US20180310643A1

US20180310643A1 - Bra wing with integrated gripping technology

Info

Publication number: US20180310643A1
Application number: US15/967,803
Authority: US
Inventors: Wendy Hanson Allen; Deneb Torano; Mayur Vansia
Original assignee: Spanx LLC
Current assignee: Spanx LLC
Priority date: 2017-05-01
Filing date: 2018-05-01
Publication date: 2018-11-01

Abstract

Difficulties with designing strapless bras include ensuring that they are comfortable, breathable, and that they do not slide down on the wearer's body. Many strapless bra designs use elastic bands or high friction polymer coatings to keep the bra in place. These additions can be uncomfortable and add weight to the bras. The bra wings disclosed herein have exposed elastic threads that grip the wearer's body to resist sliding. They are comfortable and light-weight, with free-cut edges that ensure a smooth look on the wearer's body. Single-layer construction and lack of high-friction coatings or elastics ensure breathability. Methods of making the bra with integrated gripping technology are also disclosed herein.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application 62/492,704, filed May 1, 2017, which is incorporated by reference in its entirety for all purposes.

BACKGROUND OF THE INVENTION

Strapless bras are designed to be worn under many different types of clothing. Wearers often find it desirable to keep their bras completely covered by clothing. However, many tops and dresses are not designed to cover bra straps. Strapless bras are therefore desired, so that a person can wear a support garment under any clothing without worrying about straps showing. Designing strapless bras can be difficult, because they often slide down or are uncomfortable for wearers.

SUMMARY OF THE INVENTION

Disclosed herein is a strapless bra wing designed for improved fit, on-body appearance, and comfort that stays in place without excess pressure or tightness. The bra wings are formed of a knit fabric with free-cut superior and inferior edges. The bra wings have at least a region where elastic threads are exposed to the interior surface to increase friction against the wearer's body and prevent sliding. The bra wings do not have the bonding, seams, or polymer strips along the superior and inferior edges that are conventionally used to keep a strapless bra in place. This lack of bonding/adhesives, seams, and polymer strips keeps the bra wing light in weight. The single-layer construction of the bra wing further reduces the weight of the bra, limiting the extent that it slides downward due to gravity. Many people experience skin irritation from polymer strips because they block airflow, causing the skin to break down and blister. The construction of the bra wing disclosed herein promotes breathability, reducing the skin irritation caused by polymer strips. Finally, the lack of bonding, seams, and polymer strips allow the bra wing to lay flat against the wearer, improving the on-body appearance of the bra by minimizing bulges and bumps.
The bra includes a bra wing having an exterior surface and an interior surface. The bra wing has a free-cut superior, a free-cut inferior edge, and a region with exposed elastic threads. The region can be, for example a vertical segment where the exposed elastic threads stretch from the superior edge to the inferior edge of the bra wing. The entire region with exposed elastic threads has no coatings with a higher coefficient of friction than the interior surface. In some embodiments, the region with exposed elastic threads is devoid of horizontally extending seams. In some embodiments, the region with exposed elastic threads is devoid of horizontally extending adhesives. In an embodiment, the region with exposed elastic threads is the entire interior surface of the bra wing.
In an embodiment, the bra wing includes a blend of nylon and elastane. The bra wing can also include other fiber types. In an embodiment, the bra has from 60% to 95% elastane and from 5% and 40% nylon. For example, in some embodiments, the bra wing has 84% elastane and 16% nylon. In an embodiment, the bra wing is made from a knit fabric, such as, for example, a circular knit fabric. In an embodiment, the bra wing is made from a spacer fabric having an outer component, an inner component, and a spacer component. The outer component may include a blend of nylon and elastane. The inner component can be 100% elastane. The spacer component may also contain elastane. In an embodiment, the bra wing has an elongation of from 85% to 180% at 100 N load in the length direction, the width direction, or both directions. In an embodiment, the bra wing exerts a tension force of from 5 N to 10 N at 30% elongation, from 15 N to 60 N at 50% elongation, and from 25 N to 80 N at 70% elongation in the length direction, the width direction, or both directions.
In an embodiment, the bra has a strapless configuration. The bra may also have at least one connector for a detachable strap. In an embodiment, the bra wing is formed from a single layer of fabric. The single layer of fabric may be a spacer fabric. In an embodiment, the single layer of fabric includes elastic threads knit into the fabric.
Also disclosed herein are methods of making a bra. The disclosed method includes steps of knitting elastic threads into a fabric such that the elastic threads are exposed on at least a region of a surface of the fabric and cutting at least one bra wing from the fabric. The at least one bra wing is attached to a breast support portion, such that the elastic threads are exposed on a region of the interior surface of the bra wing. The method can further include cutting the bra wing to include at least one vertical segment where exposed elastic threads stretch from a superior edge to an inferior edge of the bra wing. In an embodiment, the bra wing is cut from the fabric such that the exposed elastic threads are on the entire interior surface of the bra wing.
In an embodiment, knitting the elastic threads into the fabric of the bra wing includes circular-knitting the threads into the fabric. In an embodiment, knitting the elastic threads into the fabric includes knitting an inner component, an outer component, and a spacer component to form a spacer fabric. In an embodiment, the method of making the bra includes cutting a left wing and a right wing from the fabric, and attaching the left wing and the right wing to the breast support portion. In an embodiment, attaching the bra wing to the breast support portion includes attaching the bra wing to at least one cup.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an interior view of the bra.

