WO2013166643A1

WO2013166643A1 - Underwire for brassiere

Info

Publication number: WO2013166643A1
Application number: PCT/CN2012/075141
Authority: WO
Inventors: Changming Liang
Original assignee: Regina Miracle International (Group) Limited
Priority date: 2012-05-07
Filing date: 2012-05-07
Publication date: 2013-11-14

Abstract

An underwire (100) comprises three elements (102,104,106), which are inter-connected via male and female connecting parts. The male and female connecting parts can be moved relative to each other to extend the length of the underwire (100). The three elements (102,104,106) comprise a central element (104) and two side arms comprising a right-hand side arm (106) and a left-hand side arm (102).

Description

UNDERWIRE FOR BRASSIERE

Field of Invention

The present invention relates to an underwire for a brassiere. The invention also relates to an underwire assembly for a brassiere or breast cup and a brassiere or breast cup comprising the underwire or the underwire assembly. A method of manufacturing the brassiere and a mold for manufacturing the underwire are also provided.

Background of the invention

The function of an underwire in a brassiere is to provide support. A conventional underwire for a brassiere is substantially U-shaped, is typically made of metal or plastic and has a fixed length. The length and/or curvature of the underwire determines the cup size of the brassiere.

Since a cup size may only be selected from a discrete range of cup sizes, a variety of breast sizes may correspond to a given cup size. Accordingly, many users may not be able to find a brassiere with an underwire of a length appropriate for their specific breast size. Furthermore, the breast size of an individual user may fluctuate over time and the user may therefore find that the underwire of a discrete sized brassiere becomes uncomfortable or fails to provide sufficient support.

It is an aim of the present invention to provide an underwire which enables better fit and support of every breast size across the range of sizes corresponding to a discrete cup size and across a range of different breast sizes of an individual user. Summary of the Invention

According to a first aspect of the invention, there is provided an underwire for a brassiere, the underwire comprising at least two members movable relative to each other between a first position and a second position. By providing an underwire comprising two or more members movable relative to each other, the length or shape of the underwire and accordingly the associated cup size can be varied. A brassiere comprising such an underwire is therefore not limited to conventional discrete cup sizes. Instead, the cup size of the brassiere can be modified by an amount corresponding to a partial or fractional cup size, thereby providing a support and comfort for all breast shapes or sizes. In an exemplary embodiment, the underwire has a first length at the first position and a second length at the second position, the second length being different to the first length. For example, the second length may differ from the first length by a range of up to 10mm. The underwire may have a first radius of curvature at the first position and a second radius of curvature at the second position, the second radius of curvature being different (greater or less) to the first radius of curvature. Accordingly, movement of the underwire between the first and the second position results in a change in the associated cup size of a brassiere comprising the underwire.

The at least two members may comprise a central member and a first member. The underwire may additionally comprise a second member.

The first member may comprise a hollow tube configured to receive a first end of the central member. The first member may be situated on the underarm side of the underwire, i.e. the side of the underwire configured to be worn closest to the underarm. If the underwire comprises a second member, the second member may be configured to receive a second end of the central member different to the first end.

The central member may comprise, or be made from, one or more of: metal; plastic; carbon fibre; and glass fibre. One or both of the first and second members may comprise a plastic tube.

The underwire may further comprise a cover through which the central member is inserted. For example, the cover may comprise either elastic material or plastic material. In one example, the cover comprises a plastic tube.

In a further example, the cover comprises a first layer comprising an elastic material and a second layer comprising a fabric which is preferably a mesh fabric. The fabric layer, or preferably the mesh fabric layer, may comprise two disjoint parts, wherein a first one of the two disjoint parts is integrated with the first member and a second part of the two disjoint parts is integrated with the second member.

