NZ743748A - Sports bra - Google Patents

Abstract

A front panel section for a sports bra configured to extend across the chest region of a wearer, the front panel section constructed from at least two layers, an innermost layer and a primary layer, the innermost layer being a mesh construction having wicking properties to draw moisture away from the wearer’s skin and the secondary layer being an open cell foam. e wearer’s skin and the secondary layer being an open cell foam.

Description

Sports bra Field of the invention The present invention relates to sports bras and methods of making sports bras.

Background of the invention Lack of breast support during exercise can result in excessive breast movement.

Tests have shown that an unsupported average size 12B bust can bounce up to 8cm during running. Similar tests have shown that larger breasted women with a size 16DD bust can record vertical movement of 16.5cm.

Breast tissue does not contain muscle and support is provided by small ligaments and the surrounding skin. Excessive movement of the breasts can result in tearing and a breakdown in breast tissue. It has been reported that no amount of exercise can restore original breast shape. Movement of the breast occurs both in terms of upward and downward bounce, lateral swaying and forward movement.

Both professional and amateur athletes may partake in medium to high impact sports such as running, tennis, netball, and various other aerobic activities, daily or at least several times per week. Most of these women, particularly those with larger breast sizes, will wear specialised sports bras or sports crop tops. A number of sports bras and crop tops on the market are uncomfortable, and have very little breathability, resulting in large amounts of sweat, with dampness contributing to chaffing.

While there have been many attempts at providing sports bras, manufacturers continue to strive to develop new and improved ways of creating a solution to this known problem. The balance between providing optimum breast bounce reduction and meeting the needs of comfort is a constant battle. It is therefore an object of the present invention to provide an improved sports bra, which is comfortable for the wearer. 1002216028 Reference to any prior art in the specification is not an acknowledgment or suggestion that this prior art forms part of the common general knowledge in any jurisdiction or that this prior art could reasonably be expected to be understood, regarded as relevant, and/or combined with other pieces of prior art by a skilled person in the art.

Summary of the invention According to a first aspect, the present invention provides at least one front panel section for a sports bra configured to sit across at least one breast of a wearer, the front panel section constructed from at least two layers, an innermost layer and a primary layer, the innermost layer being a mesh construction having wicking properties to draw moisture away from the wearer’s skin and the secondary layer being an open cell foam.

According to a second aspect, the present invention provides a front panel section for a sports bra configured to extend across the chest region of a wearer, the front panel section constructed from at least two layers, an innermost layer and a primary layer, the innermost layer being a mesh construction having wicking properties to draw moisture away from the wearer’s skin and the secondary layer being an open cell foam.

Advantageously, a sports bra is provided that is constructed from one or two front panel section(s), two side straps and two shoulder straps, or from one or two front panel section(s) and a rear panel section. Alternatively, the front panel section(s) may extend into side panels that form the side and back sections of the sports bra.

Where two front panel sections are used, each is positioned over a respective breast and means may be provided to join the front panel sections together.

Preferably, a further outer layer is provided, which may be knitted or woven using polyester yarn. The further outer layer may form the means to join the two front panel sections together.

The primary layer and innermost layer may be joined together via an adhesive layer. Similarly, the outer layer may be joined to the primary layer by adhesive. 1002216028 The open cell foam is preferably made from polyurethane. It is advantageously reticulated foam such that the porosity is in the range of 95%-96%.

The innermost layer is constructed from a wicking yarn, being a yarn with a high surface area. The yarn may be 100% polyester. The yarn preferably has a high filament content, for example 75D/144F, whereby there are 144 filaments per yarn and each filament is 75 denier. The wicking properties of the innermost layer are also enhanced by using a knitted open construction to increase air permeability. This may be achieved using an eyelet mesh stitch.

The sports bra most preferably is wire free and the front panel section is seamless.

The front panel section is preferably formed via moulding, such that moulded cups and a portion adjacent the cups are formed. Where the front panel section extends across the chest region of the wearer, two individually moulded cups may be formed.

The adjacent portion can have a different density to the cups. The different densities can be achieved by compressing the primary layer to different depths. The cups can be compressed more than the adjacent portion. The different densities result in a different modulus of elasticity.

According to a third aspect, the present invention provides a front panel section for a sports bra configured to sit across at least one breast of a wearer, the front panel section being constructed from at least one continuous primary layer of foam having at least one individually moulded cup(s) and a portion adjacent the cup(s), the adjacent portion having a different density to the cup(s).

The adjacent portion may be underlying or partially underlying the cup(s).