FIG. 2 is a view of the bra wing on a wearer's body.

FIG. 3 is a view of a prior art bra wing on a wearer's body.

FIG. 4 is a cross-sectional view of a spacer fabric used in one embodiment of the bra wing.

FIG. 5 is an interior view of the fabric shown in FIG. 4.

FIG. 6 shows a schematic of an exemplary testing apparatus.

FIG. 7A shows gripping force data for fabric with unexposed elastic threads.

FIG. 7B shows gripping force data for fabric with exposed elastic threads.

FIG. 8A shows a loop diagram of one embodiment of the construction of a fabric with integrated gripping technology.

FIG. 8B shows the lapping diagram of the embodiment of construction shown in FIG. 8A.

FIG. 9A shows a loop diagram of another embodiment of the construction of a fabric with integrated gripping technology.

FIG. 9B shows the lapping diagram of the embodiment of construction shown in FIG. 9A.

DETAILED DESCRIPTION

Strapless bras are designed to be worn under tops or dresses with many different styles and configurations. One difficulty with designing strapless bras is ensuring that the bra does not slide down on the wearer's body. Many current strapless bra designs use elastic bands around the upper and lower edges of the bra, making the bra tight to resist sliding down. This tightness can create discomfort in wearers, and can lead to undesirable bumps or bulging. Many strapless bras also have multiple layers of fabric at seams or bonded edges on the wings of the bra. Elastic bands and additional layers of fabric add weight to bras, which makes the bras less comfortable and more likely to slide down. Some bras also have high friction coatings, including polymer strips or beads (such as a strip of silicone), on the interior surface of the bra wing to provide friction and keep the bra up. These coatings are not air permeable, add weight to the bra, and can cause skin irritation and sweating.
Disclosed herein is a bra wing with gripping technology integrated into the fabric. A bra wing is the part of the bra that generally extends around the sides and back of the wearer's body, and may also be referred to as the sides or back of the bra. The bra wing is often attached to cups or a similar breast support portion at the front of the bra. The bra wing disclosed herein is comfortable and light-weight. It resists sliding down on the wearer's body while maintaining sufficiently high elongation and recovery properties to ensure it stays in place. It is made from a free-cut, single-layer construction, without seams or adhesives (bonding) at the upper and lower edges of the bra wing. The bra wing is air permeable, because it is made from a single-layer construction and does not use silicone or other coatings to provide friction. The improved bra wing stays in place without excessive tightness, which also provides a smooth appearance on the wearer's body.
Use of the term “bra” is not intended to limit the construction of the disclosed garment and bra wing to any particular type of upper body or breast-supporting garment. The term “bra” as used herein refers generally to garments that provide cover or support to the breast area of the wearer. While many bras are constructed from cups and bra wings attached thereto, the garment disclosed here is not limited to this construction. The disclosed bra wing can be used on upper body garments with or without defined cups. The disclosed bra wing is also not limited to a strapless bra configuration. The disclosed bra wing provides benefits that overcome problems with strapless bras, but the disclosed bra wing also provides benefits to bras with detachable, permanent, or adjustable straps. Further, many strapless bras are convertible, with straps that can be adjusted or detached, to allow multiple different configurations and therefore greater flexibility of use for the wearer.
