GB2363313A

GB2363313A - Garments with foam padding

Info

Publication number: GB2363313A
Application number: GB0023810A
Authority: GB
Inventors: Rachel Israel
Original assignee: Delta Galil Industries Ltd
Current assignee: Delta Galil Industries Ltd
Priority date: 2000-06-12
Filing date: 2000-09-28
Publication date: 2001-12-19
Also published as: GB0023810D0; IL136686A0

Abstract

In order to improve comfort, reduce the tendency to lose shape and increase durability, a garment 10 is formed, at least in part, of a visco-elastic, open celled, high density polyurethane foam which is thermoplastic at body temperature, and a method of manufacturing a garment 10 includes the steps of: forming at least part of the garment 10 of a visco-elastic, open celled, high density polyurethane foam which is thermoplastic at body temperature; coupling the polyurethane foam to the garment; and finishing the garment. The foam may be included in bra cups or straps or in other garments such as a shirt, gown, nightgown or pants.

Description

2363313 GARMENTS The present invention relates to garments in general and,

in particular, to bras and other garments.

BACKGROUND OF THE INVENTION

Bras and other undergarments have long been known in the art. These garments are formed according to selected sizes and shapes. Conventional garments are formed with a given shape, which shape does not change when the garments are worn. Often such garments, particularly bras and swimsuit tops, will.include a padding material, generally low density (e. g., 20-30 k g/m3) polyurethane foam. Polyurethane foam is easy to cut to shape and retains its shape during use. This is both an advantage and a disadvantage. One the one hand, the garment do not change their original shape and size during wear, on 15 the other hand, its edges can create friction and rub against the wearer's body. In addition, these garments tend to lose their shape after a few washings. Thus, they have low durability.

High density polyurethane foams are known for a variety of uses. There are also known, from US Patent 4,990,545, articles with polyurethane resin 20 having memory shape characteristics. This invention relates to a thermoplastic or thermoset article, a porous sheet, a paint composition, and a synthetic leather comprising a polyurethane resin with a memory shape or with a healable characteristics therewith. The original (memorized) shape of the article or the porous sheet is reshaped into another desired form below 130' 25 C., and locked into below 40' C. Theses materials can be reverted back to their original shape by heating above 40' C. The memorized shape as an original shape of the thermoplastic article or the porous sheet can be changed I by maintaining it in a desired shape at a temperature 130'-230' C. When the paint or the synthetic leather is scratched or creased to its surface, it can be healed by heating above 40' C.

Another polyurethane foam material is known as Tempur. The Tempur 5 material is a pressure relieving, visco-clastic, open celled material, originally developed for the NASA space program in the United States in the early 1970's to provide pressure relief in space vehicles. Because of the difficulties in the manufacturing process, the material remained exclusive and expensive without much commercial use, until Fagerdala of Sweden, determined how to 10 form Tempur into a variety of sleeping aids, especially mattresses, pillows, and cushions. The Tempur-Pedic mattress molds to the angles and curves of the sleeper's body, giving the entire musculoskeletal architecture support in the correct anatomical position.

T-foam, a product of a company of the United States, is similar in some 15 of its properties and characteristics to Tempur. It has also been utilized for mattresses, in order to provide increased comfort for sleepers.

SUMMARY OF THE INVENTION

The present invention provides a garment formed, at least in part, of a 20 visco-elastic, open celled, high density polyurethane foam which is thermoplastic at body temperature, such as Tempur or T-foam. It is a particular feature of the present invention that the portion of the garment formed of this polyurethane is forni-fitting, and molds itself to the body of the wearer. This provides increased comfort for the wearer, as it prevents friction or rubbing of 25 the edges of the garment.

According to one embodiment of the invention, the garment is a bra having cups and straps, wherein the cups and/or the straps include a visco- 2 elastic, open celled, high density polyurethane foam which is thermoplastic at body temperature.

Alternatively, the garment can be a shirt, a strapless gown, a night gown, underpants, or any other garment including at least a portion which is 5 form-fitting.

There is also provided a method of manufacturing a garment, the method including the steps of forming a garment, forming at least part of the garment of a visco-elastic, open celled, high density polyurethane foam which is thermoplastic at body temperature, coupling the polyurethane to the 10 garment, and finishing the garment.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be further understood and appreciated from the following detailed description taken in conjunction with the drawings in

15 which:

Fig. 1 is a plan view of a garment manufactured and constructed according to one embodiment of the present invention; Figs. 2a and 2b are plan views of cup insert portions according to the embodiment of Fig. 1; 20 Fig. 2c is a schematic illustration of the stitched cup insert; Figs. 3a and 3b are plan views of cup outer portions according to the embodiment of Fig. 1; Fig. 3c is a schematic illustration of the stitched outer cup; Figs. 4a, 4b, 4c, 4d and 4e illustrate the method of forming a the bra of 25 Fig. 1; Fig. 5 is a plan view of a garment manufactured and constructed according to an alternative embodiment of the present invention; Figs. 6a and 6b are plan views of respective molded cup and molded foam portions according to the embodiment of Fig. 5; Figs. 7a and 7b illustrate the method of forming the bra of Fig. 5.