According to a fourth aspect, the present invention provides a front panel section for a sports bra configured to extend across the chest region of a wearer, the front panel section being constructed from at least one continuous primary layer of foam having two individually moulded cups and a portion adjacent the cups, the adjacent portion having a different density to the cups.

The adjacent portion may be underlying or partially underlying the cup(s). 1002216028 Advantageously, a sports bra is provided that is constructed from one or two front panel section(s), two side straps and two shoulder straps, or from one or two front panel section(s) and a rear panel section. Alternatively, the front panel section(s) may extend into side panels that form the side and back sections of the sports bra.

Where two front panel sections are used, each is positioned over a respective breast and means may be provided to join the front panel sections together.

The different densities result in a different modulus of elasticity. The different densities can be achieved by compressing the primary layer to different depths. The cups can be compressed more than adjacent portion.

The primary foam layer can be open cell foam. The open cell foam is preferably made from polyurethane. It is advantageously reticulated foam such that the porosity is in the range of 95%-96%.

The sports bra most preferably is wire free and the front panel section is seamless. An engraved line may be formed between the cup region and the adjacent portion.

An innermost layer may be provided having a mesh construction with wicking properties to draw moisture away from the wearer’s skin. The innermost layer is constructed from a wicking yarn, being a yarn with a high surface area. The yarn may be 100% polyester. The yarn preferably has high filament content, for example 75D/144F, whereby there are 144 filaments per yarn and each filament is 75 denier.

The wicking properties of the innermost layer are also enhanced by using a knitted open construction to increase air permeability. This may be achieved with a Jacquard knit using an eyelet mesh stitch.

Preferably, a further outer layer is provided, which may be knitted or woven using polyester yarn.

The primary layer and innermost layer may be joined together via an adhesive layer. Similarly, the outer layer may be joined to the primary layer by adhesive.

The two formed cups may separately individually support a wearer’s breasts. 1002216028 According to a fifth aspect, the present invention provides a method of moulding a front panel section for a sports bra, including: providing a flat continuous layer of foam sized to extend across the chest region of a wearer, the foam layer having a constant thickness; placing the foam layer into a mould, the mould being shaped to mould the foam layer into two individually moulded cups and a portion adjacent the cups; wherein the depth of the mould cavity in the region forming the cups is different to the depth of the mould cavity in the region forming the portion adjacent the cups, such that, after moulding, the density of the cups is different to the adjacent portion.

The adjacent portion may be underlying or partially underlying the cup(s).

According to a sixth aspect, the present invention provides a method of moulding a front panel section for a sports bra, including: providing a flat continuous layer of foam sized to extend across at least one breast of a wearer, the foam layer having a constant thickness; placing the foam layer into a mould, the mould being shaped to mould the foam layer into one or two individually moulded cups and a portion adjacent to the cup(s); wherein the depth of the mould cavity in the region forming the cup(s) is different to the depth of the mould cavity in the region forming the portion adjacent the cup(s), such that, after moulding, the density of the cup(s) is different to the adjacent portion.

The adjacent portion may be underlying or partially underlying the cup(s).The different densities result in a different modulus of elasticity. The cups can be compressed more than the adjacent portion.

The cups may be compressed from the original foam thickness by the following percentages: within the range of 45%-75% compression, more preferably within the range of 45%-65% compression, most preferably within the range of 45%-55% compression. The adjacent portion may be compressed from the original foam thickness by the following percentages: within the range of 15%-60% compression, 1002216028 more preferably within the range of 30%-55% compression, most preferably within the range of 50%-45% compression.

The foam layer can be an open cell foam. The open cell foam is preferably made from polyurethane. It is advantageously reticulated foam such that the porosity is in the range of 95%-96%.

An innermost layer may be provided having a mesh construction with wicking properties to draw moisture away from the wearer’s skin. The innermost layer is constructed from a wicking yarn, being a yarn with a high surface area. The yarn may be 100% polyester. The yarn preferably has a high filament content, for example 75D/144F, whereby there are 144 filaments per yarn and each filament is 75 denier.

The wicking properties of the innermost layer are also enhanced by using a knitted open construction to increase air permeability. This may be achieved with an eyelet mesh stitch.

Preferably, a further outer layer is provided, which may be knitted or woven using polyester yarn.

The foam layer and innermost layer may be joined together via an adhesive layer prior to moulding. Similarly, the outer layer may be joined to the foam layer by adhesive prior to moulding.

The front panel section may be joined to two side straps and two shoulder straps, or a rear panel section to form a sports bra. Alternatively, the front panel section(s) may extend into side panels that form the side and back sections of the sports bra.