As noted above, the region (or regions) of the bra wing with exposed elastic threads do not include horizontally extending seams or horizontally extending adhesives (such as, for example, adhesives used in bonding processes or adhesives used to attach polymer strips to the bra wing). Certain embodiments of the region(s) with exposed elastic threads have no seams or adhesives at all (regardless of the direction or orientation). In some embodiments, the region(s) of the bra wing with the exposed elastic threads are devoid of any coating having a higher coefficient of friction than the interior surface. In some embodiments, the entire interior surface of the bra wing is devoid of horizontally extending seams or horizontally extending adhesives. In some embodiments, the entire interior surface of the bra wing has no seams or adhesives at all (regardless of direction or orientation). In some embodiments, the entire interior surface of the bra wing is devoid of any coating having a higher coefficient of friction than the interior surface itself.
FIG. 1 illustrates an interior view of an embodiment of the bra 10. The bra 10 comprises a bra wing 12 having an exterior surface 20 and an interior surface 22. The bra wing 12 its formed of a knit fabric, and it has a free-cut superior edge 16 and a free-cut inferior edge 18. The interior surface 22 of the bra wing 12 has a region 28 where elastic threads are exposed to the interior surface 22. The fabric is knit such that the elastic threads are exposed to one side of the fabric. This is in contrast to conventional knitting methods, where elastic threads are hidden within the knitting construction of the fabric and not exposed to the exterior. In the embodiment shown in FIG. 1, the region 28 is a vertical segment where exposed elastic threads 24 stretch from the superior edge 16 to the inferior edge 18. In an embodiment, the exposed elastic threads 24 stretch the entire interior surface 22 of the bra wing 12. As used herein, an elastic thread comprises an elastomer (for example, a polyurethane elastomer). For example, the elastic threads may comprise elastane, spandex, or Lycra®. The exposure of the elastic threads increases the coefficient of friction of the interior surface 22, which, in turn, reduces sliding of the interior surface 22 against the wearer's skin.
FIG. 2 illustrates a back view of the bra wing 12 on a wearer. The bra wing 12 is positioned on the user's body generally around the ribcage area on the wearer's sides and back. The bra is positioned such that the superior edge 16 is above the inferior edge 18, closer to the wearer's shoulders. The bra wing 12 disclosed herein is designed to lay flat against the wearer's body as shown in FIG. 2, without creating bulges or bumps. FIG. 3 illustrates a prior art bra having elastic at its superior and inferior edges. The prior art bra fits tightly on the wearer's body, which results in bumps or bulges at the superior and inferior edges.
The embodiment of the bra 10 in FIG. 1 has two wings: a left wing 30 and a right wing 32. The left and right wing 30 and 32 may be connected in the back by a clasp 26. The clasp can be a hook-and-eye connector, or any other bra connector known in the art. FIG. 1 illustrates one embodiment of the invention, and is not intended to limit the invention. In another embodiment, the bra wing is one piece that extends around the back of the wearer.
FIG. 1 illustrates a bra having two cups 14. The cups provide support and coverage for the breasts of the wearer. The bra can have padded cups, unlined cups, a bandeau section, or any other configuration for breast support or coverage known in the art. The bra wings 12 are attached to the breast support portion. FIG. 1 illustrates that the bra wings 12 are attached to the sides of the cups 14. The bra wings can be attached to the breast support portion with a seam, with bonding, or can be formed continuously with fabric in the breast support portion.
The embodiment of the bra shown in FIG. 1 has a strapless configuration. The strapless bra configuration shown includes a breast support portion and bra wings, and does not include straps. The bra of the present invention can include connectors for detachable straps.
The superior edge 16 and the inferior edge 18 of the bra wing are free-cut. In the embodiment shown in FIG. 1, the vertical segment 28 with exposed elastic threads has no seams or adhesives (bonding) along the superior and inferior edges 16, 18. Therefore, there are no overlapping layers of fabric and no added bulk along the interior surface 22 against the wearer's body.
