FIGS. 1-3, fixed length, non-adjustable shoulder straps 160 are illustrated. In other examples the shoulder straps may include an adjustment system. Suitable adjustment systems may include, for example, adjustment hooks combined with adjustment ladders or slots. Sliding buckle mechanisms, a conventional hook-and-eye adjustment system, or any other adjustment mechanism known in the art may also be used.

In the upper-body support garment shown in FIGS. 1-3, neck hole binding 175 and armhole bindings 176 are used to finish the edges of the neck hole 170 and arm holes 172. In an example, the neck hole and armhole bindings 175, 176 may be formed from the same material used for the front portion outer layer 112, or may be formed from a different material. For example, the neck hole and armhole bindings 175, 176 may be formed from a different fabric and color in order to provide a contrasting and pleasing aesthetic, or formed from a particularly soft material to reduce chafing against a wearer's skin. Other characteristics that may be considered include durability, resistance to shrinkage, cost, availability and sustainability.

Based on at least some examples of the present disclosure, FIG. 4A depicts an inner-facing surface of the front portion 110 of the bra 100 (e.g., a surface or face that faces towards the wearer when the bra 100 is worn). In at least some examples, the front portion 110 includes a modesty layer 200 that layer is positioned internal to the outer layer 112. The modesty layer 200 has an outer perimeter terminal edge 202 including sections 243, 244, 245, 246, 247, 248, 249, 250 that generally align with the corresponding sides and edges of the front portion 110. The modesty layer 200 may be joined to the front portion 110 along one or more seams shown in FIG. 4A, including the seam 154 that connects the underband to the front portion 110, seam 168 which connects the modesty layer to one or more of the inner or middle layers of the shoulder strap 160, and the seams 177, 178 for bindings 175, 176. In other examples, the modesty layer may be attached by a seam or seams to the front portion along the entirety of its perimeter terminal edge 202.

The modesty layer 200 can include one or more textile layers (e.g., FIG. 5A depicts an example cross section), such as knit, woven, nonwoven, spacer textile, films, foam pads, and the like. In some examples, the modesty layer 200 can include a single textile layer. In other examples, the modesty layer 200 can include multiple textile layers that are combined, such as a laminate, composite, etc.

In at least one example, such as the example shown in FIG. 5A, the modesty layer 200 can include a first layer 260, a second layer 280, and a third layer 270 at least partially laminated between the first layer 260 and the second layer 280, where the first layer 260 is positioned closer to the outer layer 112 relative to the other two layers 270 and 280. The outer face 262 of the first layer 260 that is opposite the third layer 270 forms the outer surface of the modesty layer 200, which faces the inner face of the outer layer 112 of the upper-body support garment 100 in FIG. 1.

The central portions 220 may be each be configured to cover a nipple and areolar portion of a breast while the peripheral region 240 may be configured to cover at least a portion of the surrounding breast tissue. The central portions 220 may have a width 277 of at least 7 cm at their widest point, which may align with the nipple-covering part of the central portion 220. In some examples, the maximum width of the central portions 277 may be at least about 7 cm, at least about 8 cm, at least about 9 cm, or at least about 10 cm. In the example shown in FIG. 4A, the central portions 220 are generally circular in shape. However, as further discussed below, the central portions 220 may be configured in a variety of shapes and sizes with wider or narrower dimensions. In other examples, a single central region may be configured to cover the nipple and areolar portions of both breasts.

To further aid in the concealment of the outlines of the central regions 220 of the modesty layer 200, a non-smooth, asymmetrical, or uneven perimeter may be used around the central regions 220. The central regions may be in the shape of other geometric shapes or portions of geometric shapes, such as ovals, arc sections, or polygons. In other examples, the central regions may have non-geometric shapes, (e.g., shapes with irregular contours whose edges are not straight lines or simple curves). Illustrative examples of different central region outlines are show in FIGS. 4B-4D. It is to be understood that the modesty layer or layers in the examples in FIGS. 4B, 4C and 4D have different right- and left-side configurations for illustrative purposes, and that it is contemplated that other examples in accordance with this disclosure may have a modesty layer with the same configuration on both sides. Additionally, it is to be understood that the modesty layer of the present disclosure may be in the form of a unitary pad (such as in FIGS. 4A, 4B and 4C) that is configured to cover both breasts of a wearer or two separate modesty layers (such as 201a and 201b in FIG. 4D) can each be configured into a separate pad, one for each side of the upper-body support garment.

Referring to FIG. 4B, the central region 232 shown on the left side of the modesty layer 200 in FIG. 4B, is adjacent to the side edge 225 of the modesty layer 200, with the rest of the perimeter 226 forming an elongated curved but non-circular shape. Another example of a non-circular shaped central region 234, on the right side of modesty layer 200 in FIG. 4B, has a perimeter defined by the bottom edge 228 of the modesty layer 200, undulating edges 227, 229 and the edge 230 adjacent to the armhole binding 176. Additional examples of different configurations of the central regions can be seen in FIGS. 4C and 4D.

In the example shown in FIG. 4C, the perimeter of the left-side central region 232c is defined by edges 225C and 226c along the peripheral region, 223c along the bottom edge 228 of the modesty layer 200, and edges 222c along the side edge 225 of the modesty layer 200 and the armhole binding 176. The perimeter of the right-side central region 234c is defined by wavy edges 227c and 229c along the peripheral region, edge 228c along the bottom edge 243 of the modesty layer 200, and edge 230c along the seam 177 of neck hole binding 175. In the example shown in FIG. 4D, the modesty layer comprises two separate pieces 201a and 201b. The right side modesty has a perimeter terminal edge defined by 243a, 244, 245, 246, 247a, and 251a, and the left side modesty layer 201b has a perimeter terminal edge defined by 251b, 247b, 248, 249, 250, and 243b. The perimeter of the right-side central region 234d is defined by wavy edges 227d, 229d along the peripheral region, edge 228d along the bottom edge 243 of the modesty layer 200 and edge 230d along the seam 168 at the base of the strap 160.

