WO1997016086A1

WO1997016086A1 - Cushion strap assembly for a brassiere

Info

Publication number: WO1997016086A1
Application number: PCT/US1995/014038
Authority: WO
Inventors: Patrick Girard; Patrick Guillet
Original assignee: Playtex Apparel, Inc.
Priority date: 1995-10-31
Filing date: 1995-10-31
Publication date: 1997-05-09

Abstract

There is provided an elongated cushion strap assembly (20) for a brassiere (10) having a top exterior layer (30), a bottom exterior layer (32), an interior cushion (34) positioned between the two exterior layers, and a binding (24) sewn on the longitudinal edges of the three sandwiched layers. The cushion includes a plurality of polyester monofilaments, and the binding includes a layer of woven taffetas. To form the cushion strap, the top exterior layer, the cushion and the bottom exterior layer are laminated together to create a combined three-fabric layer. A double binding is then sewn along the longitudinal edges of the combined three-fabric layer to prevent the monofilaments of the cushion from passing through the double binding to the outside of the cushion strap. Thus, the present invention prevents the monofilaments from becoming exposed outside of the cushion strap and irritating the user's skin.

Description

CUSHION STRAP ASSEMBLY FOR A BRASSIERE

BACKGROUND OF THE INVENTION

I. Field ofthe Invention

The present invention relates generally to brassieres. More particularly, the present invention relates to a cushion strap assembly for a brassiere.

II. Description ofthe Prior Art

Brassieres typically have shoulder pads that attach to their shoulder straps to provide comfort to the wearer or user ofthe brassiere. For example, such shoulder pads

and the like are generally described in British Patent No. 1,564,871, which was published on April 16, 1980; German Patent No. DE 4,014,972 C2, which issued on February 20, 1992; European Patent No. 0,514,563 Bl, which issued on February 2, 1995; European Application No. 0,546,506 Al, which was published on June 16, 1993; European Application No. 0,602,542 Al, which was published on June 22, 1994; and PCT International Publication Number WO 94/22334 (Application No. PCT/US94/03385), which was published on October 13, 1994.

One padding for a brassiere is a cushion layer having a textile filler material that links two layers of fabric together. The filler material forms a spaced cushion between the two layers to provide comfortable padding for the brassiere. For example, European Patent No. 103,129, which issued on April 16, 1986, provides a cushion layer with padding through all portions ofthe brassiere. This patent is directed to a cushion layer

that comprises an outer knitted fabric layer, an inner knitted fabric layer and a textile filler material therebetween. The filler material is made of a two-faced warp-knitted fabric worked on a warp-knitting or raschel machine. In particular, filler threads are formed between the inner knitted fabric layer and outer knitted fabric layer to provide padding for the cushion layer.

However, the cushion layer ofthe above patent may irritate the skin ofthe user. In particular, the filler material ofthe cushion layer has a plurality of monofilaments that may extend through its outer edges and rub against the user's skin. Thus, there is a need for a cushion strap assembly that minimizes the discomfort caused by the filler material.

Therefore, the present invention is a cushion strap assembly that forms a protective layer about the edges ofthe cushion layer to prevent the filler material in the cushion layer from irritating the user's skin. In particular, the cushion layer is sandwiched between top and bottom exterior layers to form a layered arrangement and a double, two layer binding is attached along the longitudinal sides ofthe layered arrangement. Accordingly, the binding prevents the filler material ofthe cushion layer from passing to the outside ofthe cushion strap assembly. SUMMARY OF THE INVENTION

Against the foregoing background, it is a primary object ofthe present invention to provide a cushion strap assembly that includes a cushion layer having a filler material to provide a comfortable cushion for the user and a binding along the edges ofthe cushion layer to prevent any discomfort to the user.

It is another object ofthe present invention to provide such a cushion strap assembly in which the binding includes a microporous material that prevent monofilaments ofthe filler material from being exposed outside the cushion strap assembly.

It is a further object ofthe present invention to provide such a cushion strap assembly in which the binding includes a double layer for enclosing the edges ofthe cushion layer.

To accomplish the foregoing objects and advantages, the present invention, in brief summary, is a cushion strap assembly for a brassiere which comprises an elongated layered arrangement and a binding. The elongated layered arrangement includes a top exterior layer, a cushion layer positioned on a side ofthe top exterior layer and a bottom exterior layer positioned on the cushion layer on a side opposite that ofthe top exterior layer. Also, the layered arrangement has a first exterior side and a second exterior side. The binding is attached on a longitudinal edge portion ofthe first exterior side and the second exterior of said layered arrangement such that the binding prevents exposure ofthe cushion layer through the binding.

