AU2011218738B2 - Brassiere cup and brassiere made therefrom - Google Patents

Abstract

A pad for a brassiere, comprising: a molded pad shaped to comprise an apex, including: a foam layer having a peripheral edge and a smooth outer surface; an inner 5 liner layer having a peripheral edge; a shaped cover having a peripheral edge and an outer surface and positioned between said foam layer and said inner liner layer, the peripheral edges of the foam layer and the inner liner layer extending outwardly beyond the entire peripheral edge of the shaped cover; and when worn said shaped cover conceals a nipple of a wearer's breast, and the foam layer is selected to prevent io visibility of the shaped cover from the outside. c:\NRPortbl\GHMatters\MERCEDESA\2805330 I.DOCX 2109/11 -3 Fig.1

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Standard Patent Applicant: HBI Branded Apparel Enterprises, LLC Invention Title: Brassiere cup and brassiere made therefrom The following statement is a full description of this invention, including the best method for performing it known to us: -2 BRASSIERE CUP AND BRASSIERE MADE THEREFROM This application is a divisional application of acceptance Australian Patent Application No. 2009209073 filed on 30 January 2009 and which is incorporated herein in its entirety. 5 Field of the Invention This invention relates to a pad for a brassiere that offers modesty to the wearer, and a brassiere having a pair of breast-receiving cups. Background Conventional brassieres for everyday wear should offer comfort as well as io coverage to the wearer. Consumers want to feel comfortable when wearing lightweight clothes, yet confident that their undergarments, specifically brassieres, are providing adequate coverage. Brassieres that are too sheer and thin are not likely to provide the wearer with the desired level of modesty and discretion. At the other extreme, foam brassieres that are thick and offer modesty are often excessively padded, thus 15 uncomfortable and hide the wearer's natural shaping. Accordingly, there is a need for a pad or cup for a brassiere, and a brassiere, that offers modesty with lightweight padding and optimal comfort. SUMMARY OF THE INVENTION The present invention provides for a padded cup for a pad for a brassiere, 20 comprising: a molded pad shaped to comprise an apex, including: a foam layer having a peripheral edge and a smooth outer surface; an inner liner layer having a peripheral edge; a shaped cover having a peripheral edge and an outer surface and positioned between said foam layer and said inner liner layer, the peripheral edges of the foam layer and the inner liner layer extending outwardly beyond the entire peripheral edge of 25 the shaped cover; and when worn said shaped cover conceals a nipple of a wearer's breast, and the foam layer is selected to prevent visibility of the shaped cover from the outside. The present invention also provides for a brassiere comprising: a pair of breast 30 receiving cups, a pair of shoulder straps and a pair of side panels, one of said pair of shoulder straps and one of said pair of side panels connected to one of said pair of 28053301 (GHMatters) P84385.AU.I 2,09/11 -3 breast receiving cups, the other of said pair of shoulder straps and the other of said pair of side panels associated with the other of said pair of breast-receiving cups, each of said pair of breast-receiving cups comprises: an outer layer having a peripheral edge and a smooth outer surface; a foam layer having a peripheral edge; an inner liner 5 layer having a peripheral edge; and a shaped cover having a peripheral edge and an outer surface and positioned between said foam layer and said inner liner layer, the peripheral edges of the outer layer, foam layer, and inner liner layer extending outwardly beyond the entire peripheral edge of the shaped cover; when worn said shaped cover conceals a nipple of a wearer's breast, and the foam layer is selected to 10 prevent visibility of the shaped cover from the outside. BRIEF DESCRIPTION OF THE DRAWINGS These and further features of the invention will be understood by reference to the following specification in conjunction with the accompanying drawings, in which like 15 reference characters denote like elements of structure and: Figure 1 illustrates a perspective view of the padded cup of the present invention; Figure 2 illustrates an exploded view of the padded cup of Figure 1 of the present invention; 20 Figure 3 illustrates a cross-sectional view of the padded cup of the present invention, taken along line 3-3; Figure 4 illustrates a rear view of the padded cup of the present invention showing the outline of the inner surface of the cup; Figure 5 illustrates a front view of the padded cup of the present invention 25 showing the hidden lines of the concealing layer; Figure 6 