The underwire may be configured to move between the first position and the second position in accordance with a user breast shape. Additionally or alternatively, the underwire may be configured to move between the first position and the second position in response to a force exerted by the user breast. Accordingly, the underwire will automatically adjust or re-adjust to a given user breast shape. According to a second aspect of the invention, there is provided an underwire assembly comprising an underwire according to any of the above embodiments; and a sheath for containing the underwire. For example, the sheath comprises an elastic material, such as spandex.

According to a third aspect of the invention, there is provided a brassiere comprising an underwire or underwire assembly as described above.

According to a fourth aspect of the invention, there is provided a breast cup comprising an underwire or underwire assembly as described above.

According to a fifth aspect of the invention, there is provided a method of manufacturing a brassiere, the method comprising providing an inner panel and an outer panel; placing an underwire or underwire assembly, as described above, between the inner and outer panels; and connecting together the inner and outer panels with the underwire or underwire assembly therebetween.

For example, connecting together the inner and outer panels with the underwire or underwire assembly may comprise sewing the underwire or underwire assembly to one or both of the inner and outer panels.

If the underwire comprises a central element inserted through a cover, wherein the cover comprises a plastic tube, the method may comprise placing the underwire between the inner and outer panels and forming the cover by injection molding.

If the underwire comprises a central element inserted through a cover comprising a first layer comprising an elastic material and a second layer comprising a fabric or, preferably, a mesh fabric, the method may comprise placing the underwire between the inner and outer panels and connecting the fabric layer and the first and second members.

According to a sixth aspect of the invention, there is provided a mold for manufacturing an underwire comprising a central element inserted through a cover, as described above, the mold comprising: a cavity for housing the central member and for injecting plastics into, such that the plastics form a casing around the metallic wire.

Brief description of the drawings The present invention will now be described in detail with reference to the accompanying drawings, in which:

Figure 1 is a frontal view of an underwire in accordance with a first embodiment of the present invention;

Figure 2 is a frontal view of a brassiere comprising the underwire of figure 1 ;

Figure 3 is a frontal view of an underwire in accordance with a further embodiment of the invention;

Figure 4 is a frontal view of an underwire in accordance with a further embodiment of the invention; Figure 5 is a frontal view of an underwire in accordance with a further embodiment of the invention; and

Figure 6 is a cross-sectional view of a junction between the members of the underwire of figure 5 and a cover located around the junction.

Detailed description of the invention

Figure 1 shows an underwire 100 in accordance with one embodiment of the invention. As can be seen from these figures, the underwire 100 is substantially U-shaped, to conform to the cup of a brassiere although the shape is not a perfect U-shape. For example, one arm of the underwire has a steeper gradient and is shorter than the other arm to conform to breast shape.

In the embodiment shown in figure 1 , the underwire 100 comprises three members, parts, elements or subsections 102, 104, 106, which are inter-connected via male and female connecting parts and which can be moved relative to each other to reversibly extend the length of the underwire 100. The three members comprise a central element 104 and two side arms comprising a right-hand side arm 106 and a left-hand side arm 102.

The central element 104 is similar to a conventional underwire and provides vertical support to the breast. However, the central element 104 is shorter than a conventional underwire and comprises a male mating portion (length or subsection) at each end. In the embodiment shown in figure 1 , the central element 104 comprises a metallic wire. However, the central element 104 may alternatively comprise plastic, carbon fibre, glass fibre or any relatively hard material. The side arms 102 and 106 each comprise a tube which may be made from any suitable material. For example, the tubes may be made of plastic such as Polypropylene (PP), Thermoplastic elastomers (TPE), Thermoplastic Rubber (TPR) or Polyurethane (PU), in which case the tubes may be formed by injection molding. Each of the tubes comprises a respective solid portion 102a and 106a and a respective hollow portion or female mating portion 102b and 106b.

The hollow portion 106b of the right-hand side arm 106 is configured (or adapted) to receive mating portion on the right-hand side of the central element 104. Similarly, the hollow portion 102b of the left-hand side arm is configured to receive the mating portion on the left-hand side of the central element 104.