In the examples shown in FIGS. 4B, 4C and 4D, the peripheral region 240 comprises multiple sections that are separated by one or both of the central regions (e.g., 234b in FIG. 4B, 232c and 234c in FIG. 4C, and 234d in FIG. 4D). In these examples, at least one portion of one of the central region perimeters runs along the perimeter terminal edge 202 of the modesty layer 200 (e.g., 225b, 228b and 230b of FIG. 4B, 222c, 223c, 228c and 230c in FIG. 4C, and 228d and 230d in FIG. 4D). In examples where the central region has at least two portions of its perimeter along the perimeter terminal edge 202 spaced apart from each other, the central region may be able to absorb additional tension between these two portions when the bra 100 is worn, which may create a flattening effect that further minimizes any protrusion of the central region out from the front portion 110.

Turning back to the example of FIG. 5A, in at least some examples, the third layer 270 (e.g., the middle layer between the layers 260 and 280) may include a foam layer. In addition, the third layer 270 may include two central regions 220 (e.g., also depicted in FIG. 5A) that have a thickness 274 that is greater than the thickness 275 of the foam layer around the peripheral region 240 of the central regions 220. As such, each central region 220 includes a shoulder 278 that transitions from the thinner portions 272 to the thicker central regions 220. In some examples of the modesty layer 200, as shown in FIG. 5A, the shoulder 278 of the central regions 220 may be shaped to have a bevel (i.e., a sloping edge), which may help to further smooth out the transition between the central regions 220 and the peripheral region 240 and reduce any visible outline of the central region 220 that can be seen through the outer layer 112 of the front portion 110 of the bra 100. In an example, the angle 279 of the surface of the shoulder bevel 278 (when viewed from a cross-section such as the view in FIG. 5A) may form about a 135 degree angle with the surface of the peripheral region 240. In other examples, this angle may be between from about 115 degrees to about 155 degrees, though larger or small angles are also within the scope of this disclosure. The surface of the shoulder may also be rounded or curvilinear when viewed from a cross-section, as opposed to flat. The shoulder 278 thus acts as a transition region between a transition region from the second region of the foam layer (central region 220) to the first region of the foam layer (peripheral region), where the transition region decreases in thickness from the second region to the first region.

In at least some examples, the thinner foam layer 272, the first layer 260, and the second layer 280 form a peripheral region 240 around the central regions 220. The peripheral region 240 can, in some instances, include a continuous (e.g., uninterrupted) region that forms a perimeter 224 around each of the two central regions 220. However, as further described herein, the peripheral region 240 may be formed from several different sections that are not necessarily contiguous with each other. The laminate has an inner face 282 which faces the wearer when the bra 100 is in a worn state, and an outer face 262 that faces away from the wearer and towards the inner facing surface of the front portion 110 of the bra 100. In some examples, the foam of the thinner foam layer 272 of the peripheral region 240 is denser than the foam of the central regions 220. Thus, the foam layer 270 may include a first region (e.g., the peripheral region 240) with a first foam density and first thickness and a second region (e.g., the central region 220) with a second foam density and second foam thickness, where the foam of the second region is thinner and denser than the foam in the first region.

As seen in FIGS. 5A-D, the central regions 220 of the modesty layer 200, having a greater thickness 274 (e.g., as compared to the thickness 275 of peripheral region 240), can provide additional modesty coverage for the wearer. In examples, the foam of central regions 220 may have a thickness 274 between about 1.2 mm and about 6.2 mm. The foam layer's ability to provide modesty can be affected by both the density of the foam layer and the thickness of the central region. A denser foam may allow for a thinner central region to provide sufficient modesty protection than a less dense foam, which may require a greater thickness in order to provide the same level of modesty protection. In some examples, a foam layer 270 can include a central region 220 having a thickness 274 between about 1.21 mm and about 2.2 mm. In some examples, the foam layer 270 can include a central region 220 having a thickness 274 between about 2.8 mm and about 3.2 mm. In other examples, the central region 220 can include a central region 220 having a thickness 274 between about 3.8 mm and about 4.2 mm, or between about 4.8 mm and about 6.2 mm.

In some examples, the central region 220 may have an average thickness in a range of about 6 mm to about 2 mm. In an example, the foam layer 270 of the peripheral region section 240 may generally have an average thickness 275 of between about 0.8 mm and about 1.2 mm.

Thus, the ratio between the thickness of the central region 220 and the peripheral region 240 may be from about 7.75:1 to about 4:1, or from about 4:1 to about 2.3:1, or from about 2.75:1 to 1.01:1. The relative thinness of the peripheral region 240 allows for flatter seams to be formed when the modesty layer is attached to other parts of the bra, such as the middle and inner layers of front strap sections 162. These flatter seams may reduce or eliminate any outline of the seams that may be visible through the outer layer 112 of the bra 100. In viewing the example of FIG. 4A, it is appreciated that including the inner and middle strap layers, in addition to providing strength, also aids in creating a smoother visual appearance of the bra, since it increases the overall thickness of the strap to be closer to the thickness of the front portion 110 of the bra 100, which includes the modesty layer 200 and the front portion outer layer 112.