In addition, the present invention is generally directed to a brassiere which comprises a pair of brassiere straps in which each strap has a cushion strap assembly as described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and still further the objects and advantages ofthe present invention will be more apparent from the following detailed explanation ofthe preferred embodiments ofthe invention in connection with the accompanying drawings:

Fig. 1 is a perspective view of a brassiere having a pair ofthe brassiere straps, each strap incoφorating the cushion strap assembly ofthe present invention;

Fig. 2 is a bottom perspective view ofthe cushion strap assembly of Fig. 1;

Fig. 3 is a sectional view ofthe cushion strap assembly taken along line 3-3 of Fig.

2 showing the components ofthe cushion strap assembly;

Fig. 4 is a diagrammatic view ofthe cushion strap assembly of Fig. 2 illustrating the method for forming the layered arrangement ofthe cushion strap assembly; and

Fig. 5 is a sectional view of a cushion strap assembly that is not an embodiment of the present invention but simply illustrates a problem that may occur when a double binding ofthe present invention is not utilized. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the figures and, in particular, Fig. 1, there is provided a brassiere generally represented by reference numeral 10. The brassiere 10 includes a pair of

shoulder straps 15, and each shoulder strap includes a cushion strap assembly 20. Each cushion strap assembly 20 may be attached to the strap 15 or integral with the strap as shown in Fig. 1.

Referring to Fig. 2, the cushion strap assembly 20 is a generally a thin, elongated pad that includes a layered arrangement 22 and a pair of bindings 24 along longitudinal edges 26 ofthe layered arrangement. The longitudinal edges 26 ofthe cushion strap assembly 20 are curved to provide greater width and support at its mid-section 28 which typically rests at the top ofthe user's shoulders. In addition, the bindings 24 provide a smooth, rounded side along the longitudinal sides 26 to provide the user with comfort at both of those areas.

Referring to Fig. 3, the layered arrangement 22 ofthe cushion strap assembly 20 includes a top exterior layer 30 and bottom exterior layer 32, an interior cushion layer 34

of duplex or dual fabric positioned between the top exterior layer and bottom exterior layer. The top exterior layer 30 is constructed of a fabric that is aesthetically suitable for the exterior of a brassiere, preferably interlock fabric that is 100% polyester. The bottom

32 exterior layer is also a fabric and is, preferably, made of a single cotton jersey. The cushion layer 34 ofthe layered arrangement 22 has two layers or sides, specifically a first layer 36 and a second layer 38, and a monofilament layer 40 therebetween. The monofilament layer 40 has a plurality of polyester monofilaments 42 that link the first layer 36 and the second layer 38 and, yet, provides substantially equal spacing between the two layers. Thus, the monofilaments 42 act as a cushion material to

comfortably rest on the user's shoulders. An example of such cushion layer is provided in European Patent No. 103, 129, cited above. However, other types of cushion layers may be used for the present invention.

It is to be understood that, preferably, the cushion strap assembly 20 ofthe present invention is a substantially thin pad as shown in Fig. 2. Thus, the proportions shown in Fig. 3, particularly the thickness ofthe cushion strap assembly, has been distorted to more clearly show the inner portion ofthe cushion strap assembly 20.

Referring to Fig. 4, any conventional method for producing the layered arrangement 22 may used so long as a textile filler material, i.e., monofilaments 42, is

arranged between the first layer 36 and the second layer 38 . For the preferred embodiment, a double needle bar raschel machine (not shown) is used to form the monofilament layer 40 between the two layers 36, 38 ofthe monofilament layer. In particular, the rachel machine forms monofilaments 42 between the first layer 36 and the

second layer 38, making long sinker stitches 44 at each layer. The rachel machine includes three bars that guide the filler thread to two needle rows such that the monofilaments 42 are formed between the first layer 36 and the second layer 38 as shown in Fig. 4. After the monofilament layer 40 is formed, the top exterior layer 30 and the bottom exterior layer 32 are laminated, temporarily or permanently, to the monofilament layer 40 to create the layered arrangement 22. A binding 46 is then attached along the longitudinal edges 26 ofthe layered arrangement 22 as described below.

Referring again to Fig. 3, the binding 46 has an inner binding layer 48 and an outer binding layer 50. The edges 52 ofthe binding that attach to the edges ofthe top exterior layer and the bottom exterior layer may be folded over, as shown in Fig. 3. For the preferred embodiment, the binding 46 is sewn to the edges 52 ofthe top exterior layer 36

and the bottom exterior layer 38, as represented by line 54, thus enclosing the edges in the binding.

The inner binding layer 48 ofthe binding 46 includes a microporous material to prevent any portion ofthe cushion layer 34, including the monofilaments 42, from passing through the binding and being exposed outside ofthe cushion strap assembly 20. For the preferred embodiment, the inner binding layer 48 includes a taffeta weave material, preferably taffeta weave 100% polyester, and a microporous spreading, preferably 100%

microporous polyurethane type MIC 802. Such binding is available from Tissage de Quintenas in France as product no. 3680 1 8.