Alternatively, one or both ends of the central element 104 may comprise female mating portions (or hollow portions) in which case the corresponding side arm 102 and/or 106 will comprise a male mating portion.

The central element 104 may optionally be encased or enclosed within a cover 108. As can be seen in figure 1 (a), the cover 108 has a similar cross-sectional dimension to the side arms 102 and 106. The cover 108 is configured to fit between the side arms 102 and 106 and lie substantially flush with the side arms 102 and 106 when the underwire is in an un-extended state. Accordingly, the cover 108 and the side arms 102 and 106 comprise a flat or smooth outline across the length of the underwire 100 when the underwire 100 is in the un-extended state. The cover 108 is therefore a similar size and comprises a similar material to the side arms 102 and 106 and may also be formed by injection molding.

The cover 108 may comprise a hollow tube through which the central element 104 passes. Additionally, the cover 108 may be either movable or fixed relative to the central element 104. In the case where the cover 108 is fixed with respect to the central element 104, the cover 108 may be injection molded with the central element 104 during injection molding of the cover 108.

In an un-extended position or state, as shown in figures 1 (a), the mating portions of the central element 104 are substantially (or almost entirely) contained within the corresponding hollow portions 102b and 106b. The side arms 102 and 106 therefore meet, or are in close proximity to, respective ends of the cover 108 at junctions 110 and 112. It will be appreciated that if the central element 104 is not enclosed within a cover 108, the side arms 102 and 106 will meet, or be in close proximity to, each other when the underwire 100 is in the un-extended position. In this case, the junctions 110 and 112 will occur at substantially the same point resulting in a single junction between the side arms 102 and 106. Optionally, the single junction may extend over a length of the central element 104. In this case, the side arms 102 and 106 are spaced apart when the underwire 100 is in the un-extended position.

In the un-extended position, the length of the underwire 100 corresponds to a discrete cup size. This length is essentially the same as the length of a conventional underwire for the same discrete cup size. In what follows, the length of an underwire 100 is the distance along the underwire from one end of the underwire 100 to the other end. This length might alternatively be referred to as the curvature length or arc length of the underwire.

In order to extend the underwire 100, the side arms 102 and 106 can be moved along the central element 104 in opposing directions to each other so that the mating portions of the central element 104 are no longer fully contained within the hollow portions 102b and 106b. In this way, the length of the underwire 100 is extended by an amount corresponding to the combined length of the mating portions no longer contained within the hollow portions 102b and 106b in the extended position.

The underwire 100 may be configured to be extendible by any suitable length, thereby providing a continuous range of cup sizes or fractional cup sizes instead of the discrete cup sizes of conventional underwire brassieres. The underwire 100 may be extendible by any length within a range of 0 to 20mm with a preferred extension range of 0 to 10mm. The hollow portions 102b, 106b and/or the mating portions of the central element 104 may be configured to prevent the side arms 102 and 106 from Over-extending' or becoming disconnected from each other. For example, the mating portions of the central element 104 may comprise a protruding element at each end which prevents the removal of the element end from the corresponding hollow portion of the side arm.

Starting from an extended position, retraction of the side arms (or movement of the side arms 102 and 106 along the central element 104 towards each other) causes the mating portions of the central element 104 to move within the hollow portions 102b and 106b and the underwire to return to its original, un-extended length.

The hollow portions of the tubes 102b and 106b and the mating portions of the central element 104 may be configured so that the side arms 102 and 106 can slide along the central element 104. Additionally or alternatively, the hollow portions 102b and 106b may be configured so that the side arms 102 and 106 move in a stepwise manner (or between discrete points) along the central element 104.

The underwire 100 is encased in a sheath, fabric pocket or sock, or wire channel (not shown) comprising an elastic material, for example spandex. The underwire and the sheath are then connected, attached, or affixed to the brassiere cup, for example by sewing.