The fabric of the bra wing 12 can be a blend of elastic and non-elastic threads. As used herein, an elastic thread comprises an elastomer (for example, a polyurethane elastomer). For example, the elastic threads may comprise elastane, spandex, or Lycra®. The non-elastic threads can be formed of, for example, nylon, polyester, wool, acrylic, polypropylene, and/or regenerative fiber such as rayon, acetate, and/or cellulosic fiber like cotton, or a combination of any of the above. In some embodiments, the fabric 42 is from about 60% to about 95% elastane and from about 5% to about 40% nylon. In some embodiments, the fabric 42 is from about 79% to about 89% elastane and from about 11% to about 21% nylon. For example, the bra wing may be 84% elastane and 16% nylon. In some embodiments, the fabric 42 is 100% elastane threads.
The exposed elastic threads 24 are knit into the fabric of the bra wing such that they are exposed on the interior surface 22 of the bra wing 12, providing grip on the wearer's body. The knitting technique used to form the bra wing can be circular knit, double knit, or warp knit fabric. The fabric is knit such that the elastic threads are exposed to one side of the fabric. This is in contrast to conventional knitting methods, where elastic threads are hidden within the knitting construction of the fabric and not exposed to the exterior. The elastic threads 24 can be exposed along the entire interior surface 22 of the bra, on a vertical segment of the interior surface 22, or on a region of any shape or size. In some embodiments, the region having exposed elastic threads is devoid of seams and bonding. In some embodiments, the region having exposed elastic threads is devoid of elastic, additional layers of fabric, or any coatings having a higher coefficient of friction than the interior surface 22. For example, the interior surface 22 of the entire vertical segment 28 shown in FIG. 1 is devoid of seams, bonding, elastics, additional fabric, and high-friction coatings.
FIG. 4 illustrates a cross-section of an embodiment of a knitted spacer fabric that can be used to make the bra wing 12. Using spacer fabric 34 eliminates the need to laminate or bond multiple layers together. In an embodiment, the spacer component 40 is thin, providing minimal space between the inner and outer components 36, 38. A thin spacer fabric 34 helps create a smooth line on the wearer's body, and allows for a flat look underneath clothing without any bumps or bulges.
The spacer fabric 34 has an inner component 36, an outer component 38, and a spacer component 40. The exposed elastic threads 24 are knit into the fabric of the inner component 36 such that they are exposed on the interior surface 22 of the bra wing 12. In some embodiments, 100% of the threads of inner component 36 are elastane threads. In another embodiment, the inner component 36 is a blend of elastane and non-elastic threads, as described above. FIG. 5 shows an example circular, double-knit construction of the inner component 36, showing exposed elastic threads 24.
The outer component 38 is on the exterior surface 20 of the bra wing 12. The outer component includes non-elastic threads 44. The non-elastic threads can be formed of, for example, nylon, polyester, wool, acrylic, polypropylene, and/or regenerative fiber such as rayon, acetate, and/or cellulosic fiber like cotton, or a combination of any of the above. In an embodiment, the outer component 38 is a blend of elastane and other fibers. In an embodiment, the outer component 38 is a blend of elastane and nylon. In an embodiment, the outer component 38 is 100% elastane. In an embodiment, the inner component 36 of the spacer fabric contains a higher percentage of elastane than the outer component 38.
The spacer component 40 is between the inner component 36 and outer component 38, as shown in FIG. 4. In an embodiment, the spacer component 40 is 100% elastane. In another embodiment, the spacer component 40 is a blend of elastane and other fibers.