The foam layer may be composed of any foam or other material that exhibits elastic resilience after experiencing compression during normal usage and wearing conditions but that will remain at least partially compressed after being compressed (and optionally heated) during the manufacturing processes. The foam may be elastomeric but does not have viscoelastic properties. For example, the elastomeric foam immediately returns to its original state in response to stress and the elastomeric foam does not exhibit hysteresis that is characteristic of viscoelastic materials in a stress-strain curve.

The foam is a polymeric foam. The polymeric foam is the product of foaming a foamable material, thereby forming a polymeric material having a multicellular structure. Before being foamed, the foamable material may include one or more thermoplastic polymers. In some examples, the foamable material includes thermoplastic polymers, the thermoplastic polymers are not crosslinked during the foaming process, and the resulting foam is a thermoplastic foam (i.e., a foam in which the polymeric material of the foam is a thermoplastic material. A thermoplastic is a solid when cooled, and can be repeatedly softened and melted on heating. A thermoplastic foam when heated, fully melts and loses its multicellular structure. In other examples, the foamable material includes one or more thermoplastic polymers, the one or more thermoplastic polymers become crosslinked during or following the foaming process, and the resulting foam is a crosslinked foam which retains some thermoplastic properties to the extent that it is possible to soften and mold the crosslinked foam, but, when heated, the polymeric material of the crosslinked foam degrades or decomposes before it fully melts and loses its multicellular structure.

Alternatively, the foamable material may include one or more pre-polymers or oligomers which become polymerized before, during or following the foaming process. In one such example, the foamable material includes one or more pre-polymers or oligomers polymerize into thermoplastic polymers. In another such example, the foamable material includes one or more pre-polymers or oligomers which polymerize and crosslink.

The foam is a multicellular thermoplastic foam. The foam is a molded foam, meaning that the foam has been molded either during or after the foaming process (e.g., using heat, pressure or both heat and pressure). In one example, the molded foam includes a solidified skin surrounding a multi-cellular foam core. When the foam is molded after it has been foamed, the molding process can be used to alter its surface(s), its volume, its density, its multicellular structure, or any combination thereof. In one example, the molded foam is the product of exposing a foam pre-form (e.g., a pre-molded or cut piece of foam) to heat, pressure or a combination of heat and pressure, thereby altering a surface, volume, density, multicellular structure or any combination thereof, of the foam pre-form. For example, the molded foam can have a thicker skin or a different surface texture in one or more regions as compared to the foam pre-form, the molded foam can have a smaller overall volume as compared to the foam pre-form, the molded foam can include one or more regions in which the multicellular structure of the foam has been altered to have a higher density as compared to the foam pre-form, the molded foam can include one or more regions in which the shape of the cells of the multicellular structure have been altered as compared to the foam pre-form, or any combination thereof.

In another example, the molded foam (that is, the foam molded using heat or pressure, or both heat and pressure) may be molded during a molding process to form a first region and a second region, where the first region is more compressed than the second region. Further, the first region may comprise a skin on an outer surface, the skin covering the cell structure of the foam. The skin on the surface of the first compressed region may be formed during the molding process, and the second region may have a thinner skin (e.g., when the second region being compressed but less than the first region such that the thickness of the second region is greater than the first region) compared to the first region or not include a skin on its surface (e.g., when the second region is not compressed).

In yet another example, the molded foam may comprise a transition region between the first and the second region. The transition region may be a sloped surface between the first and the second region. During the molding process, the mold may be configured to form the transition region, and in one example, a skin may be formed on the sloped surface (e.g., due to constraints applied by the mold). In this example, the first region and the transition region may each have a skin on a surface of the cell structure of the foam while second region may have a thinner skin with respect to the first region or no skin.

In some examples, the foam can be a foam having a surface including a first region with a skin on a surface of the cell structure of the foam, and a second region without a skin on a cell structure of the foam, such that the cell structure of the foam is exposed at the surface of the second region. For example, the skin of the first region can be a skin formed during a molding process. The second region in which the cell structure of the foam is exposed can be formed by cutting, shaving or skiving away a skin which previously defined the surface of the second region, or by expanding the foam in a manner such that a skin is not formed at the surface in the second region.

In examples where the foamable material (the material used to form the foam) includes one or more polymers, the one or more polymers may comprise, consist essentially of, or consist of a polymer chosen from a polyurethane, a polyurea, a polyester, a polyether, a polyamide, a polyimide, a polyolefin, a polystyrene, a polysiloxane, a polycarbonate, a polyacetate, and any combination thereof, including homopolymers and copolymers thereof. The one or more polymers may include a polymer chosen from a polyurethane, a polyester, a polyamide, a polystyrene, a polyolefin, and any combination thereof. The foamable material can comprise an elastomeric polyurethane, such as an elastomeric polyester-polyurethane. The foamable material can comprise a polyester homopolymer or a polyester copolymer, such as elastomeric polyetherester copolymer. The foamable material can comprise a polyamide, such as an elastomeric polyamide copolymer, including an elastomeric polyamide block copolymer. The foamable material can comprise a polystyrene copolymer, such as an elastomeric styrene-ethylene-butadiene-styrene (SEBS) copolymer. The foamable material can comprise a polyolefin homopolymer or a polyolefin copolymer, such as an elastomeric ethylene-propylene copolymer, or an elastomeric ethylene-vinyl acetate (EVA) copolymer.