illustrates a brassiere incorporating the padded cup of the present invention; Figure 7 illustrates an alternative embodiment of the padded cup of the present invention; 2805330_1 (GHMatters) P84385.AU. I 2/09/111 -4 Figure 8 illustrates a rear view of the padded cup of Figure 7, showing the embossed relief on the inner surface of the cup; and Figure 9 illustrates a front view of the padded cup of Figure 7, showing the hidden lines of the concealing layer. s DETAILED DESCRIPTION In reference to the drawings and, in particular, to Figure 1, there is illustrated a brassiere cup, generally represented by reference numeral 10. The brassiere cup 10 is a molded multi-layer construction. Cup 10 has an inner layer 15 at a concave surface or inner surface of cup 10. Cup 10 has an outer layer 35 at a convex layer or surface of io cup 10. Between inner layer 15 and outer layer 35 is a foam layer 30. Foam layer 30 has a degree of thickness to provide a light degree of coverage and loft when placed in a brassiere. Cup 10 has an apex 40 centrally located at mid portion of the cup 10. While cup 10 has a generally uniform thickness, regions of differing thicknesses could also be used in the cup 10 to offer different effects to the wearer. 15 Referring to Fig. 2, cup 10 is shown in an exploded view. Between inner layer 15 and foam layer 30 is a fourth layer, or concealing layer 20. Layer 20 has a smaller surface than layers 15, 30 or 35. Layer 20 is centrally located over apex 40 of the cup 10. When the cup 10 is fitted within a brassiere, layer 20 is coincident with apex 40 of the brassiere to offer complete coverage and modesty to the wearer. While layer 20 is 20 shown coincident with the apex 40, on a different style of brassiere, for example, balconette or demi-cup brassieres, layer 20 would be coincident with the desired anatomical feature to provide optimal modesty. Cup 10 provides a thin low to medium coverage pad, as shown in Fig. 3. Typically such cups, when formed in a brassiere, will not provide substantial modesty 25 to the wearer when thin or revealing outer clothes are worn. However, concealing layer 20, of the present invention is centrally located to ensure that despite the minimal thickness of the cup 10, that adequate coverage is provided. Were layer 20 not present between layers 15 and 30, the wearer's modesty would not be preserved and undesired exposure of the nipple would be visible through the outer clothing. When cup 30 10 is incorporated into a brassiere of the present invention, a minimally padded brassiere is formed that provides full modesty and coverage to the wearer. Such a brassiere incorporating cup 10 eliminates the need to wear a heavily padded brassiere to achieve full modesty. 2805330_1 (GHMatters) P84385.AU. I 2/09/11 Referring to Figs. 2, 4 and 5, cover 20 is located between layer 15 and foam layer 30, to ensure invisibility beneath outer clothing. Foam layer 30 acts as a buffer to prevent any possible relief or visibility of the concealing layer beneath clothing. Were layer 20 between foam layer 30 and outer layer 35, then layer 20 would possibly be 5 visible through outer layer 35 and beneath clothing. While layer 20 is invisible from outer layer 35, it is visible through concave layer 15 in relief. Layer 20 is preferably a layer of material, such as, nylon, although other materials such as polyester or cotton that have a smooth surface when molded/laminated between inner layer 15 and foam layer 30, could also be used. io Similarly, a laminated package of a combination of materials that have a smooth surface when molded, could also be used. Layer 20 is preferably made of any material or combination of materials that easily drapes or conforms during the lamination and molding processes. Layer 15 made from a material such as polyester, nylon, cotton blend or a rayon blend, or any other material that is easily molded. Layer 35 is made 15 from the same or similar material as layer 15 that is easily molded. Layer 30 is a layer of foam, preferably polyurethane foam, or any other similar material that is easily molded and laminated and capable of withstanding heat and numerous washings. Referring to Fig. 4, the concave or inner surface of cup 10 is shown. Layer 20 is shown and shaped as a flower. While layer 20 has a decorative shape, the shape is 20 also functional. The flower shape permits layer 20 to more easily conform to the shape of the apex compared to other shapes. For example a purely circular concealing layer, if made from a stiff material, would tend to have puckers or ripples at its edges when it is molded at the apex of the pad. A circular shape of a supple material, however, would provide proper draping. Other shapes that would also be functional as well as 25 decorative are a clover, a star or a sunburst. As shown in Fig. 5, the outer surface