5 DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to garments formed, at least in part, of a form-fitting polyurethane foam material. Preferably, the material is a visco elastic, open celled, high density polyurethane foam which is thermoplastic at body temperature, such as TempurTm, manufactured and marketed by 10 Fagerdala of Sweden, or so-called T-foam. The Tempuim material is five times more dense than conventional polyurethane and is temperature sensitive. Below 60 degrees Fahrenheit, the TempurTm material becomes much firmer, but at body temperature, it becomes quite plaint, molding itself TM to the body's shape. The Tempur material is breatheable, anti-microbial, 15 hypo-allergenic, CK and formaldehyde free. The preferred TempuJm material has a density of between about 40 and about 120 kg/m 3, most preferably between about 100 and about 120 k g/M3.

It is a particular feature of the present invention that the garments mold themselves to the wearer's body, thus providing an extremely comfortable fit 20 and a more aesthetic appearance. The polyurethane foam selected for the garments of the invention contour themselves to the natural curve of the contacted body surface, without any pressure points. In addition, the material has memory, and returns to its original shape, such as after being wrinkled or cleaned. Thus, it maintains its shape, even after washing in a machine and 25 drying in a dryer, unlike conventional polyurethane in garments.

Referring now to Fig. 1, there is shown a plan view of a garment manufactured and constructed according to one embodiment of the present 4 invention, here illustrated, for purposes of example only, as a bra 10. It will be appreciated that the invention is equally applicable to any other garment wherein a form-fitting portion is desired, although it is particularly suitable for padded bras, swimsuits, strapless gowns, and so forth. As can be seen, bra 10 includes a pair of cups 12, joined by a center portion 14, and a wing 16 coupled to each cup, with straps 18 being coupled to the wings 16.

According to the embodiment of the present invention illustrated in Fig. 1, the cups 12 are formed of a visco-elastic polyurethane foam material which is thermoplastic at body temperature. Thus, the center portion, wings and 10 straps have shapes and sizes determined at the time of manufacture. On the other hand, top and bottom foam cup insert portions 22, 24 are formed of a selected shape, such as those shown in plan view in Figs. 2a and 2b, which will mold themselves to the breasts of the wearer when the bra, or other garment, is worn.

15 One exemplary method of forming a bra with two piece foam cups is illustrated in Figs. 2a to 4e. The bottom foam cup 24 and top foam cup 22 are joined, as by botting the overbust edges together with a two needle lockstitch, as seen in Fig. 2c. Preferably, the edge of the foam is covered, as by NT40 tape.) Then, the bottom fabric cup 26 (Fig. 3b) is joined to the top fabric cup 28 (Fig. 3a), as by a 5 mm. single needle lockstitch seam, as shown in Fig. 3c.

Next, open plough overbust seams in the outer and inner cups are formed, as shown in Fig. 4a, the neck edge is bagged out with outer and inner fabric pieces to leave a 5 mm. seam allowance. All the layers are single needled together at the underarm, and the foam cup is inserted between the outer and inner cups and spot tacked, as shown in Figs. 4b and 4c.

The bottom edge 29 of the outer and inner cup fabric is now turned up towards the inside of the bra to form a wire casing, but without folding the foam insert (Fig. 4d). Finally, the wire casing is two needle lockstitched onto the cup, to form the bra of Fig. 1.

Fig. 5 is a plan view of a garment manufactured and constructed according to an alternative embodiment of the present invention, here shown 5 as a molded cup bra 30. According to this method, the outer and inner moulded cup 32 of Fig. 6a is placed together with the molded foam portion 34 of Fig. 6b. The neck edge joining the outer and inner cups only is bagged out 38, as shown in Fig. 7a, and the foam cup is inserted between the inner and outer cups. All the layers are basted together along the underarm 36, and the 10 foam cups are spot tacked in place onto the inner cup. The wire casing seam allowance 3.9 is turned up on the outer and inner cups, while keeping the foam cup flat. Finally, the wire casing is sewn onto the cup, as shown in Fig. 7b, as with a two needle lockstitch.

It will be appreciated that the invention is not limited to what has been 15 described hereinabove merely by way of example and modifications can be made within the spirit of the invention.

9

Claims

A garment formed, at least in part, of a visco-elastic, open celled, high density polyurethane foam which is thermoplastic at body temperature.
2. The garment according to claim 1, wherein said polyurethane foam includes TempurTm.
3. The garment according to claim 1, wherein said polyurethane 10 foam includes T-foam.
4. The garment according to any of claims 1 to 3, wherein said garment is a bra having cups, and at least said cups include a visco-elastic, open celled, high density polyurethane foam which is thermoplastic at body 15 temperature.
5. The garment according to any of claims 1 to 3, wherein said garment is a bra having straps, and at least said straps include a visco-elastic, open celled, high density polyurethane foam which is thermoplastic at body temperature.
6. The garment according to any of claims 1 to 3, wherein said garment is a gown, and at least a portion of said gown includes a visco-elastic, open celled, high density polyurethane foam which is thermoplastic at body 25 temperature.
7 7. The garment according to any of claims 1 to 3, wherein said garment is an underpant, and at least a portion of said underpant includes a visco- elastic. open celled, high density polyurethane foam which is thermoplastic at body temperature. 5
8. A method of manufacturing a garment comprising the steps of. forming a garment; forming at least part of said garment of a visco-elastic, open celled, high density polyurethane foam which is thermoplastic at body temperature; 10 coupling said polyurethane foam to said garment; and finishing said garment.
9. A garment substantially as herein described with reference to, and as shown in, Figures 1 to 4e or Figures 5 to 7b of the accompanying drawings.
10. A method of manufacturing a garment, substantially as herein described with reference to Figures 1 to 4e or Figures 5 to 7b of the accompanying drawings.

CI