The polymeric material of the foam (e.g., the solidified material forming the cell walls of the multicellular foam) includes one or more polymers. The one or more polymers may comprise, consist essentially of, or consist of a polymer chosen from a polyurethane, a polyurea, a polyester, a polyether, a polyamide, a polyimide, a polyolefin, a polystyrene, a polysiloxane, a polycarbonate, a polyacetate, and any combination thereof, including homopolymers and copolymers thereof. The one or more polymers may include a polymer chosen from a polyurethane, a polyester, a polyamide, a polystyrene, a polyolefin, and any combination thereof. The polymeric material of the foam can comprise an elastomeric polyurethane, such as an elastomeric polyester-polyurethane. The polymeric material of the foam can comprise a polyester homopolymer or a polyester copolymer, such as elastomeric polyetherester copolymer. The polymeric material of the foam can comprise a polyamide, such as an elastomeric polyamide copolymer, including an elastomeric polyamide block copolymer. The polymeric material of the foam can comprise a polystyrene copolymer, such as an elastomeric styrene-ethylene-butadiene-styrene (SEBS) copolymer. The polymeric material of the foam can comprise a polyolefin homopolymer or a polyolefin copolymer, such as an elastomeric ethylene-propylene copolymer, or an elastomeric ethylene-vinyl acetate (EVA) copolymer.

The one or more polymers of the foamable material or of the polymeric material may comprise, consist essentially of, or consist of elastomers. An elastomer may be defined as a polymer having an elongation at break greater than 100 percent, or greater than 200 percent, or greater than 400 percent, as determined using ASTM D-412-98 at 25 degrees Celsius. An elastomeric material may be defined as a composition having an elongation at break greater than 100 percent, or greater than 200 percent, or greater than 400 percent, as determined using ASTM D-412-98 at 25 degrees Celsius.

Further, the polymeric material of the foam may have a substantially closed cell configuration. As one example, at least 80% of the cells of the multi-cellular foam may be closed cells.

Various methods of foaming the foamable material can be used in accordance with the present disclosure, resulting a chemically-blown foam or a physically-blown foam. When a chemical blowing agent is used, the foam is a chemically-blown foam. A chemical blowing agent is a compound which, when reacted with a second chemical or on disassociation or decomposition (e.g., when heated to a disassociation or decomposition temperature), release a gas. Examples of chemical foaming agents include sodium bicarbonate, ammonium carbonate, ammonium bicarbonate, calcium azide, azodicarbonamide, hydrazocarbonamide, benzenesulfonyl hydrazide, dinitrosopentamethylene tetramine, toluenesulfonyl hydrazide, p,p′-oxybis(benzenesulfonylhydrazide), azobisisobutyronitrile, barium azodicarboxylate, and any combination thereof. In some aspects, the blowing agent comprises or consists of one or more chemical blowing agents.

When a physical blowing agent is used, the foam is a physically-blown foam. A physical blowing agent is a compound which phase transitions from a solid, liquid or supercritical fluid to a gas when the temperature, pressure, or temperature and pressure are changed. Physical blowing agents include low-boiling-point hydrocarbons, such as hydrocarbons such as isobutene and pentane, and partially halogenated hydrocarbons such as partially halogenated fluorochlorohydrocarbons. Physical blowing agents also include inert gasses and supercritical fluids. In some aspects, the blowing agent used to form the foam includes or consists of a physical blowing agent. In one such aspect, the blowing agent comprises or consists of a supercritical fluid, such as supercritical carbon dioxide (CO2) or supercritical nitrogen (N2).

Optionally, the foamable material and the resulting polymer material of the foam may comprise one or more additives. Examples of additives include fillers, polymerization initiators, crosslinking agents, UV light absorbers, anti-oxidants, processing aids such as lubricants and plasticizers, and colorants, such as pigments and dyes. Fillers may include non-polymeric fillers such as silica, clay, and titanium dioxide. In some aspects, the foamable material may be a material which polymerizes or crosslinks or both polymerizes and crosslinks before, during or following the foaming process. The polymerization may be initiated by a polymerization initiator present in the foamable material. The crosslinking may be initiated by a crosslinking agent present in the foamable material, and produces a crosslinked foam.

In examples, the foam layer 270 may be comprised of a different material, or a combination of foam with another material or materials, at least some of which may also be capable of being compressed. In some examples, spacer textile may be used in combination with or in place of the foam. The term “spacer textile” is meant to encompass both warp knit and weft knit spacer textiles as is known in the art of textiles. Knit spacer textiles are generally formed by utilizing at least one tie yarn to interknit first and second layers of the textile. More specifically, each of the first layer and the second layer may be knit separately, and the tie yarn(s) is used to connect the first layer and the second layer. For instance, the tie yarns may have “loop” portions that extend into each of the first layer and the second layer where the loop portions are interlooped with yarns in the first layer and the second layer to connect the two layers. In example aspects, the tie yarns are oriented generally orthogonal to the surface planes of the first and second layers and act to space apart the first and second layers. The result is that a space is formed between the first and second layers that may be used to retain or store perspiration, milk, and/or other forms of moisture. The spacer textile may be attached to one or more of the other layers by sewing, adhesives, bonding, or other methods, and may be attached along one or more seams or across at least a portion of adjacent surfaces.

The stretch layer may be composed of a knit, woven or nonwoven textile. Desirable characteristics and factors to consider when selecting a stretch material include comfort against the wearer's skin, cost and availability. In an example, the first stretch layer 260 and the second stretch layer 280 each have a thickness between about 0.1 mm and about 1.0 mm. In another example, the first stretch layer 260 is composed of a different material than that of the second stretch layer 280, with the first stretch layer 260 having a different thickness than that of the second stretch layer 280.

