U.S. patent application number 11/045246 was filed with the patent office on 2005-06-16 for protected underwire.
This patent application is currently assigned to Sara Lee Corporation. Invention is credited to Batcha, Deborah, Falla, Gloria.
Application Number | 20050130559 11/045246 |
Document ID | / |
Family ID | 34652896 |
Filed Date | 2005-06-16 |
United States Patent
Application |
20050130559 |
Kind Code |
A1 |
Falla, Gloria ; et
al. |
June 16, 2005 |
Protected underwire
Abstract
In a first embodiment, a first fabric layer has gelatinous
strips, thereby separating the first fabric layer into sections. A
second fabric layer is positioned upon the first fabric layer, and
an underwire is positioned on the second fabric layer opposite the
first fabric layer. The first fabric layer is then folded onto
itself to enclose the second fabric layer and the underwire. In a
second embodiment, a third, or intermediate, fabric layer is
positioned between the first and second fabric layers. In a third
embodiment, an underwire is surrounded by a first, non-woven fabric
layer. A second, rigid-type fabric having a bladder with a
gelatinous material is positioned on the first fabric. The first
fabric is wrapped around the underwire, and the bladder is
positioned against the body of the wearer.
Inventors: |
Falla, Gloria; (Demarest,
NJ) ; Batcha, Deborah; (New York, NY) |
Correspondence
Address: |
Charles N.J. Ruggiero, ESQ.
OHLANDT, GREELEY, RUGGIERO & PERLE, L.L.P.
10th FLOOR
ONE LANDMARK SQUARE
STAMFORD
CT
06901-2682
US
|
Assignee: |
Sara Lee Corporation
|
Family ID: |
34652896 |
Appl. No.: |
11/045246 |
Filed: |
January 28, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11045246 |
Jan 28, 2005 |
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10732571 |
Dec 10, 2003 |
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10732571 |
Dec 10, 2003 |
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10313992 |
Dec 6, 2002 |
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6682395 |
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Current U.S.
Class: |
450/54 |
Current CPC
Class: |
C22C 38/42 20130101;
C22C 38/50 20130101; C22C 38/44 20130101; C22C 38/06 20130101 |
Class at
Publication: |
450/054 |
International
Class: |
A41C 001/14 |
Claims
What is claimed is:
1. A cushioning structure for an underwire of a brassiere,
comprising: a first layer of fabric disposed about at least a
portion of said underwire; a first gelatinous material between said
first layer and said underwire; a second layer of fabric disposed
about at least a portion of said first layer of fabric; and a
second gelatinous material between said first layer of fabric and
said second layer of fabric.
2. The cushioning structure of claim 1, further comprising an inner
layer of fabric between said first gelatinous material and said
underwire.
3. The cushioning structure of claim 2, wherein said first and said
second layer of fabric is made of a non-woven, non-stretchable
material.
4. The cushioning structure of claim 1, further comprising a fourth
layer of fabric between said gelatinous material and said second
layer.
5. The cushioning structure of claim 4, wherein said fourth layer
is a woven, non-stretchable material.
6. The cushioning structure of claim 1, wherein said second outer
layer and said first outer layer are folded to enclose said first
and second gelatinous material and said underwire.
7. The cushioning structure of claim 1, wherein one of said first
and second gelatinous materials is silicone.
8. The cushioning structure of claim 1, wherein said underwire has
a first end and a second end, and wherein each of said first and
second ends has a protective tip positioned thereupon.
9. The cushioning structure of claim 1, wherein said inner layer is
made of a stretchable material.
10. The cushioning structure of claim 1, wherein said inner layer
is made of a three bar powernet knit.
11. The cushioning structure of claim 1, wherein said inner layer
is made of a combination of nylon and spandex.
12. The cushioning structure of claim 1, wherein said inner layer
is about 78% to about 84% nylon.
13. The cushioning structure of claim 1, said inner layer is about
16% to about 22%.
14. The cushioning structure of claim 1, wherein said inner layer
is about 81% nylon and 19% spandex.
15. The cushioning structure of claim 2, wherein-said first and
second outer layers are made of polyester.
16. The cushioning structure of claim 2, wherein said first and
second outer layers are made of 100% polyester.
17. The cushioning structure of claim 3, wherein said fourth layer
is made of nylon taffeta.
18. A cushioning structure for an underwire of a brassiere,
comprising a composite structure having at least two layers of
fabric and at least two layers of a gelatinous material, said
composite structure having an overall weight, wherein said at least
two layers of gelatinous material has a weight of about 56% of said
overall weight.