of cup 10 does not show the outline of concealing layer 20. Fig. 6 shows a brassiere 50 that incorporates the cup 10 at 55. Brassiere 50 is shown as a softcup brassiere, however, cup 10 of the present invention can be incorporated into an underwire, a strapless brassiere, a sports brassiere, or a demi-cup 30 brassiere for example. Brassiere 50, when worn, offers the wearer the convenience and comfort of a lightweight brassiere and the confidence and modesty of a heavily padded brassiere. Concealing layer generally has a smaller surface area than inner liner layer 15, foam layer 30 and outer layer 35. By having a smaller surface area than 2805330_1 (GHMatters) P84385.AU.l 2/09/11 the other layers of cup 10, brassiere 50 offers a low padded brassiere that provides full modesty and coverage. Turning now to Figure 7, an alternative embodiment of the brassiere cup 100 is shown. This embodiment also comprises a multi-layer construction including an inner s layer 115 at the concave surface, or inner surface, a foam pad 130, and an outer layer 135 at a convex surface, or outer surface, of the cup 100 construction. Inner layer 115, outer layer 135, and foam layer 130 are all formed of materials similar to those materials described hereinabove for the embodiment illustrated in Figures 1 through 6. The foam layer 130 is situated between the inner layer 115 and the outer layer 10 135, again having a degree of thickness sufficient to provide a light degree of coverage and loft when formed in a brassiere. As shown in Figure 7, a concealing layer 120 is approximately centrally located over the apex 140 of the cup 100. As shown in Figures 7 through 9, a decorative shape, such as a flower, is formed during the molding process of the brassiere cup 100. Rather than die- cutting a 15 concealing layer 120 of a particular decorative shape in advance of positioning the concealing layer 120 between the foam layer 130 and the inner layer 115, the multi layer cup 100 is initially formed with a shaped, but non- decorative, concealing layer 120. It has been found that beginning the multilayer construction with a non-decorative concealing layer is less costly that a die-cut, or pre-cut, concealing layer both in terms 20 of the cost of the concealing layer itself, and in the cost of the labor required to position properly the smaller die-cut concealing layer between the foam layer 130 and the inner layer 115. As best seen in Figures 8 and 9, the concealing layer 120 of this embodiment does not initially have a decorative shape; rather, the concealing layer 120 is an oval- shaped layer that is suitably dimensioned and suitable for laminating 25 and molding. Other shapes suitable for molding, without puckering or wrinkling when molded, may be used. During the molding process, a decorative design, such as a raised flower 127, may be formed by the molding apparatus. Specifically, the female portion of the mold has a smooth surface, as is conventional, such that the outer shape and appearance of 30 the foam pad and brassiere cup are smooth, shape enhancing, and concealing. The male mold portion, however, has a decoratively-shaped recess of a selected design, such as the flower shown in Figure 8, formed therein. Thus, during the molding process, as the male portion of the mold compresses the multiple layers to form the 28053301 (GHMatters) P84385.AU. I 2109/1 -7 breast cup, the layers forming the cup are not compressed within the recessed area of the mold to the same extent that the surrounding areas of the cup 100 are compressed. This results in a raised, or embossed, decorative area 127 on the inner surface of the inside layer 115 of the brassiere cup 100 and a smooth outer surface 5 135. As shown in Figure 9, neither the embossed decorative area 127 nor the outline of concealing layer 120 are visible on the outside layer 135 of the cup 100, or brassiere. Not only does this manner of molding produce an aesthetically pleasing design on the inside surface of the brassiere cup, but it also results in a concealing io layer 120 at the apex 140 that has a greater thickness, and thus greater concealment at the apex 140. As will be appreciated, the unembossed area of the concealing cover 120 also provides concealment about the apex 140, although without the same decorative effect as the decorative area 127. Further, the decorative effect of the decorative area 127 is aesthetically pleasing to the wearer. is While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope thereof. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without 20 departing from the scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the disclosure. In the claims which follow and in the preceding description of the invention, 25 except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. 30 2805330_1 (GHMatters) P84385.AU.I 2/09/i1