Where two front panel sections are used, each is positioned over a respective breast and means may be provided to join the front panel sections together.

According to a seventh aspect, there is provided one or two front panel section(s) for a sports bra of the first, second, third or fourth aspect made according to the method of the fifth or sixth aspect.

According to an eighth aspect, there is provided a sports bra incorporating one or two front panel section(s) according to the first, second, third or fourth aspect. 1002216028 Brief description of the drawings Further aspects of the present invention and further embodiments of the aspects described in the preceding paragraphs will become apparent from the following description, given by way of example and with reference to the accompanying drawings, in which: Figure 1 is a rear view of a front panel section for a sports bra according to a first embodiment of the present invention; Figure 2 is a rear view of a front panel section for a sports bra according to a second embodiment of the present invention; Figure 3 is a schematic representation of a closed cell foam; Figure 4 is a schematic representation of a normal cell foam; Figure 5 is a schematic representation of an open cell foam; Figure 6 is a graph illustrating the air permeability of open cell foam versus normal cell foam; Figure 7 is a diagrammatical cross-section of a standard yarn; Figure 8 is a diagrammatical cross-section of a wicking yarn according to an aspect of the present invention; Figure 9 is rear view of a front panel section with cross-sectional views through lines A and B; Figure 10 is a rear view of a front panel section for a sports bra according to another embodiment of the present invention; Figure 11 is a front view of the front panel section for a sports bra of Figure 10; Figure 12 is a rear view of two front panel sections for a sports bra according to a further embodiment of the present invention. 1002216028 Detailed description of the embodiments Figures 1 and 2 show two different front panel sections used to construct sports bras. Whilst a completely constructed sports bra is not illustrated in the drawings, it is readily apparent to a person skilled in the art that the front panel section of Figure 1 would be connected to two side panels and two shoulder straps to form a complete sports bra of a generally standard bra construction. Similarly, it will be readily apparent that the front panel section shown in Figure 2 would be connected to a rear panel at the sides and tops of the shoulder straps to form a complete sports bra taking the form more readily referred to as a “crop top”. However, the front panel section of Figures 1 and 2 are both formed with separately moulded cups (described further below), such that Figure 2 differs from standard “crop tops” that have a single band across the chest region.

The front panel sections 10 shown in Figures 1-2 and 9-11 are defined by a cup region 12, having two independent cups 14, and an adjacent portion 16 directly underlying the cup region. The junction between the cup region 12 and the adjacent portion 16 forms a line 18 underlying a wearer’s breasts. The line 18 is typically positioned where an underwire may be positioned, however the present invention is directed to a wireless sports bra construction.

The front panel section 10 is constructed from at least two layers. A primary layer 20 is made from an open cell foam. Preferably it is reticulated polyurethane foam having 95 to 96% porosity. The more open the foam, the greater the breathability of the garment.

Three different foam cell constructions are represented in Figures 3 through 5.

Figure 3 shows a closed cell foam, which would not be used for the present invention as it provides no air permeability. Each of the cell walls 21 are closed. Figure 4 shows a normal foam typically used in the construction of bras. A small number of the cell walls 21 have small openings 23. This normal foam has very little air permeability being 23 litres/min, as shown in the right hand column of the graph of Figure 6. The breathability of such normal foam is 100 cm3/cm2/s. An open cell foam, as used in the present invention, is shown in Figure 5, having a porosity of 95-96%. A large percentage of the cell walls 21 have an opening 23, the openings being larger in size than in a normal 1002216028 foam. The air permeability of 134 litres/min is shown in the left hand column of the graph of Figure 6. The breathability of this foam is 222 cm3/cm2/s.

The innermost layer 22 is constructed to be wicking, such that it draws moisture away from a wearer’s skin, preventing sweat from beading on the inside surface of the bra. The beading of sweat is common place in many sports bras, particularly those having a foam layer.

The wicking properties of the innermost layer 22 can be achieved by both the type of yarn used and the type of knitting. To create a yarn with good wicking characteristics, one method is to increase the surface area of the yarn. This can be accomplished by having a high filament content. As shown in Figure 7, a low filament content yarn is illustrated whereby seven filaments 24 are shown, with each filament having a large cross-section. In contrast, Figure 8 shows a high filament content yarn, whereby fifty-three filaments 24 are shown, with each filament having a small cross- section. With a greater number of filaments, there is more surface area for moisture to be absorbed and spread. An optimum yarn may be a 75D/144F yarn, whereby there are 144 filaments per yarn and each filament is 75 denier.