19. A method of forming a cushioning structure comprising the steps
of: applying a first gelatinous material to a side of a first layer
of material; applying a second gelatinous material to a side of a
second layer of material; positioning said second layer of material
with said second gelatinous material on said first layer of
material with said first gelatinous material; positioning an inner
layer of material on said first gelatinous material opposite said
first layer of material; positioning an underwire upon said inner
layer opposite said gelatinous material; folding said second outer
layer and said first outer layer about a fold line to enclose said
second gelatinous material, said first gelatinous material, said
inner layer of material and said underwire thereby forming a
casing; and sealing said casing along an upper edge of said second
outer layer of material opposite said fold line.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 10/313,992 filed Dec. 26, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to brassieres. More
particularly, the present invention relates to a protected
brassiere underwire and method of making the same.
[0004] 2. Description of the Related Art
[0005] The use of underwire elements, especially U-shaped
underwires, for shaping and supporting the lower periphery of
brassiere or bra cups has long been known in the art. The term
"underwire" has been in common use to refer to such elements. An
underwire includes metal wires, coated metal wires, as well as wire
elements made of many different materials, such as plastic or other
polymeric materials. These underwires must be rigid enough,
particularly in the plane of the brassiere, to provide adequate
support for the bust and yet flexible enough to conform easily to
the wearer's body for comfort and appearance. Such underwires are
provided in a variety of shapes and configurations and must satisfy
a number of requirements. For example, the underwire must not poke
through the fabric to cause damage to the clothing of the wearer,
and possibly injury to the wearer. It also must be readily
insertable. Commonly, such underwires have been inserted into
fabric sleeves disposed about the lower periphery of the bra
cups.
[0006] Modern underwires are generally formed of relatively thin
lengths of metal or polymeric material having a rectangular or
rounded cross-section. A fairly stiff length of such material is
shaped into a generalized U-shape and positioned in a sleeve
disposed about the lower periphery of each bra cup. These stiff
metal underwires are sometimes coated with various polymeric
materials and often have plastic or enamel tips disposed at each
end of the underwire.
[0007] While underwires have achieved widespread usage, certain
disadvantages result from their use. These disadvantages relate to
the relative stiffness, and therefore discomfort of these
conventional underwires, and to the uniformity of that stiffness
and, thus, the lack of adaptability to the needs of various
users.
[0008] In light of the foregoing, there is an ongoing need for
underwires or underwire structures, that are comfortable to wear,
resilient, and adequately support the breasts of the wearer.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide a
cushion feel underwire or underwire structure.
[0010] It is an another object of the present invention to provide
such an underwire structure that has a greater cushioning ability
or greater "loft" than the underwire structures of the prior
art.
[0011] It is still another object of the present invention to
provide such an underwire structure that avoids having a thick
appearance and/or a stiff feel.
[0012] It is yet another object of the present invention to provide
such an underwire structure that can be used in a number of
different sized brassieres.
[0013] It is a further object of the present invention to provide
such an underwire structure that is particularly comfortable to
wear, and can be conveniently assembled in the brassiere.
[0014] It is still a further object of the present invention to
provide such an underwire structure that has its own casing.
[0015] These and other objects and advantages of the present
invention are achieved by the underwire structure of the present
invention. In a first embodiment, there are provided two or more
outer fabric layers. The outer fabric layers each have gelatinous
strips associated therewith. The gelatinous strips separate the
outer fabric layers into sections. An inner fabric layer is
positioned upon the gelatinous strips of the first outer fabric
layer. This inner fabric layer is preferably non-woven. An
underwire is positioned on the inner fabric layer opposite the
outer fabric layer. The outer fabric layers are then folded to
enclose the gelatinous strips, the inner fabric layer and the
underwire. Thus, the underwire is enclosed in a casing formed by
the outer fabric layers. Once the outer fabric layers are folded, a
fold line is created.
[0016] In a second embodiment, there is provided four fabric layers
and an underwire. As in the first embodiment, the first and second
outer fabric layers each have at least one surface with gelatinous
strips, thereby separating the surface and/or outer fabric layer
into sections. The second outer fabric layer forms an outside
covering for the underwire. As in the first embodiment, an inner
fabric layer is positioned on the underwire to form an inside
covering for the underwire. The inner fabric layer is preferably
non-woven. An intermediate fabric layer is positioned between the
first outer and inner fabric layers to form a second interior
covering for the underwire. The underwire is positioned on the
inner fabric layer opposite the intermediate fabric layer. The
second and first outer fabric layers are folded to enclose the
inner and intermediate fabric layers and the underwire. Thus, the
underwire is encased by all four fabric layers. In this second
embodiment, a fold line is knitted into the second outer fabric
layer and first outer fabric layer prior to folding.