Claims (20)

1. A pad for a brassiere, comprising: 5 a molded pad shaped to comprise an apex, including: a foam layer having a peripheral edge and a smooth outer surface; an inner liner layer having a peripheral edge; a shaped cover having a peripheral edge and an outer surface and positioned between said foam layer and said inner liner layer, the io peripheral edges of the foam layer and the inner liner layer extending outwardly beyond the entire peripheral edge of the shaped cover; and when worn said shaped cover conceals a nipple of a wearer's breast, and the foam layer is selected to prevent visibility of the shaped cover from the outside.

2. The pad according to claim 1, further comprising an outer layer, said outer 15 layer disposed over said foam layer.

3. The pad according to claim 2, wherein said outer layer is selected from a material selected from the group consisting of polyester, nylon, cotton, rayon and blends thereof. 20

4. The pad according to claim 1, wherein said shaped cover comprises a material selected from the group consisting of nylon, polyester, cotton, and blends thereof.

5. The pad according to claim 1, wherein said shaped cover has a decorative shape selected from the group consisting of a clover, a flower, a star and a sunburst. 25

6. The pad according to claim 1, wherein said foam layer is polyurethane foam.

7. The pad according to claim 2, wherein said foam layer, said outer layer, said liner layer and said shaped cover are molded to form a cup. 3270107_1 (GHMatters) P84385.AU.I 11104/12 -9

8. A pad for a brassiere comprising: a molded multiple layer laminated pad having a peripheral edge and a smooth outer surface; 5 wherein one of said multiple layers is a shaped cover having a peripheral edge and an outer surface, the peripheral edges of other layers extending outwardly beyond the entire peripheral edge of the shaped cover, a nipple of the breast being concealed when said brassiere is worn, and the shaped cover is not visible when viewed from the outside. 10

9. The pad according to claim 8, wherein the pad comprises a liner layer on one side of said shaped cover and a foam layer on the other side of said shaped cover.

10. The pad according to claim 9, further comprising a fabric layer covering is said foam layer.

11. The pad according to claim 10, wherein said fabric layer is selected from a material selected from the group consisting of polyester, nylon, cotton, rayon and blends thereof. 20

12. The pad according to claim 8, wherein said shaped cover comprises a material selected from the group consisting of nylon, polyester, cotton and blends thereof.

13. The pad according to claim 8, wherein said shaped cover has a decorative shape selected from the group consisting of a clover, a flower, a star and a sunburst. 25

14. The pad according to claim 9, wherein said foam layer is polyurethane foam.

15. A brassiere comprising: a pair of breast-receiving cups, a pair of shoulder straps and a pair of side panels, one of said pair of shoulder 30 straps and one of said pair of side panels connected to one of said pair of breast 2805330_1 (GHMatters) P84385.AU.1 2/09/11 -10 receiving cups, the other of said pair of shoulder straps and the other of said pair of side panels associated with the other of said pair of breast-receiving cups, each of said pair of breast-receiving cups comprises: 5 an outer layer having a peripheral edge and a smooth outer surface; a foam layer having a peripheral edge; an inner liner layer having a peripheral edge; and a shaped cover having a peripheral edge and an outer surface and io positioned between said foam layer and said inner liner layer, the peripheral edges of the outer layer, foam layer, and inner liner layer extending outwardly beyond the entire peripheral edge of the shaped cover; when worn said shaped cover conceals a nipple of a wearer's breast, and the is foam layer is selected to prevent visibility of the shaped cover from the outside.

16. The brassiere according to claim 15, wherein said outer layer is selected from a material selected from the group consisting of polyester, nylon, cotton, and blends thereof.

17. The brassiere according to claim 15, wherein said shaped cover is made 20 from a material selected from the group consisting of nylon, polyester, cotton and blends thereof.

18. The brassiere according to claim 15, wherein said shaped cover has a decorative shape selected from the group consisting of a clover, a flower, a star and a sunburst. 25

19. The brassiere according to claim 15, wherein said foam layer is polyurethane foam.

20. A pad for a brassiere or a brassiere, substantially as herein described with 30 reference to the accompanying drawings. 3270107_ 1 (GHMatters) P84385.AU. 11104/12