AU2004205334A1 - Padded strap assembly - Google Patents

Description

P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Padded strap assembly The following statement is a full description of this invention, including the best method of performing it known to us: 004535684 2 PADDED STRAP ASSEMBLY Field of the Invention The present invention relates generally to padded strap assemblies for garments. More particularly, but not exclusively, the invention relates to laminated padded straps for brassieres and similar garments, to a method of making such straps, and to a brassiere incorporating the strap assembly.

Background of the Invention It is well known that the shoulder straps of brassieres cause discomfort to many wearers. Straps can also cause indentations and irritations on a wearer's shoulder and various attempts have been made to minimise these disadvantages.

Separate pads that attach to the underside of a brassiere strap have been provided to cushion and distribute the load of the strap. Separate pads can be difficult to keep in position and often result in a bulky and unattractive appearance.

To overcome these problems a number of patents have issued directed to incorporating padding within the brassiere strap. The padding has variously comprised fabric cushioning, rubber or foam inserts, felting, and fibrous layers.

US patent 4,638,513 discloses a layered and sewn padded elastic strap.

The strap surface has undulations which provide an unattractive appearance. US patent 5,165,113 is directed to a padded strap with a smooth and attractive outer appearance, without seams or wrinkles. This is accomplished by providing a laminated structure with a core material of foam and outer layers of fabric. The laminate is heated and compressed. By not compressing a portion in the centre of the strap a single padded area is formed.

US patent 5,984,762 discloses a laminated stretch cushion strap having a stretchable cover. A sealed gel insert is disclosed in International publication number WO 03/007738.

004535684 3 The mere mention of the above-mentioned prior patent documents is not to be taken as an admission that any aspect of the contents of the documents, or of any part of the contents, is or was common general knowledge in the relevant art in Australia.

While there have been many attempts at providing a padded shoulder strap for brassieres, manufacturers continue to strive to develop new and improved ways of creating a solution to this well known problem. It is therefore an object of the present invention to provide an improved padded strap assembly which is comfortable for the wearer and aesthetically pleasing when worn under clothing.

Summary of the Invention It has been realised that an improved padded strap assembly can be obtained by providing a plurality of cushioning cells spaced longitudinally along the strap and held by one or more outer fabric layers.

The invention accordingly provides a padded strap assembly, including: a fabric body including at least one fabric layer extending longitudinally of the strap assembly; and a plurality of cushioning cells retained by said fabric body so as to be spaced longitudinally of said at least one fabric layer.

Preferably, said cells are formed by an elongate integral body of a material that forms cushioning material in said cells. Said body may, for example, comprise respective portions forming said cells linked by relatively thin web portions.

Preferably said fabric body includes two fabric layers bonded to respective sides of said cushioning cells so as to sandwich the cells between the fabric layers. When the cells are formed by said elongate integral body, such body is a core of the strap assembly. In this case, the sandwiching of each cell is such that the cell is compressed about its periphery so as to be thinner at the periphery than 004535684 4 at the centre. For example, the cell may exhibit a tapered and/or domed appearance in at least some cross-sections.

Typically, said cushioning material is resiliently compressible. Preferably said cushioning material is a foam or fibre fill material. Advantageously, said foam is a polyurethane foam.

Advantageously said fabric layer(s) is bonded to said cells or integral body by adhesive. Typically, said adhesive is heat activated and may be applied to either said cells or said fabric layer(s).

Advantageously, said strap assembly is relatively wider in a central region intermediate its ends and tapers to relatively narrower to sections that extend to the ends of the strap.

Typically, there is provided means for securing said padded strap assembly to a garment. Preferably, said garment is a brassiere.

In an advantageous application, the strap assembly is a shoulder strap for a brassiere or like garment.

In another aspect, the invention provides a brassiere incorporating as shoulder straps a pair of strap assemblies as described.

The invention further provides a method of making a padded strap assembly including: providing in overlaid juxtaposition an assembly of at least one core portion of cushioning material, at least two fabric layers positioned on respective sides of said core portion(s), and at least one adhesive web layer positioned between said core portion(s) and each of said fabric layer; 004535684 placing said assembly between two mating mould parts, wherein at least one mould part defines a plurality of recesses spaced longitudinally of the said assembly; heating said mould parts; and closing said mould parts to define spaced fabric sandwiched cells of said cushioning material at said recesses, linked by thinner strap segments.