The fabric used for the bra wing has high elongation and recovery values. This provides maximum comfort and allows the bra to stay up, without being too tight on the wearer and without the need for heavy elastics which can weigh down a bra. Values for the elongation, tension force, and recovery can be determined using ASTM D4964-96 (2016), Standard Test Method for Tension and Elongation of Elastic Fabrics (Constant-Rate-of-Extension Type Tensile Testing Machine). The specimen tested is a looped piece of fabric approximately 3 inches wide and 5 inches in length (from the first end of the loop to the second end of the loop). The machine speed is 500 mm/min. To test the specimens, the following procedure is used: (1) the specimen in loop form is placed around the clamps of the testing machine, which then undergoes a longitudinal pull; (2) cycle three times from zero to 100 N load; (3) record values from the third extension-load curve. The percent elongation is measured at 100 Newtons (N) load. The tension force is measured at 30%, 50%, and 70% elongation. The % fabric recovery is measured by dividing the original length by the length after three extension cycles, after the specimen is removed from the testing machine and relaxed for 60 seconds. In an embodiment, the fabric has an elongation in the length direction of from about 85% to about 180% at 100 N load. In an embodiment, the fabric exerts a tension force in the length direction of from about 5 N to about 40 N at 30% elongation, from about 15 N to about 60 N at 50% elongation, and from about 25 N to about 80 N at 70% elongation. In an embodiment, the fabric has an elongation in the width direction of from about 85% to about 180% at 100 N load. In an embodiment, the fabric exerts a tension force in the width direction of from about 5 N to about 40 N at 30% elongation, of from about 15 N to about 60 N at 50% elongation, and from about 25 N to about 80 N at 70% elongation. In an embodiment, the fabric has a recovery of from about 85% to about 100%. In an embodiment, the weight of the fabric is between 300 g/m²and 500 g/m².
Exposure of elastic threads to a surface increases the gripping force of an elastic fabric (i.e., the force needed to move a fabric along a surface) as compared to the same elastic fabric with unexposed elastic threads. In some embodiments, the gripping force might increase by a factor of anywhere from about 20% to about 170% when previously unexposed elastic threads are exposed to the surface of the fabric (including about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80%, about 90%, about 100%, about 110%, about 120%, about 130%, about 140%, about 150%, about 160%, and about 170%). For example, the gripping force of a fabric with exposed elastic threads might be from 100% to 140% greater than the gripping force of the same fabric with unexposed elastic threads.
Stretching an elastic fabric with exposed elastic threads can increase the gripping force. In some embodiments, when stretched by 30% of the length of the fabric, the gripping force of a fabric having exposed elastic threads might increase by a factor of anywhere from about 140% to about 340% (including, about 140%, about 160%, about 180%, about 200%, about 220%, about 240%, about 260%, about 280%, about 300%, about 320%, and about 340%. In some embodiments, when stretched by 30% of the length of the fabric, the gripping force of a fabric having exposed elastic threads might increase by a factor of 200% to 260%. As such, when the bra wings disclosed herein are stretched across a wearer's torso, the gripping force preventing movement of the bra wing may be greater than any gripping force measured when the bra wing is in an unstretched state.
When comparing a stretched fabric with exposed elastic threads versus unexposed elastic threads, the gripping force is also increased. For example, the gripping force of an elastic fabric having exposed elastic threads and stretched by 30% can be greater than the gripping force of an 30% stretched elastic fabric having unexposed elastic threads by a factor of from about 20% to about 80%, including, for example about 20%, about 30%, about 40%, about 50%, about 60%, about 70% and about 80%.