In at least some examples, one or more of the stretch layers 260, 280 are elastomeric, which can serve to provide structural integrity to the laminate of the modesty layer 200 while permitting some stretch of the laminate to occur without breaking or permanently deforming the foam layer 270. In other words, the stretch layers 260, 280 act as a limiting factor in the amount of stretch experienced by the modesty layer 200 when the upper-body support garment 100 is worn, while also allowing some amount of stretching to occur.

The modesty layer 200 can include one or more additional features to contribute to the functionality of the modesty layer 200. In some instances, the modesty layer 200 can include one or more additional material layers positioned internal to the second layer 280. For example, the modesty layer 200 can include a film (e.g., film 290 in FIG. 5B) bonded to the central regions 220, which could otherwise have exposed foamed material. The film 290 can, among other things, help to seal the foamed material in the central regions 220 that are not covered by the second stretch layer 280 from exposure to moisture and air.

In some examples, such as the one shown in FIG. 5B, a second material layer 292 can be arranged internal to the modesty layer 200 (e.g., configured to be between the modesty layer 200 and the wearer when the bra is worn). The second material layer 292 can cover the central regions 520, as well as the peripheral regions 240. In some examples, the second material layer 292 can include a film. In other examples, the second material layer 292 can include a knit layer, woven layer, spacer textile, film, or any combination thereof. In another example, the second material layer 292 may be another foam layer, (e.g., shaved foam) or flocking. The second material layer 292 can further smooth out the transition between the central regions 220 and the peripheral region 240, mitigating or eliminating pad lines from being visible through the outer layer 112 of the bra 100.

In other examples, the second material layer 292 can be arranged next to the foam layer 270, e.g., between the foam layer 200 and the first stretch layer 260, or between the foam layer 270 and the second stretch layer 280. In some of these examples, the second material layer 292 may include a spacer textile, at least portions of which may also be compressed. The second material layer may be attached to the other layers by sewing, adhesives, bonding, or other methods, and may be attached along one or more seams or across at least a portion of adjacent surfaces.

In examples, the second material layer may include a spacer textile having a first thickness in a first portion and a second thickness in a second portion. The thickness of the first portion may gradually change or transition along the edge of the first portion from the first thickness to the second thickness or to a third thickness.

In some examples, the second portion of the second material layer may include spacer textile that is compressed (e.g., by the application of heat, pressure, or both) and the first portion of the second material layer may include spacer textile that is uncompressed or less compressed than the spacer textile of the second portion.

In other examples of the modesty layer, such as the one shown in FIG. 5C, the second layer 280 can include openings or voids (e.g., 284), and the central regions 220 can be positioned in (and extend through) the voids 284. The shoulders 278 may have a different profile than the bevel shown in FIG. 5, such as a rounded profile. In some examples, such as the one shown in FIG. 5D, the central regions 220 may subsequently be covered by another material layer 290. The material layer 290 may be a film similar to the film used for second material layer 292 in the example of FIG. 5E. Such a film can help reduce yellowing of the foam and moisture absorption by the foam. In other examples, the material layer 290 may be used to improve comfort against a wearer's skin.

As shown in FIGS. 5A-5D, in an unworn state the outer surface 210 of the modesty layer 200 is generally flat, including the portions of the outer surface 210 opposite the thicker central regions 220 and their respective shoulders 278. In an assembled and worn state, the outer surface 210 and modesty layer 200 will be generally contoured to the user's body.

The modesty layer 200 may be manufactured in any manner known in the art for making laminated articles. For example, in an example and with reference to FIGS. 6 and 7, to manufacture modesty layer 200, portions of material for first stretch layer 260, foam material for foam 270, and material for second stretch layer material 280 are provided, such as by cutting the pieces from larger bolts of material. In examples where a modesty layer such as the ones shown in FIG. 5C are being manufactured, voids 284 in the second stretch layer 280 are formed, such as by cutting or stamping them out. The portions of material may then be placed on a first platen 300 of a press in layers, with the first stretch layer portion 260 being nearest to the top surface 302 of the first platen 300 and the second stretch layer portion 280 being furthest from the first platen 300, with the foam portion 270 being positioned in between. A second platen 320 of the press, having voided regions 322 that correspond to the shapes of the central regions, can then be closed over the layers of material. Pressure (and optionally heat) are then applied to compress the layers together into a single laminate and to form the peripheral region 240, while leaving the foam corresponding to the voided regions 322 in the second platen 320 relatively uncompressed, forming the central regions 220 of the modesty layer 200. In examples of manufacturing modesty layers such as the one shown in the example of 5D, the second film 290 can then be attached or applied over the exposed surfaces of the central regions 220. In examples, finishing steps, such as a final shaping of the perimeter terminal edge 202 of the peripheral region 240 (e.g., via cutting or stamping, can then be performed. In other examples, the shaping of the perimeter terminal edge 202 can be performed prior to arranging the layers in the press.

In examples, the manufacturing of the modesty layer 200 can include additionally shaping of the central region 220. As shown in FIG. 5A, the shoulder 278 is shaped to include a bevel. The bevel may be formed by varying the amount of compression the foam in the shoulder region experiences during the lamination phase of the manufacturing process. For example, the voided regions 322 in the second platen 320 may have angled surfaces configured so that they compress the portions of the foam layer 270 corresponding to the shoulder 278 of the central region 220 by varying degrees so that the beveled shoulder 278 of FIG. 5E may be formed. A shoulder 278 manufactured in this fashion may have a gradated thickness and density, with the density of the form at any point being between the density of the foam in the peripheral region and the density of the relatively uncompressed foam in the central region, depending on the amount of compression experienced by the foam at that point in the shoulder. It is to be appreciated that the relative foam density of the foam layer at any point will generally be inversely related to the relative thickness of the foam at that point.