Figure 2 shows a frontal view of a brassiere 200 comprising an underwire 100 in each cup. When the brassiere 200 is worn, the weight and shape of the user's breast exerts a force on the underwire 100. The extent and direction of this force is proportional to the weight and shape (or size) of the user's breast. For example, if the user's breast shape matches the discrete cup size exactly, the breast exerts a predominantly vertical force on the underwire 100. In this situation, the underwire will remain in the un-extended position and the side arms 102 and 106, together with the central element 104, provide a vertical support to the breast.

However, if the user's breast size is greater than the discrete cup size of the brassiere the breast will also exert a significant horizontal or sideways force on the underwire 100. If this horizontal force is greater than the elastic force exerted by the sheath, the side arms 102 and 106 move along the central element 104, thereby causing the underwire 100 to move from an un-extended position to an extended, partially extended, or stretched position. The extent of movement of the side arms 102 and 106 and the resulting extension of the underwire 100, is therefore proportional to the breast weight and/or shape. Accordingly, the underwire 100 will self-adjust, self-regulate, or configure itself to a suitable length and therefore a suitable cup size for an individual user.

It will be appreciated that the extent of movement of the side arms 102 and 106 is also dependent on the elastic force exerted by the sheath and the firmness or flexibility of the brassiere can therefore be controlled through selection of the sheath elasticity. On removal of the brassiere, the force exerted by the breast is removed. Accordingly, the force exerted by the elastic sheath causes the side arms 102 and 106 to return to their original position, thereby causing the underwire 100 to return to its un-extended length. Hence, the underwire 100 will re-adjust to the specific breast shape of the user at any given time and a brassiere comprising the underwire 100 will continue to provide support and comfort irrespective of fluctuations of breast shape. Figure 3 depicts a further embodiment of the invention. This further embodiment is similar to the embodiment of figure 1 . However, in this embodiment the central element 104 is not contained within a cover 108. Instead, as can be seen in figure 3, the central portion of the central element 104, i.e. the portion between the two mating portions, has a similar cross- sectional dimension to the cross-sectional dimension of the side arms 102 and 106. The cross- sectional dimension of the central element 104 is therefore thicker or larger than the cross- sectional dimension of the mating portions of the central element. In the un-extended position, the central portion of the central element 104 and the side arms 102 and 106 therefore provide a substantially uniform or flat external shape across the length of the underwire 100.

A further embodiment of the invention is shown in figure 4. This embodiment is similar to the embodiment of claim 1 . However, instead of three inter-connected members 102, 104 and 106, the underwire 100 of the embodiment shown in figure 4 comprises two inter-connected side arms 302 and 304.

A first one of the side arms 302 may be similar to either one of side arms 102 and 106. However, instead of being configured to receive the mating portion of the central element 104, the first side arm 302 is configured to receive a mating portion of the second side arm 304 at a junction 306. Additionally or alternatively, the second side arm 304 may be configured to receive a mating portion of the first side arm 302 at the junction 306.

Accordingly, the second side arm 304 comprises any suitable mating portion that enables the first side arm 302 to be movably connected thereto so that the length of the underwire 100 can be reversibly extended as described above in relation to figures 1 to 3. For example, the second side arm 304 may comprise one of the side arms 102 or 106 integrated with the central element 104.