A schematic of a device that can be used to measure gripping force is shown in FIG. 6. A nitrile sleeve 46 is pulled over a cylinder 48 having a known circumference and secured near the top 49 of the cylinder 48. An elongated fabric tube 50 is pulled over the sleeve 46 and the cylinder 48. The bottom end 52 of the elongated fabric tube 46 hangs off the bottom edge 53 of the sleeve-covered cylinder 48. A clamp 54 attaches the bottom end 52 of the fabric tube 48 to a movable cross head 56. The cylinder 48 and nitrile sleeve 46 are held in place during testing, while the movable cross head 56 is slowly advanced away from the cylinder 48, pulling the fabric tube 46 as it travels. The movable cross head 56 moves in the direction shown by the black arrow in FIG. 6. MTS tensile testing can be used for data acquisition. This MTS is equipped with 1000 N load cell and programmed in tensile mode to move the cross-head at 50 mm/min and capture the resistance force offered by fabrics as they move against the nitrile sleeve. To vary the level of stretch, elongated fabric tubes of varying circumferences can be constructed (such that a smaller circumference tube is stretched to a greater extent than a larger circumference tube when positioned on the cylinder 48)
FIGS. 7A and 7B show the results of testing of the gripping force of fabric with exposed versus unexposed elastic threads (with and without a 30% stretch). FIG. 7A particularly shows the data generated using elastic fabric with unexposed elastic threads. FIG. 7B shows the data generated using an elastic fabric having nearly the same specifications and material content—the only difference being that the elastic threads are exposed to the surface of the fabric. Black arrows indicate the point during testing at which the fabric began to slide against the head of the testing machine. The gripping force for the unstretched elastic fabric with unexposed elastic threads was about 500 grams of force. The gripping force for the elastic fabric with unexposed elastic threads stretched by 30% was about 2600 grams of force (gf) (about a 420% increase over the unexposed, unstretched fabric). The gripping force for the unstretched elastic fabric with exposed elastic threads was about 1100 grams of force (about a 120% increase over the unexposed, unstretched fabric). Finally, the gripping force for the elastic fabric with exposed elastic threads stretched by 30% was about 3600 grams of force (about a 40% increase over the unexposed, stretched fabric and about a 230% increase over the exposed, unstretched fabric). Typically, the force required to move an object along a surface decreases once the object is in motion because the counteracting force of inertia has been overcome. This is seen as peaks in the force required to move the cross head for both unexposed group (for 0% and 30% stretch) and for the exposed group at 0% stretch. The peaks occur when the fabric begins to slide. However, the exposed group at 30% stretch continues to require a substantial amount of force even after sliding begins at 3600 grams of force (gf), due to the high friction of the stretched fabric.
Sample fabric tubes used to generate the data shown in FIGS. 7A and 7B can be constructed per the dimensions in Table 1 for corresponding fabric stretch. For example, the 0% stretch fabric tube can be constructed as follows: 1) cut fabric of length 10 cm, and width of at least 12 cm, 2) measure 9.5 cm in width direction and draw lines at each end, and 3) fold the fabric and match lines measuring 9.5 cm and stitch along this line form a fabric loop, with loop length of 9.5 cm and length of 10 cm. As described above, the sample holding device is a stainless steel cylinder with a circumference of 9.5 cm and height (length) of 5 cm. This cylinder was covered with a nitrile sleeve and clamped at the top, providing an effective height of 4.2 cm. The cylinder/sleeve set-up is fixed to immovable jaw on the MTS tensile testing machine, so that a tube of fabric from above table can be put on to the cylinder with nitrile sleeve. The fabric tube is mounted all the way to the clamp (but not clamped) and the bottom of fabric sleeve is clamped in the movable cross-head of MTS.