The type of knitting used can also increase the wicking abilities of the fabric layer.

The more open the knitting construction, the greater the air permeability. An example may be an eyelet mesh stitch. It will be appreciated that a suitable fabric layer may be achieved using a different knitting technique, with a woven fabric, and with a number of different yarn types.

An outer layer 26 may be provided on the outside of the foam layer 20 (representatively shown in Figure 9). This layer can be constructed from a similar fabric to the innermost layer or an alternative fabric. It is important that the outer layer is breathable to allow air to flow through the foam and innermost layer. It is preferable that both the innermost layer and the outer layer are constructed from polyester yarn, to enable the front panel section to be moulded at high temperatures. The outer layer 26 and innermost layer 22 are fixed to the foam layer 20 via adhesive layers to form an integrated cohesive blank prior to moulding. This would likely be a spray adhesive applied to the surfaces of sheets to form a laminate prior to cutting of the front panel sections. 1002216028 As can be seen from Figures 9, 10 and 11, the independent cups 14 are formed into the front panel section 10 by moulding to create the three dimensional structure that is seamless. The independent cups 14 separately support the wearer’s breast, which distinguishes the present invention from a standard “crop top”.

The moulding process used to create the three dimensional structure of the front panel section 10 includes a combination of heat and pressure. A flat continuous layer of foam having a constant thickness is clamped into the mould. This layer is then compressed between a male mould head and a female mould head to form the cups. In the closed position, the cavity created between the male and female mould heads varies in depth in different regions of the mould. The result of this is that the foam is compressed under greater pressure in some areas than in others. In the present invention, the depth of the cavity in the cup region is less than in the adjacent portion.

The final product therefore has moulded cups that are thinner than the adjacent portion.

This means that the density of the cup region is greater than the density in the adjacent portion. The cup region therefore has a smaller modulus of elasticity than the adjacent portion, such that compression of the breasts is obtained to limit movement. The transition point between the cup region 12 and the adjacent portion 16 results in a embossed line 18 being formed to provide a defined edge, in the embodiment illustrated this is similar to where an underwire would be present in a standard underwire bra.

As examples only, the original foam thickness may be 7mm. During moulding, the cup region may be compressed down to 3.85mm-1.75mm (45%-75% compression), more preferably 3.85mm-2.45mm (45%-65% compression), most preferably 3.85mm- 3.15mm (45%-55% compression). The adjacent portion may be compressed to a lesser degree, and corresponding compressed thicknesses may be 5.95mm-2.8mm (15%-60% compression), more preferably 4.9mm-3.15mm (30%-55% compression), most preferably 3.5mm-3.85mm (50%-45% compression). Whilst some of these ranges intersect, it is appreciated that the cup compression will be greater than the compression of the adjacent portion.

In an alternative embodiment shown in Figure 12, two front panel sections 10 may be used to create a sports bra. Each front panel section is formed similarly to other embodiments discussed above. Each front panel section 10 includes a cup region 12 1002216028 forming an independent cup 14, and an adjacent portion 16. Adjacent portion 16 is on the outer side of cup 14, with a small portion partially underlying the cup. It will be appreciated that the adjacent portion could also extend underneath the cup or on the inner side of the cup.

The two front panel sections 10 may be joined together by means of an additional outer layer or by other means, such as a central clasp. Such sports bra constructions will be readily apparent to a person skilled in the art.

The present invention provides a moulded sports bar that provides the required restriction to a wearer’s breast, with each breast supported separately. The construction of the bra provides superior breathability and wicking properties to increase the wearer’s comfort.

It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention. 1002216028

Claims (34)

The claims defining the invention are as follows:

1. A front panel section for a sports bra configured to sit across at least one breast of a wearer, the front panel section constructed from at least two 5 layers, an innermost layer and a primary layer, the innermost layer being a mesh construction having wicking properties to draw moisture away from the wearer’s skin and the secondary layer being an open cell foam.

2. A front panel section for a sports bra according to claim 1, wherein the panel 10 is configured to extend across the chest region of a wearer.

3. A front panel section for a sports bra according to claim 1 or claim 2, wherein the primary layer and innermost layer are joined together via an adhesive layer.

4. A front panel section for a sports bra according to any one of the preceding claims, wherein the open cell foam is made from polyurethane.

5. A front panel section for a sports bra according to any one of the preceding 20 claims, wherein the open cell foam is reticulated foam such that the porosity is in the range of 95%-96%.