Alternatively, the first side arm 302 may comprise a side arm 102 or 106 whilst the second side arm 304 comprises a metal wire or any other substantially solid (or non-hollow) component comprising e.g. plastic, carbon fibre, glass fibre or any relatively hard material. For example, the second side arm 304 may comprise a central element 104 the length of which has been increased to reach around the breast without the need for an additional side arm. In this embodiment, the first side arm 302 is preferably situated on the underarm side of the underwire 100 because this side of the underwire requires less support than the opposing side (i.e. the side of the underwire configured to be positioned closest to the centre of the brassiere). A further embodiment of the invention is shown in figure 5. This embodiment comprises an underwire 100 as described above in relation to figure 4. However, in this embodiment, the underwire 100 is not encased within a sheath as described in relation to figure 1 . Instead, the "elastic" function provided by the sheath in the previous embodiments (the function which causes the side arms 302 and 304 to return to the un-extended state when the user removes the brassiere) is performed by fabric cover 502 located over, about or around junction 306. The fabric cover 502 comprises elastic and is attached, fastened or connected to each of the side arms 302 and 304, thereby exerting a force drawing the side arms 302 and 304 towards each other. Hence, once the force exerted by the breast is removed, e.g. on removal of the brassiere, the force exerted by the fabric cover 502 causes the underwire 100 to return to its original un-extended position.

Figure 6 shows a cross-sectional view of the fabric cover 502 and the junction 306 between the members 302 and 304 of the underwire shown in figure 5. In the embodiment shown in figure 6, the fabric cover 502 comprises an elastic layer 602. The elastic layer 602 may comprise any suitable elastic material, for example, spandex. The elastic layer 602 is attached, fastened, or connected, e.g. by sewing, to a layer of mesh fabric. In the embodiment shown in figure 6, the mesh fabric layer comprises two separate (or disjoint) pieces of mesh fabric 604 and 606. Each of the mesh pieces 604 and 606 is "integrated" with or connected to a respective side arm 304 and 306. The mesh pieces may be integrated with the side arms by any suitable means, for example, by injection molding. Alternatively, the mesh fabric layer may comprise a single piece of mesh fabric each end of which is integrated with, or connected to, a respective side arm 304 or 306. The connection between the elastic layer 602 and the mesh pieces 604 and 606 transfers the force exerted by the elastic layer 602 to the side arms 304 and 306. This force acts to draw the side arms towards each other, thereby causing the underwire to return to its un-extended position when not in use. In alternative embodiments, the mesh fabric may be replaced by any other fabric or material suitable for attachment to the elastic layer 602 (for example by sewing) so that the force exerted by the elastic layer 602 is transferred to the side arms 302 and 304.

The embodiment shown in figures 5 and 6 is particularly suitable for use with a molded bra cup in which the underwire is molded together with the foam and fabric layers constituting the cup when the cup is molded. See, for example US 2004/0224604A1 , the contents of which are incorporated by reference herein, for a method of molding such a cup. In the embodiment of figures 5 and 6 the side arms 304 and 306 of the underwire 100 replace the fabric sheath (see for example US 2004/0224604A1 ). In particular, the side arms 302 and 304 prevent any sharp components, e.g. any metallic wire, of the underwire 100 from piercing through the foam and fabric layers of the brassiere cups, for example when washing the brassiere. However, the underwire 100 of the embodiments of figures 5 and 6 may additionally be encased in a sheath, which is sewn to a brassiere cup. Alternatively, the sheath encasing the underwire 100 may be molded together with foam and fabric layers to form a brassiere cup. Whilst the embodiment of the invention shown in figures 5 and 6 relate to the underwire of figure 4, it will be appreciated that in an alternative embodiment the fabric cover shown in figures 5 and 6 may be used in conjunction with the underwire described in relation to any of figures 1 to 3. In this case, a respective fabric cover 502 may be arranged around each of the junctions 110 and 112. Alternatively, the fabric cover may be arranged to cover both the junctions 110 and 112.

It will be appreciated that this description is by way of example only; alterations and modifications may be made to the described embodiment without departing from the scope of the invention as defined in the claims. For example, whilst in the above embodiments of the invention the side arms 102 and 106 comprise female mating portions and the central element 104 comprises male mating portions, it will be appreciated that one or both of the side arms 102 and 106 may comprise a male mating portion with the corresponding end of the central element 104 comprising a female mating portion. Alternatively, the underwire 100 may comprise more than three members, each adjacent pair of members being connected together via a male and female connection similar to that described above.