Typically, the heat of the mould parts melts and compresses the core portion(s) at said thinner strap segments, and may activate the adhesive.

Advantageously, the sandwiching of each cell is such that the cell is compressed about its periphery so as to be thinner at the periphery than at the centre. For example, the cell may exhibit a tapered and/or domed appearance in at least some cross-sections.

Preferably, one mould part is flat and the other defines a plurality of recesses, wherein, after moulding, one side of said padded strap assembly is more nearly flat than the other side.

Brief Description of the Drawings A preferred embodiment of the invention will now be described with reference to the accompanying drawings, in which: Figure 1 shows a top view of a padded brassiere strap assembly in a noncurved position, according to an embodiment of the present invention; Figure 2 shows an exaggerated longitudinal cross-sectional view of the strap assembly on line A-A in Figure 1; Figure 3 shows an exaggerated transverse cross-sectional view of the strap assembly on line B-B in Figure 1; 004535684 6 Figure 4 shows a schematic cross-sectional view of a fabric and foam assembly in readiness in a mould for forming the padded strap assembly illustrated in Figure 1; and Figure 5 shows the padded strap assembly of Figure 1 forming part of a brassiere being worn by a user.

Description of Preferred Embodiment Figures 1, 2 and 3 show a section of a padded strap assembly in the form of a padded brassiere strap 10. As shown in Figures 2 and 3 strap 10 includes a core body 12 which is made from foam, eg. polyurethane foam. Adhesive web layers 14 which are heat activated bond two fabric layers 16, 18 to the core body 12 on respective sides. Core body 12 is formed into a plurality of cells 20 in which the foam serves as a cushioning material; these cushioning cells 20 are spaced longitudinally of the strap and are of different profiles as shown and define padded zones 21 of the strap. Multiple cells 20 are provided, spread over the shoulder engaging part of the strap.

As can be seen from Figures 2 and 3 the thickness of the padded zones 21 is greater than the thickness of the intervening web portions 32 and of the periphery of the strap. The padded zones 21 are formed by placing a laminate of the core body 12, adhesive web layers 14 and fabric layers 16, 18 between two mating mould parts 22, 24 (Figure The mould parts 22, 24 have a plurality of recesses 26 and surrounding lands 28. The mould parts 22, 24 are heated and upon closure of the mould the adhesive is activated and the core portion between lands 28 is melted and permanently compressed to form web portions 32. The portions of the laminate 30 between the recesses 26 are much less compressed and so form padded zones 21.

As a result of the heating and compressing process, cells 20 and therefore padded zones 21 are thickest at the middle and the thickness gradually reduces towards their periphery which was closest to the mould lands 28. At this periphery, 004535684 7 cells 20 are compressed so as to be thinner, and indeed the cells exhibit a tapered or domed appearance in cross-section.

As illustrated in Figure 1 the width of strap 10 is widest across line B-B in a central region of the strap. This increased width disperses the loads carried. Strap 10 tapers from this central region to relatively narrower end sections to a width which will match the width of the brassiere 34 (Figure 5) at the point 38 where the strap is attached.

As can be seen in Figure 5, a pair of brassiere straps 10 can be incorporated as shoulder straps 10 in a brassiere 34 by being attached by stitching or other suitable means, to the cups at the front of the brassiere and, typically via adjustment straps, to the body encircling panels at the rear. When the brassier is worn, the padded zones 21 sit across the top of a wearer's shoulder 36. The loads carried by the brassiere 34 are distributed over the width of the strap 10 and padded zones 21 cushion the shoulder, creating a garment which is comfortable to the wearer yet aesthetically pleasing. It is found in practice that the partially compressed, spaced and therefore discrete cushioning cells of foam conform easily to the local topography of the shoulder and readily accommodate irregularities. It is observed that the cells of foam have an almost fluid-like quality, and it is believed that comfort is enhanced by the extended length of foam periphery defined by the cells and therefore by the padded zones.

It is thought that the padded zones allow air to flow between them thus increasing the evaporation of moisture from the skin. The padded cells may also help stimulate blood flow with increased body movement and have more of a massage effect on the skin.