Additional or alternative manufacturing processes may be used to shape foam layer 270 of this disclosure. For example, the different regions of the foam layer 270 (e.g., the shoulder 278 and the peripheral region 240) may first be formed (e.g., via compression or other manufacturing processes such as shaving, milling, cutting or embossing) prior to laminating the foam layer together with the first and second textile layers. In another example, one or more additional layers of foam may be added to the foam layer 270 in the central regions 220, further increasing the thickness of the resultant central regions relative to the compressed peripheral regions 240 having a single foam layer.

In another example, the peripheral region 240 may also include different regions of varying thickness, such as having less thickness along the perimeter terminal edge 202 of the modesty layer 200. This may be accomplished, for example, by configuring the surfaces of the first platen 300 and second platen 320 used in manufacturing the modesty layer 200 to further compress the laminate in certain regions of the peripheral region 240. The transition regions between these regions of varying thicknesses may be gradual, to smooth out any visible effects through the outer layer 112 of the upper-body support garment 100.

As previously discussed, the foam layer 270 may include one or more additional materials, such as spacer textile, in addition to the foam or in place of the foam in the foam layer 270, or as an additional layer one of the outer faces of the modesty layer 200. In some examples, the spacer textile or other material may be positioned together with the other layers prior to the platens compressing the layers together. In other examples the spacer textile or other material may be compressed before or after being added to the modesty layer 200.

Turning now to FIG. 8, a flow diagram of an exemplary method 800 of manufacturing a chest-covering portion of an upper-body support garment is provided. In a first step 802, a modesty layer is formed by compressing a laminate to form a peripheral region, such as peripheral region 240, that at least partially circumscribes one or more central regions that are less compressed than the peripheral region. In step 804, the peripheral region is attached to a first material layer along a seam. In step 806, an upper-body support garment is constructed by arranging the first material layer to be external to the modesty layer when the upper-body support garment is in an as-worn configuration. In examples, a secondary layer of the upper support garment may be applied to an inner face of the modesty layer of the central region, and may be affixed along at least a portion of the seam that attaches the peripheral region to the first material layer.

Other exemplary configurations are contemplated herein. For example, the modesty layer 200 may be further contoured to generally conform to a front profile of a wearer's torso. The contour may be accomplished by heating the laminate of the modesty layer 200 to a first temperature in a mold.

In other examples, the thickness of the peripheral region 240 may vary, with peripheral region 240 being thinnest at the edges that attach to the seam of the upper-body support garment and thickest adjacent to the central region shoulder 278.

In another example, in addition to shaping the shoulder 278 of the central region 220 (such as by forming a bevel), the central region 220 may undergo additional shaping using any suitable form of manufacture.

In another example, the first stretch layer 260 also has voids that correspond with the voids 284 in the second stretch layer 280 of the examples shown in FIGS. 5C and 5D, and the foam layer may also extend out from these voids in the first stretch layer 260.

In some examples, the laminate of the modesty layer can be combined with one or more additional structures for additional functionality. For example, one or more additional foam layers (e.g., shaved foam), flocking, additional lamination or material layers, or printing may also be applied to one or both sides of the laminate in the compressed regions, the non-compressed regions, or both. These additional layers may be added one or both surfaces of the foam layer prior to laminating one or both stretch layers to the foam layer. In other examples, the additional layers may be added to one or more of the surfaces of the stretch layer before or after lamination with the foam layer. In addition, different types of bonding may be used to maintain the desired thickness or loft of the laminate in particular areas while taking into account these additional structures or processes. Furthermore, in alternative embodiments, the layers may be formed of different materials than those described above. For example, the layers on either side of the foam layer may be comprised of a textile that does not exhibit stretch or elasticity, or alternatively may comprise a film instead of a textile.

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

Clause 1. An upper-body support garment comprising: a chest-covering portion comprising: a first material layer comprising an outer face and an inner face; and a laminate affixed adjacent the inner face and comprising a peripheral region that at least partially circumscribes a central region and that is thinner than the central region; wherein the first material layer is affixed to the peripheral region along a seam.

Clause 2. The upper-body support garment according to clause 1, wherein the laminate comprises a first laminate layer, a second laminate layer, and a foam layer between the first laminate layer and the second laminate layer.

Clause 3. The upper-body support garment according to clause 2, wherein the laminate further comprises a perimeter terminal edge around the peripheral region, and wherein the perimeter terminal edge is affixed to the first material layer along the seam.

Clause 4. The upper-body support garment according to clause 3, wherein the perimeter terminal edge comprises the foam layer laminated between the first laminate layer and the second laminate layer.

Clause 5. The upper-body support garment according to clause 4, wherein the perimeter terminal edge is affixed to the first material layer along the seam and around an entirety of the laminate.

Clause 6. The upper-body support garment according to clause 4 or 5, wherein a first portion of a perimeter of the central region runs along the perimeter terminal edge.

Clause 7. The upper-body support garment according to clause 6, wherein at least a second portion of the perimeter of the central region runs along the perimeter terminal edge.

Clause 8. The upper-body support garment according to any of clauses 1 to 7, wherein: the laminate comprises a laminate outer face and a laminate inner face; the laminate inner face comprises a shoulder that transitions from the peripheral region to the central region; and the laminate outer face is flat at a portion of the outer face that is opposite the shoulder.

Clause 9. The upper-body support garment according to any of clauses 1 to 8, wherein: the peripheral region comprises a thickness in a range of about 0.8 mm to about 1.2 mm; and the central region comprises a thickness in a range of about 1.8 mm to about 2.2 mm.