TABLE 1

	Effective	- %	Flap width	Total	Sample
Pre-stretch	width (cm)	width	(cm)	width, cm	Length (cm)

P0 (0%)	9.5		2.5	12	10
P30 (30%)	6.65	2.85	5.35	12	10

In an embodiment, the bra can include gripping polymer tape on or adjacent to the breast support regions. This tape adds additional grip to the front area of the bra to provide additional friction with the body, which helps keep the bra up in regions that do not have exposed elastic threads. In an embodiment, the bra wings provide grip to the sides of the body, and the polymer tape provides grip to the front of the body. In an embodiment, the polymer tape is attached to the breast support portion of the bra. In an embodiment, the polymer tape is attached to the cups of the bra. In an embodiment, the polymer tape is attached to the area around the cups. For example, the polymer tape can be attached to the bra between the cups, near the underwire, or in more than one location. In an embodiment, the polymer tape includes polyurethane. In an embodiment, the polymer tape is bonded to the bra with heat.
Alternative constructions of the fabric with exposed elastic threads are shown in FIGS. 8-9. FIGS. 8A and 8 B show the construction of an embodiment of a fabric that is made using a warp knitting machine. FIG. 8A is a loop diagram of an embodiment of the fabric of the garment. FIG. 8B is a lapping diagram of the embodiment of the fabric shown in FIG. 8A. FIGS. 9A and 9B show the construction of an alternate embodiment of a fabric made using a warp knitting machine. FIG. 9A is a loop diagram of an alternate embodiment of the fabric of the garment. FIG. 9B is a lapping diagram of the embodiment of the fabric shown in FIG. 9A.
Two types of fibers are used to produce the fabric shown in FIGS. 8 and 9. The left-pointing arrowheads in FIG. 8A and in FIG. 9A point to and contact elastic threads. In the lapping diagrams of FIGS. 8B and 9 B, the left hand thread marked I is the non-elastic thread, and the right hand thread marked II is the elastic thread. As mentioned above, the elastic threads include an elastomer, for example, a polyurethane elastomer such as elastane, spandex, or Lycra®. The linear density of the elastic threads is at least 80 denier. In some embodiments, the linear density can be anywhere from 80 denier to 280 denier. For example, the elastic threads can be 80 denier, 100 denier, 120 denier, 140 denier, 160 denier, 180 denier, 200 denier, 220 denier, 240 denier, 260 denier, or 280 denier. This relatively high linear density of elastic threads results in a comfortable bra wing that stays in place without being too tight due to the high degree of elongation, tension force, and recovery of the fabric (described above).
The content of the elastomer in the fabric can be, for example from about 40% to about 50%. In some embodiments, the content of the elastomer in the fabric is about 45%. The right-pointing . arrowheads in FIGS. 8A and 9A point to and contact non-elastic threads. The non-elastic threads can be formed of a variety of materials, including, but not limited to: nylon, polyester, wool, acrylic, and/or regenerative fiber such as rayon, acetate, and/or cellulosic fiber like cotton, or a combination of any of the above.
Methods of making a bra 10 include knitting elastic threads 24 into a fabric such at the elastic threads 24 are exposed on a surface of the fabric. A bra wing 12 is then cut from the fabric, and the bra wing 12 is attached to a breast support portion such that the exposed elastic threads 24 are positioned on the interior surface 22 of the bra wing 12. The superior edge 16 and the inferior 18 of the bra wing 12 are free-cut, meaning they are devoid of seams, adhesives, or bonding. In an embodiment, the bra wing 12 is cut from the fabric such that the bra wing 12 has at least one vertical segment 28 where exposed elastic threads 24 stretch from the superior edge 16 to the inferior edge 18. In an embodiment, the bra wing 12 is cut from the fabric such that the exposed elastic threads 24 stretch the entire interior surface 22 of the bra wing 12.
In an embodiment, knitting the elastic threads into the fabric comprises double-knitting the elastic threads into the fabric. In an embodiment, knitting the elastic threads into the fabric comprises knitting an inner component 36, an outer component 38, and a spacer component 40. This creates a spacer fabric 34, and the bra wing 12 is then cut from the spacer fabric 34.
In an embodiment, attaching the bra wing 12 to a breast support portion comprises attaching the bra wing 12 to at least one cup 14. In an embodiment, cutting the bra wing 12 from the fabric comprises cutting a left wing 30 and a right wing 32. The method further comprises attaching the left wing 30 and right wing 32 to the breast support portion. In an embodiment, the bra wing is attached to the breast support portion by sewing. In an embodiment, the bra wing is attached to the breast support portion by bonding. In an embodiment, the bra wing is attached to the breast support by ultrasonic seaming.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The implementation was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various implementations with various modifications as are suited to the particular use contemplated.

Claims

What is claimed is:

1. A bra comprising:

a bra wing having an exterior surface and an interior surface, the interior surface comprising a region with exposed elastic threads configured to directly contact the body of a wearer; and

wherein the bra wing has a free-cut superior and inferior edge.