[0017] In a third embodiment, there is also provided an underwire.
The underwire is surrounded by a non-woven fabric layer. A bladder
containing a gelatinous material is encased by a rigid-type fabric.
The bladder is positioned on the non-woven fabric layer opposite
the underwire. The purpose of the non-woven fabric is to reduce the
risk of the underwire poking through the rigid fabric encasing the
bladder. The bladder is preformed or pre-made into a preshaped
configuration. The fabric encasing the bladder is preferably a
rigid fabric. More preferably, the fabric encasing the bladder is a
tricot or warp knit fabric. The non-woven fabric is wrapped around
the underwire, and the bladder is positioned against the body
fabric that forms the breast cup of the brassiere.
[0018] In all embodiments, the non-woven fabric layer may also be
made of a stretchable material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The objects and advantages of the present invention will be
more apparent from the following detailed description of the
present invention, in conjunction with the accompanying drawings
wherein:
[0020] FIG. 1 is a schematic drawing showing a first embodiment of
the present invention;
[0021] FIG. 2 is a magnified view of the stretch fabric used for
any of the outer layers in the first embodiment of the present
invention;
[0022] FIG. 3 is a schematic drawing showing an alternative to the
first embodiment of the present invention;
[0023] FIG. 4 is a schematic drawing showing a second alternative
to the first embodiment of the present invention;
[0024] FIG. 5 is a schematic drawing showing a second embodiment of
the present invention;
[0025] FIG. 6 is a schematic drawing showing an alternative to the
second embodiment of the present invention; and
[0026] FIG. 7 is a schematic drawing showing a third embodiment of
the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring to the drawings, and in particular, FIG. 1, there
is provided a first embodiment of an underwire structure of the
present invention generally represented by reference numeral 10.
Underwire structure 10 has a first outer layer of material 20 upon
which a first gelatinous material 50 is applied. Underwire
structure 10 also has a second outer layer of material 70 upon
which a second gelatinous material 75 is applied. It should be
noted that, while first and second outer material layers are
preferred, multiple layers may be employed to provide enhanced
cushioning effect. Gelatinous materials 50 and 75 are preferably
applied in one or more strips to first outer material layer 20 and
second outer material layer 70. However, it should be noted that
gelatinous materials 50 and 75 may be applied in any manner known
in the art. Non-limiting examples include sinusodial, dashed or
dotted patterns. An inner layer of material 30 is positioned
adjacent to gelatinous material 50 on first outer material layer
20, and an underwire 40 is positioned on or adjacent to inner
material layer 30 opposite first outer material layer 20.
[0028] As shown in FIG. 2, outer material layers 20 and 70 (outer
layer 20 represented) preferably have two strips of gelatinous
material 50 placed thereon. Accordingly, the outer material layers
preferably have three regions that are not covered by gelatinous
material 50. These three regions are two sew regions or edges 24,
and a fold line or third sew region 28. Fold line 28 is located
along the center of outer material layer 20.
[0029] Referring again to FIG. 1, second outer material layer 70
with gelatinous material 75 is adjacent to first outer material
layer 20 with gelatinous material 50. First outer material layer 20
with gelatinous material 50 is also adjacent to inner material
layer 30 with one side of inner material layer 30 contacting
gelatinous material 50. Second outer material layer 70, gelatinous
material 75, first outer material layer 20, gelatinous material 50
and inner material layer 30 are wrapped around underwire 40. A body
fabric 60 is positioned on a side of underwire 40 opposite inner
material layer 30. Second outer material layer 70 with gelatinous
material 75 and first outer material layer 20 with gelatinous
material 50 provide a cushioned feel and loft about underwire 40
thereby making the underwire structure more comfortable for the
wearer. Inner material layer 30 prevents underwire 40 from-poking
through outer material layer 20.
[0030] During assembly, second outer material layer 70 and first
outer material layer 20 are positioned adjacent to one another.