Clause 10. The upper-body support garment according to any of clauses 1 to 9, further comprising a second material layer between the inner face of the first material layer and the central region.

Clause 11. The upper-body support garment according to clause 8, wherein the laminate further comprises a second material layer attached to the laminate inner face.

Clause 12. The upper-body support garment according to any of clauses 1 to 11, wherein at least a portion of a perimeter of the central region has an undulating profile.

Clause 13. The upper-body support garment according to any of clauses 1 to 12, wherein a perimeter of the central region is fully circumscribed by the peripheral region.

Clause 14. A method of manufacturing a chest-covering portion for an upper-body support garment, the method comprising the steps of: compressing a peripheral region of a laminate textile to form a modesty layer for the chest-covering portion, wherein the peripheral region at least partially circumscribes a central region that is less compressed than the peripheral region; attaching the peripheral region to a first material layer along a seam; and constructing an upper-body support garment by arranging the first material layer external relative to the modesty layer.

Clause 15. The method according to clause 14, wherein the peripheral region is compressed to comprise a peripheral region thickness in a range of about 0.08 to 1.2 mm.

Clause 16. The method according to clause 15, wherein the central region comprises a thickness in a range of about 1.8 to 2.2 mm.

Clause 17. The method according to clause 16, wherein: the laminate textile comprises a first face and a second face opposite the first face; compressing comprises applying a platen of a heat press to the second face; and the first face is oriented towards the first material layer in the upper-body support garment.

Clause 18. The method according to clause 17 further comprising, applying a secondary layer to an inner face of the central region, the inner face positioned on the second face of the laminate textile.

Clause 19. The method according to any of clauses 14 to 18, wherein the laminate textile comprises a first layer, a second layer, and a foam layer between the first layer and the second layer.

Clause 20. The method according to any of clauses 14 to 19, wherein compressing comprises applying a platen of a heat press to the peripheral region, and wherein the platen comprises a voided portion that forms the less compressed central region.

Clause 21. A composite comprising: a first textile layer; a foam layer adjacent the first textile layer, the foam layer including a first region and a second region contiguous with the first region; wherein: the first region has a first thickness and a first foam density, and the second region has a second thickness and a second foam density; the first foam density is greater than the second foam density; and the first thickness is less than the second thickness.

Clause 22. The composite according to clause 21, wherein a ratio between the second thickness and the first thickness is in a range from about 7.75:1 and 1.01:1.

Clause 23. The composite according to clauses 21 or 22, wherein the second region has a second shape, and wherein the second region is at least partially circumscribed by the first region.

Clause 24. The composite according to clause 23, wherein the second shape has a curved edge.

Clause 25. The composite according to clause 23 or 24, wherein the second shape is a non-geometric shape.

Clause 26. The composite according to any of clauses 21 to 25, further comprising a transition region from the second region to the first region, wherein the transition region decreases in thickness from the second region to the second region.

Clause 27. The composite according clause 26, wherein the composite comprises at least part of a pad of an upper-body support garment.

Clause 28. The composite according to clause 27, wherein the pad comprises one or more of a first breast covering portion and a second breast covering portion, each of the one or more first and the second breast covering portions including the first region, the second region, and the transition region.

Clause 29. The composite according to any of clauses 21 to 28, wherein the foam layer comprises a molded foam.

Clause 30. The composite according to clause 29, wherein the first region comprises a first skin on a surface of the foam layer.

Clause 31. The composite according to clause 30, wherein the second region has no skin on the surface of the foam layer.

Clause 32. The composite according to clause 30, wherein the second region comprises a second skin on the surface of the foam layer that is thinner than the first skin.

Clause 33. The composite according to any of clauses 21 to 32, wherein the composite comprises at least part of a pad of an article of apparel.

Clause 34. A pad for an upper-body garment, the pad comprising: a laminate comprising: a first textile layer; and a foam layer adjacent the first textile layer, the foam layer including a first region and a second region contiguous with the first region; wherein: the first region has a first thickness and a first foam density, and the second region has a second thickness and a second foam density; the first foam density is greater than the second foam density; and the first thickness is less than the second thickness.

Clause 35. The pad according to clause 34, wherein the laminate further comprises a second textile layer adjacent the foam layer and opposite the first textile layer.

Clause 36. The pad according to clause 34 or 35, wherein the laminate further comprises a third region contiguous to the first region and separate from the second region, wherein the third region has a third thickness that is greater than the first thickness and a third foam density that less than the first foam density.

Clause 37. The pad according to clause 36, wherein the third thickness is about equal to the second thickness and the third foam density that is about equal to the second foam density.

Clause 38. The pad according to any of clauses 34 to 37, wherein the second region further comprises a transition region adjacent the first region, the transition region having a gradated density between the first foam density and the second foam density.

Clause 39. A method of manufacturing a pad for an upper-body garment, the method comprising the steps of: providing a foam layer having a first thickness; and compressing a first portion of the foam layer to a second thickness that is less than the first thickness while leaving a second portion of the foam layer uncompressed or less compressed; wherein the first portion at least partially surrounds the second portion.

Clause 40. The method according to clause 39, wherein the foam layer comprises a second portion, the second portion having a third thickness after the compressing step that is greater than the second thickness of the first portion.

Clause 41. The method according to clause 40, wherein the third thickness is less than the first thickness.

Clause 42. The method according to any clause 39 to 41, further comprising the step of laminating a first textile layer to a first surface of the foam layer.

Clause 43. The method according to clause 42, further comprising the step of laminating a second textile layer to a second surface of the foam layer, the second surface being opposite the first surface.

Clause 44. The method according to clause 43, wherein the steps of laminating the first textile layer and the second textile layer are performed simultaneously with the compressing step.