2. The bra of claim 1, wherein the region is a vertical segment stretching from the superior edge to the inferior edge of the bra wing.

3. The bra of claim 1, wherein the region with exposed elastic threads is the entire interior surface of the bra wing.

4. The bra of claim 1, wherein the region with exposed elastic threads is devoid of horizontally extending seams.

5. The bra of claim 1, wherein the region with exposed elastic threads is devoid of horizontally extending adhesives.

6. The bra of claim 1, wherein the region with exposed elastic threads is devoid of any coatings having a higher coefficient of friction than the interior surface.

7. The bra of claim 1, wherein the bra wing comprises a blend of nylon and elastane.

8. The bra of claim 1, wherein the bra wing comprises from 60% to 95% elastane and from 5% to 40% nylon.

9. The bra of claim 1, wherein the bra wing comprises a knit fabric.

10. The bra of claim 9, wherein the bra wing comprises a circular knit fabric.

11. The bra of claim 1, wherein the bra wing comprises spacer fabric having an outer component, an inner component, and a spacer component.

12. The bra of claim 11, wherein the outer component comprises a blend of nylon and elastane.

13. The bra of claim 11, wherein the inner component comprises 100% elastane.

14. The bra of claim 11, wherein the spacer component comprises elastane.

15. The bra of claim 1, wherein the linear density of the exposed elastic threads is at least 80 denier.

16. The bra of claim 15, wherein the linear density of the exposed elastic threads is from 80 denier to 280 denier.

17. The bra of claim 1, wherein the bra wing has a tension force of from 5 N to 40 N at 30% elongation, from 15 N to 60 N at 50% elongation, and from 25 N to 80 N at 70% elongation in the length direction.

18. The bra of claim 1, wherein the bra wing has a tension force of 5 N to 40 N at 30% elongation, from 15 N to 60 N at 50% elongation, and from 25 N to 80 N at 70% elongation in the width direction.

19. The bra of claim 1, wherein the bra has a strapless configuration.

20. The bra of claim 19, wherein the bra has at least one connector for a detachable strap.

21. The bra of claim 1, wherein the bra wing is formed from a single layer of fabric.

22. The bra of claim 21, wherein the single layer of fabric is spacer fabric.

23. The bra of claim 21, wherein the exposed elastic threads are knit into the single layer of fabric.

24. The bra of claim 1, wherein the bra wing has an elongation of from 85% to 180% in the width direction at 100 N load.

25. The bra of claim 1, wherein the bra wing has an elongation of from 85% to 180% in the length direction at 100 N load.

26. A method of making a bra, the method comprising:

knitting elastic threads into a fabric such that the elastic threads are exposed on a region of a surface of the fabric;

cutting at least one bra wing from the fabric;

attaching at least one bra wing to a breast support portion such that the elastic threads are exposed on a region of an interior surface of the bra wing; and

leaving superior and inferior edges of the bra wing in a free-cut state.

27. The method of claim 26, wherein cutting the bra wing from the fabric comprises cutting the bra wing such that the exposed elastic threads stretch from a superior edge to an inferior edge of the bra wing on at least one vertical segment.

28. The method of claim 26, wherein cutting the bra wing from the fabric comprises cutting the bra wing such that the exposed elastic threads stretch the entire interior surface of the bra wing.

29. The method of claim 26, wherein knitting elastic threads into a fabric comprises circular-knitting the elastic threads into the fabric.

30. The method of claim 26, wherein knitting elastic threads into a fabric comprises knitting an inner component, an outer component, and a spacer component.

31. The method of claim 26, wherein cutting at least one bra wing from the fabric comprises cutting a left wing and a right wing, and attaching at least one bra wing to the breast support portion comprises attaching the left wing and right wing to the breast support portion.

32. The method of claim 26, wherein attaching at least one bra wing to a breast support portion comprises attaching the bra wing to at least one cup.

33. The method of claim 26, wherein the bra wing has an elongation of from 85% to 180% in the width direction at 100 N load.

34. The method of claim 26, wherein the bra wing has an elongation of from 85% to 180% in the length direction at 100 N load.