Inner material layer 30 is positioned adjacent to gelatinous
material 50 of outer material layer 20. Underwire 40 is positioned
on or adjacent to inner material layer 30 opposite outer material
layer 20. Body fabric 60 is positioned on one side of underwire 40
opposite inner material layer 30. Preferably, a portion of body
fabric 60 is positioned on one side of underwire 40 such that body
fabric 60 is in the same plane as underwire 40. Second outer
material layer 70 and first outer material layer 20 are then folded
about fold line 28 to enclose gelatinous material 75, gelatinous
material 50, and inner material layer 30 about the end of body
fabric 60 and underwire 40. When outer material layer 20 and inner
material layer 30 are folded along fold line 28, a channel is
created for underwire 40. Thus, in this embodiment, a casing for
underwire 40 is formed by second outer material layer 70,
gelatinous material 75, first outer material layer 20, gelatinous
material 50 and inner material layer 30. In the first embodiment
shown in FIG. 1, the underwire casing is sealed using single needle
stitching.
[0031] Body fabric 60 may be positioned in alternative locations in
relation to underwire structure 10. Referring to FIG. 3, body
fabric 60 may be positioned such that it is not in the same plane
as underwire 40. Instead, when second outer material layer 70 and
first outer material layer 20 are folded, body fabric 60 is
sandwiched directly between the ends of second outer fabric layer
70 and does not come into contact with underwire 40.
[0032] Referring to FIG. 4, body fabric 60 may be connected to
second outer material layer 70 at an upper edge of underwire
structure 10. This type of underwire casing is sealed using double
needle stitching.
[0033] In a second embodiment of the present invention, shown in
FIG. 5, underwire structure 10 has at least four layers of
material, second outer material layer 70, first outer material
layer 20, an inner material layer 30 and an intermediate material
layer 25 positioned between first outer material layer 20 and inner
material layer 30, and an underwire 40 positioned on inner material
layer 30 opposite intermediate material layer 25. Gelatinous
material 50 is placed on an interior surface of first outer
material layer 20. Gelatinous material 75 is placed on an interior
surface of second outer material layer 20. Second outer material
layer 70 forms an outside covering around gelatinous material 75,
first outer material layer 20, gelatinous material 50, intermediate
layer 25, inner material layer 30 and underwire 40.
[0034] Inner material layer 30 is positioned on underwire 40 to
form an inside covering for the underwire. The function of inner
material layer 30 is to prevent underwire 40 from poking through
the other layers of material.
[0035] Intermediate material layer 25 is positioned between outer
material layer 20 and inner material layer 30 to form a second
interior covering for underwire 40. Body fabric 60 is preferably
positioned on one side of underwire 40 opposite inner material
layer 30. The positioning of body fabric 60 in FIG. 5 is analogous
to the positioning shown in FIG. 1 in that a portion of the body
fabric is in the same plane as underwire 40.
[0036] Second outer material layer 70 and first outer material
layer 20 are folded about fold line 28 to enclose inner material
layer 30 and intermediate material layer 25 about the end of body
fabric 60 and underwire 40 creating a multi-layer underwire channel
for housing the underwire. Thus, in this embodiment, a casing for
underwire 40 is formed by second outer material layer 70,
gelatinous material 75, first outer material layer 20, gelatinous
material 50, intermediate material layer 25 and inner material
layer 30. In this embodiment, stitching, preferably, single needle
stitching, is used to seal the casing.
[0037] As discussed with reference to FIGS. 3 and 4, body fabric 60
may be positioned in alternative locations in relation to underwire
structure 10. As shown in FIG. 6, body fabric 60 is positioned such
that it is not in the same plane as underwire 40. Instead, when
second outer material layer 70 and first outer material layer 20
are folded, body fabric 60 is sandwiched directly between the ends
of intermediate fabric layer 25. In another alternative, body
fabric 60 is connected to second outer material layer 70 at an
upper edge of underwire structure 10. As in FIG. 4, this type of
casing is sealed utilizing stitching, preferably double needle
stitching.
[0038] Second outer material layer 70 and first outer material
layer 20 are preferably made of a stretchable material. More
preferably, second outer material layer 70 and first outer material
layer 20 are made of a three bar powernet knit. Second outer
material layer 70 and first outer material layer 20 may be made of
varying combinations of nylon and spandex. The percentage of nylon
ranges from about 78% to about 84% based on fabric content, while
the percentage of spandex ranges from about 16% to about 22% based
on fabric content. Preferably, second outer material layer 70 and
first outer material layer 20 are made of about 81% nylon and about
19% spandex. Second outer material layer 70 and first outer
material layer 20 are lightweight, ranging from about 5 ounces per
yard squared (oz/yd.sup.2) to about 5.8 oz/yd.sup.2. The tensile
length of second outer material layer 70 and first outer material
layer 20 is minimally about 25 pounds (lbs.), while the tensile
width of second outer material layer 70 and first outer material
layer 20 is minimally about 33 lbs.