Clause 45. The method according to any of clauses 39-45, further comprising the step of forming a region within the first portion configured for being attached along a seam of the upper body garment.

The recitation of “and/or” as used herein in connection with two or more elements should be interpreted to mean only one element, or a combination of elements. For example, “element A, element B, and/or element C” may include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or elements A, B, and C. In addition, “at least one of element A or element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Further, “at least one of element A and element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.

This above detailed description is provided in order to meet statutory requirements. However, this description is not intended to limit the scope of the disclosure described herein. Rather, the claimed subject matter may be embodied in different ways, to include different steps, different combinations of steps, different elements, and/or different combinations of elements, similar or equivalent to those described in this disclosure, and in conjunction with other present or future technologies. The examples herein are intended in all respects to be illustrative rather than restrictive. In this sense, alternative examples or implementations can become apparent to those of ordinary skill in the art to which the present subject matter pertains without departing from the scope hereof.

Claims

1. An upper-body support garment comprising:

a chest-covering portion comprising: a first material layer comprising an outer face and an inner face; and a laminate affixed adjacent the inner face and comprising a peripheral region that at least partially circumscribes a central region and that is thinner than the central region;

wherein the first material layer is affixed to the peripheral region along a seam.

2. The upper-body support garment of claim 1, wherein the laminate comprises a first laminate layer, a second laminate layer, and a foam layer between the first laminate layer and the second laminate layer.

3. The upper-body support garment of claim 2, wherein the laminate further comprises a perimeter terminal edge around the peripheral region, and wherein the perimeter terminal edge is affixed to the first material layer along the seam.

4. The upper-body support garment of claim 3, wherein the perimeter terminal edge comprises the foam layer laminated between the first laminate layer and the second laminate layer.

5. The upper-body support garment of claim 4, wherein the perimeter terminal edge is affixed to the first material layer along the seam and around an entirety of the laminate.

6. The upper-body support garment of claim 4, wherein a first portion of a perimeter of the central region runs along the perimeter terminal edge.

7. The upper-body support garment of claim 6, wherein at least a second portion of the perimeter of the central region runs along the perimeter terminal edge.

8. The upper-body support garment of claim 1, wherein:

the laminate comprises a laminate outer face and a laminate inner face;

the laminate inner face comprises a shoulder that transitions from the peripheral region to the central region; and

the laminate outer face is flat at a portion of the outer face that is opposite the shoulder.

9. The upper-body support garment of claim 1, wherein:

the peripheral region comprises a thickness in a range of about 0.8 mm to about 1.2 mm; and

the central region comprises a thickness in a range of about 1.8 mm to about 2.2 mm.

10. The upper-body support garment of claim 1, further comprising a second material layer between the inner face of the first material layer and the central region.

11. The upper-body support garment of claim 8, wherein the laminate further comprises a second material layer attached to the laminate inner face.

12. The upper-body support garment of claim 1, wherein at least a portion of a perimeter of the central region has an undulating profile.

13. The upper-body support garment of claim 1, wherein a perimeter of the central region is fully circumscribed by the peripheral region.

14. A composite comprising:

a first textile layer;

a foam layer adjacent the first textile layer, the foam layer including a first region and a second region contiguous with the first region;

wherein: the first region has a first thickness and a first foam density, and the second region has a second thickness and a second foam density; the first foam density is greater than the second foam density; and the first thickness is less than the second thickness.

15. The composite of claim 14, wherein a ratio between the second thickness and the first thickness is in a range from about 7.75:1 and 1.01:1.

16. The composite of claim 14, wherein the second region has a second shape, and wherein the second region is at least partially circumscribed by the first region.

17. The composite of claim 16, wherein the second shape has a curved edge.

18. The composite of claim 16, wherein the second shape is a non-geometric shape.

19. The composite of claim 14, further comprising a transition region from the second region to the first region, wherein the transition region decreases in thickness from the second region to the second region.

20. The composite of claim 19, wherein the composite comprises at least part of a pad of an upper-body support garment.

21. The composite of claim 20, wherein the pad comprises one or more of a first breast covering portion and a second breast covering portion, each of the one or more first and the second breast covering portions including the first region, the second region, and the transition region.

22. The composite of claim 14, wherein the foam layer comprises a molded foam.

23. The composite of claim 22, wherein the first region comprises a first skin on a surface of the foam layer.

24. The composite of claim 23, wherein the second region has no skin on the surface of the foam layer.

25. The composite of claim 22, wherein the second region comprises a second skin on the surface of the foam layer that is thinner than the first skin.

26. The composite of claim 14, wherein the composite comprises at least part of a pad of an article of apparel.

27. A pad for an upper-body garment, the pad comprising:

a laminate comprising: a first textile layer; and a foam layer adjacent the first textile layer, the foam layer including

a first region and a second region contiguous with the first region;

wherein: the first region has a first thickness and a first foam density, and the second region has a second thickness and a second foam density; the first foam density is greater than the second foam density; and the first thickness is less than the second thickness.

28. The pad of claim 27, wherein the laminate further comprises a second textile layer adjacent the foam layer and opposite the first textile layer.

29. The pad of claim 27, wherein the laminate further comprises a third region contiguous to the first region and separate from the second region, wherein the third region has a third thickness that is greater than the first thickness and a third foam density that less than the first foam density.

30. The pad of claim 29, wherein the third thickness is about equal to the second thickness and the third foam density that is about equal to the second foam density.

31. The pad of claim 27, wherein the second region further comprises a transition region adjacent the first region, the transition region having a gradated density between the first foam density and the second foam density.