For the preferred embodiment, the inner binding layer 48 is a spreaded woven

fabric having a width of about 147 cm to about 153 cm and a weight of about 58 g/m² to about 70 g/m². Also, the preferred inner binding layer has a length of about 28 picks/cm

and a width of about 98 ends/cm in which the residual shrinkage is from about 0% to about 2% and the elongation is from about 0% to about 5% for the length and the width. In addition, the content ofthe preferred inner binding layer is about 80% polyester and about 20% polyurethane, and the yarn detail for the polyester is warp 50 dtex and weft 76dtex.

The binding 46 also has an outer binding layer 50 that may be of any type of knitted or woven material that is comfortable against the user's skin, preferably knitted fabric. The two layer structure 48, 50 ofthe binding 46 provides a shoulder strap that both prevents the monofilaments 42 from irritating the user and, further, provides a soft, comfortable surface against the user's skin.

Fig. 5 is a representation of a cushion strap assembly 120 without the inner binding layer ofthe binding that illustrates a problem that may occur when a binding ofthe present invention is not used. Without the inner binding layer, the monofilaments 142 may become exposed outside ofthe cushion strap assembly 120 and rub against one's skin which could cause irritation. As shown on the right side of Fig. 5, the monofilaments 142 may extend through the outer binding layer 150 and become exposed outside ofthe cushion strap assembly 20. In contrast, as shown on the right side of Fig. 3, the monofilaments 42 are contained within the cushion strap assembly 20 by the inner binding layer 48 ofthe binding

46. Accordingly, the inner binding layer 48 is an important part ofthe present invention. The invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made

therein without departing from the spirit and scope ofthe invention as defined in the

appended claims.

Claims

Wherefore, I claim:

1. A cushion strap assembly for a brassiere comprising:

an elongated layered arrangement including a top exterior layer, a cushion layer

positioned on a side ofthe top exterior layer and a bottom exterior layer positioned on the

cushion layer on a side opposite that ofthe top exterior layer, said layered arrangement having a first exterior side and a second exterior side; and

a binding being attached on a longitudinal edge portion ofthe first exterior side and

the second exterior of said layered arrangement, wherein said binding prevents exposure of the cushion layer through the binding.

2. The cushion strap assembly of claim 1, wherein said binding includes a

microporous material to prevent any portion ofthe cushion layer from passing through the binding.

3. The cushion strap assembly of claim 2, wherein said microporous material

of said binding is polyurethane.

4. The cushion strap assembly of claim 1, wherein said binding includes a

taffeta weave material.

5. The cushion strap assembly of claim 4, wherein said taffeta weave material of said binding is polyester.

6. The cushion strap assembly of claim 1, wherein said binding includes an inner layer having a microporous material and an outer layer positioned on one side of said inner layer.

7. The cushion strap assembly of claim 6, wherein said outer material is at least one material selected from the group consisting of: a knitted material and a woven material.

8. The cushion strap assembly of claim 7, wherein said outer material is a knitted fabric.

9. The cushion strap assembly of claim 1, wherein said cushion layer includes a cushion portion having a first layer, a monofilament layer on a side ofthe first layer and a second layer positioned on the monofilament layer on a side opposite that ofthe first layer, wherein the monofilament layer links the first layer to the second layer.

10. The cushion strap assembly of claim 9, wherein the monofilament includes a plurality of polyester monofilaments.

11. The cushion strap assembly of claim 9, wherein each ofthe first layer and the second layer ofthe cushion portion is a fabric.

12. The cushion strap assembly of claim 1, wherein said top exterior layer is

constructed of an interlock fabric of polyester.

13. The cushion strap assembly of claim 1, wherein said bottom exterior layer is constructed of a single cotton jersey.

14. A brassiere comprising:

a pair of brassiere straps, each of said straps having a cushion strap assembly, each cushion strap assembly having an elongated layered arrangement and a binding;

said elongated layered arrangement including a top exterior layer, a cushion layer positioned on a side ofthe top exterior layer and a bottom exterior layer positioned on the cushion layer on a side opposite that ofthe top exterior layer, said layered arrangement having a first exterior side and a second exterior side; and

said binding being attached on a longitudinal edge portion ofthe first exterior side and the second exterior of said layered arrangement, wherein said binding prevents exposure ofthe cushion layer through the binding.

15. The brassiere of claim 14, wherein said binding includes a microporous material to prevent any portion ofthe cushion layer from passing through the binding.

16. The brassiere of claim 15, wherein said microporous material of said binding is polyurethane.

17. The brassiere of claim 14, wherein said binding includes a taffeta weave material.

18. The brassiere of claim 17, wherein said taffeta weave material of said binding is polyester.

19. The brassiere of claim 14, wherein said binding includes an inner layer having a microporous material and an outer layer positioned on one side of said inner layer.

20. The brassiere of claim 19, wherein said outer material is at least one material selected from the group consisting of: a knitted material and a woven material.

21. The brassiere of claim 20, wherein said outer material is a knitted fabric.