[0039] Gelatinous material 75 and 50 is preferably silicone.
However, any liquid material can be used that is safe for contact
with a wearer and has a soft feel. Gelatinous material 75 and 50 is
applied on second outer layer 70 and first outer material layer 20
in strips or tracks. Preferably, gelatinous material 75 is about
56% of the overall weight of the combination of outer material
layer 70 and gelatinous material 75. Preferably, gelatinous
material 50 is about 56% of the overall weight of the combination
of outer material layer 20 and gelatinous material 50. The height
or thickness of the strips of gelatinous material 75 and 50 ranges
from about 0.02 inches to about 0.03 inches. The width of these
strips ranges from about {fraction (3/16)} inches to about 1/4
inches. The width between the strips ranges from about {fraction
(1/16)} inches to about 1/8 inches. The width of sew region 24
ranges from about 1/8 inches to about {fraction (3/16)} inches.
[0040] Inner material layer 30 is preferably made of a non-woven,
non-stretchable fabric material. However, inner material layer 30
may be made of a stretchable material. Inner material layer 30 is
preferably made of polyester. More preferably, inner material layer
30 is made of 100% polyester. Inner material layer 30 is
lightweight, preferably about 5 oz./yd.sup.2.+-.10%. The burst
strength of inner material layer 30 is minimally about 110 lb. per
square inch. The tensile strength of inner material layer 30 is
minimally about 55 lbs. The preferred thickness of inner material
layer 30 falls in the range of about 0.53 mm to about 0.84 mm.
Inner material layer 30 is sold commercially under the name
TIETEX.RTM. by Tietex International Ltd.
[0041] Intermediate material layer 25 is a preferably a woven,
non-stretchable material. However, intermediate material layer 25
may be made of a stretchable material. More preferably,
intermediate material layer 25 is a nylon taffeta. Intermediate
material layer 25 is also lightweight, ranging from about 1.8
oz/yd.sup.2 to about 2.2 oz/yd.sup.2. The tensile length of
intermediate material layer 25 is minimally about 70 lbs., while
the tensile width of intermediate material layer is minimally about
60 lbs.
[0042] It should be understood that these dimensions may vary
depending upon the desired criteria for each group of potential
customers.
[0043] In either embodiment, an important aspect of the present
invention is that the casing of the underwire preferably be
stretchable. However, it may be non-stretchable.
[0044] Referring to FIG. 7, there is provided a third embodiment of
the underwire structure of the present invention generally
represented by reference numeral 100. Underwire structure 100
includes a two ply structure that has a bladder 110 having a
gelatinous material placed in or on a layer of a first fabric 140.
The gelatinous material is preferably silicone, but may be any type
of liquid material that is safe for contact with a wearer and has a
soft feel. This structure is placed on a layer of a second fabric
120, and an underwire 130. In this embodiment, only second fabric
layer 120 is wrapped around underwire 130. First fabric layer 140
with bladder 110 is positioned on the second fabric layer
120/underwire 130 structure with bladder 110 positioned against a
body fabric 160 and opposite a garment or outer brassiere layer
170. In this embodiment, double needle stitching is preferably used
to seal the casing. First fabric layer 140 is a rigid fabric, such
as a tricot or warp knit fabric, which does not stretch.
[0045] Significantly, the bladder configuration can fit a number of
different underwire sizes. Preferably, one bladder will fit at
least three sizes of underwires.
[0046] In all embodiments of the present invention, each end of the
underwire optionally may have a protective tip positioned thereon.
In addition, the wire casing or channel must have enough room at
its ends to avoid poke-through of the underwire.
[0047] The present invention provides underwire structures that
have the underwire encased by a gelatinous material. These
structures provide a cushiony feel, yet are not thick or bulky.
Moreover, the cushiony feel is so pronounced that there is a loft
created so that the wearer has a softness and pliability, yet the
desired support under the breast area.
[0048] The present invention having been described with particular
reference to the preferred forms thereof, it will be obvious that
various changes and modifications may be made without departing
from the spirit and scope of the invention as defined herein.
* * * * *