Claims

1 . An underwire for a brassiere, the underwire comprising:

at least two members movable relative to each other between a first position and a second position.

2. The underwire of claim 1 , wherein:

the underwire has a first length at the first position and a second length at the second position, the second length being different to the first length.

3. The underwire of claim 2, wherein the second length differs from the first length by a range of up to 10mm.

4. The underwire of claim 1 , wherein:

the underwire has a first radius of curvature at the first position and a second radius of curvature at the second position, the second radius of curvature being different to the first radius of curvature.

5. The underwire of any of the preceding claims, wherein the at least two members comprise a central member and a first member.

6. The underwire of claim 5, further comprising a second member.

7. The underwire of claim 5 or claim 6, wherein the first member comprises a hollow tube configured to receive a first end of the central member.

8. The underwire of claim 7, wherein the first member is situated on the underarm side of the underwire.

9. The underwire of claim 7 when dependent on claim 6, wherein the second member is configured to receive a second end of the central member different to the first end.

10. The underwire of any of claims 5 to 8, wherein the central member is made from one or more of:

metal;

plastic;

carbon fibre; and glass fibre.

1 1 . The underwire of claim 6 or claim 7, wherein one or both of the first and second members comprises a plastic tube.

12. The underwire of any of claims 5 to 11 , further comprising a cover through which the central member is inserted.

13. The underwire of claim 12, wherein the cover comprises one of:

elastic material; or

plastic material.

14. The underwire of claim 13, wherein the cover comprises a plastic tube.

15. The underwire of claim 13, wherein the cover comprises a first layer comprising an elastic material and a second layer comprising a fabric.

16. The underwire of claim 15, wherein the second layer comprises two disjoint parts, wherein a first one of the two disjoint parts is integrated with the first member and a second part of the two disjoint parts is integrated with the second member.

17. The underwire of any of the preceding claims, wherein the members are further configured to move between the first position and the second position in accordance with a user breast shape.

18. The underwire of any of the preceding claims, wherein the members are configured to move between the first position and the second position in response to a force exerted by the user breast.

19. An underwire assembly comprising:

an underwire according to any one of the preceding claims; and

a sheath for containing the underwire.

20. The underwire assembly of claim 19, wherein the sheath comprises an elastic material, such as spandex.

21 . A brassiere comprising an underwire according to any one of claims 1 to 18.

22. A brassiere comprising an underwire assembly according to claim 19 or claim 20.

23. A breast cup comprising an underwire according to any one of claims 1 to 18.

24. A breast cup comprising an underwire assembly according to claim 19 or claim 20.

25. A method of manufacturing a brassiere, the method comprising:

providing an inner panel and an outer panel;

placing an underwire in accordance with any one of claims 1 to 18 or an underwire assembly in accordance with claim 19 or claim 20 between the inner and outer panels; and

connecting together the inner and outer panels with the underwire or underwire assembly therebetween.

26. The method of claim 25, wherein connecting together the inner and outer panels with the underwire or underwire assembly comprises sewing the underwire or underwire assembly to one or both of the inner and the outer panels.

27. The method of claim 25, comprising placing an underwire in accordance with claim 14 between the inner and outer panels and wherein the method further comprises forming the cover by injection molding.

28. The method of claim 25, comprising placing an underwire in accordance with claim 16 between the inner and outer panels and wherein the method further comprises connecting the second layer and the first and second members.

29. A mold for manufacturing an underwire according to claim 14, the mold comprising:

a cavity for housing the central member and for injecting plastics into, such that the plastics form a casing around the metallic wire.

30. An underwire substantially as hereinbefore described with reference to any of figures 1 to 6.

31 . A brassiere substantially as hereinbefore described with reference to any one of figures 1 to 6.

32. A method of manufacturing a brassiere substantially as hereinbefore described with reference to any of figures 1 to 6.

33. A mold for manufacturing a brassiere substantially as hereinbefore described with reference to any of figures 1 to 6.