6. A front panel section for a sports bra according to any one of the preceding claims, wherein the innermost layer is constructed from a wicking yarn, being 25 a yarn with a high surface area.

7. A front panel section for a sports bra according to claim 6, wherein the yarn is 100% polyester. 30

8. A front panel section for a sports bra according to claim 6 or 7, wherein the yarn has a high filament content. 1002216028

9. A front panel section for a sports bra according to claim 6, 7 or 8, wherein a knitted open construction is used to increase air permeability.

10. A front panel section for a sports bra according to claim 9, wherein the knitted 5 open construction is an eyelet mesh stitch.

11. A front panel section for a sports bra according to any one of the preceding claims, formed via moulding, such that moulded cups and a portion adjacent the cups are formed.

12. A front panel section for a sports bra according to claim 11, wherein the adjacent portion has a different density to the cups.

13. A front panel section for a sports bra according to claim 12, wherein the 15 different density is achieved by compressing the cups more than the adjacent portion.

14. A sports bra constructed from one or two front panel section(s) according to any one of claims 1 to 13, and either from two side straps and two shoulder 20 straps, or a rear panel section.

15. A sports bra constructed from one or two front panel section(s) according to any one of claims 1 to 13, wherein the front panel section(s) extend into side panels that form the side and back sections of the sports bra.

16. A sports bra according to claim 14 or 15, whereby, when two front panel sections are used, each is positioned over a respective breast and means may be provided to join the front panel sections together. 30

17. A sport bra according to any one of claims 14 to 16, further including an outer layer, knitted or woven using polyester yarn. 1002216028

18. A front panel section for a sports bra configured to sit across at least one breast of a wearer, the front panel section being constructed from at least one continuous primary layer of foam having at least one individually moulded cup(s) and a portion adjacent the cup(s), the adjacent portion having a 5 different density to the cup(s).

19. A front panel section for a sports bra according to claim 18, wherein the adjacent portion is underlying or partially underlying the cup(s). 10

20. A front panel section for a sports bra configured to extend across the chest region of a wearer, the front panel section being constructed from at least one continuous primary layer of foam having two individually moulded cups and a portion adjacent the cups, the adjacent portion having a different density to the cups.

21. A front panel section for a sports bra according to claim 20, wherein the adjacent portion is underlying or partially underlying the cup(s).

22. A front panel section for a sports bra according to any one of claims 18 to 21, 20 wherein the different densities result in a different modulus of elasticity.

23. A front panel section for a sports bra according to claim 22, wherein the different densities is achieved by compressing the primary layer to different depths.

24. A front panel section for a sports bra according to claim 23, where the cups are compressed more than adjacent portion.

25. A front panel section for a sports bra according to any one of claims 18 to 24, 30 wherein the primary foam layer is open cell foam. 1002216028

26. A front panel section for a sports bra according to any one of claims 18 to 25, wherein the open cell foam is reticulated foam such that the porosity is in the range of 95%-96%. 5

27. A method of moulding a front panel section for a sports bra, including: providing a flat continuous layer of foam sized to extend across the chest region of a wearer, the foam layer having a constant thickness; placing the foam layer into a mould, the mould being shaped to mould the foam layer into two individually moulded cups and a portion adjacent the 10 cups; wherein the depth of the mould cavity in the region forming the cups is different to the depth of the mould cavity in the region forming the portion adjacent the cups, such that, after moulding, the density of the cups is different to the adjacent portion.

28. The method according to claim 27, wherein the adjacent portion is underlying or partially underlying the cup(s).

29. A method of moulding a front panel section for a sports bra, including: 20 providing a flat continuous layer of foam sized to extend across at least one breast of a wearer, the foam layer having a constant thickness; placing the foam layer into a mould, the mould being shaped to mould the foam layer into one or two individually moulded cups and a portion adjacent to the cup(s); 25 wherein the depth of the mould cavity in the region forming the cup(s) is different to the depth of the mould cavity in the region forming the portion adjacent the cup(s), such that, after moulding, the density of the cup(s) is different to the adjacent portion.

30 30. A method according to claim 29, wherein the adjacent portion is underlying or partially underlying the cup(s). 1002216028

31. A method according to claim 29 or 30, wherein the different densities result in a different modulus of elasticity.

32. A method according to any one of claims 29 to 31, wherein the cups are 5 compressed more than the adjacent portion.

33. A method according to any one of claim 29 to 32, wherein the foam layer and innermost layer are joined together via an adhesive layer prior to moulding. 10

34. A method according to any one of claims 29 to 32, wherein an outer lay is joined to the foam layer by adhesive prior to moulding.