WO2022263875A1

WO2022263875A1 - Seamless underwire bra and nursing garment

Info

Publication number: WO2022263875A1
Application number: PCT/IB2021/055219
Authority: WO
Inventors: Lisa STANTON
Original assignee: Bravado Holding Ag
Priority date: 2021-06-14
Filing date: 2021-06-14
Publication date: 2022-12-22

Abstract

An underwire garment (100) includes a unitary exterior layer, an interior layer integral with and seamlessly connected to the exterior layer, and wire channels (166, 168) connected only to the interior layer. The underwire garment also includes insert pockets (144, 146) formed between the layers above the wire channels, and foam inserts adapted for selective placement within the insert pockets. In a nursing version of the underwire garment, the insert pockets are adapted to selectively connect to respective clasps (130, 132) on respective shoulder straps. A method of manufacturing an underwire garment includes folding a tubular knit piece of material along a bottom band (108) to create two unitary layers, sewing the layers together, attaching wire channels, and providing foam inserts for placement between the layers above the wire channels.

Description

SEAMLESS UNDERWIRE BRA AND NURSING GARMENT FIELD OF THE DISCLOSURE

[0001] This disclosure relates generally to an underwire garment, and specifically to a seamless underwire bra or seamless underwire nursing garment that includes two layers that create foam insert pockets above the underwire channels.

BACKGROUND

[0002] Bras typically fall into one of two categories: highly structured in order to achieve lift and a rounder look, or minimally structured in order to achieve flexibility and enhance comfort Existing underwire bras fall into the former category. Underwire bras have wire channels containing wires that provide support on the underside of each breast. The bottom portion of the bra that wraps around a wearer’s body is cut where it connects to the wire channels. A stiff pre-formed pad is connected above the wire channels. The resulting underwire bra provides a lifted and mostly predetermined appearance under clothing, which can be desirable. For example, some women find the lift provided by an underwire necessary to achieve an aesthetic that they desire.

[0003] However, underwire bras can also be uncomfortable and ill-fitting. The seams of underwire bras can chafe against a wearer’s skin. If the underwire bra fits poorly, the wearer can experience significant discomfort and even injury due to the rigidity of the underwire that is locked into the frame of the bra to provide shape and support. Breast shape, breast size, and breast symmetry varies widely among women within the population and may also vary for a given woman at different times in her menstrual cycle or at different stages of her life. In particular, women who are nursing experience a notable change in breast size and shape depending on the amount of milk available within the alveoli for extraction. The highly structured nature of existing underwire bras precludes the flexibility needed to accommodate these anatomical variations, and thus some women who would otherwise prefer to wear an underwire bra choose not to do so. Lactation consultants routinely advise nursing women to avoid underwire bras because the firm structure of an underwire bra can contribute to blocked milk ducts, reduced milk supply, and mastitis.

SUMMARY

[0004] The present disclosure is directed to a seamless underwire bra and a seamless underwire nursing garment that limit chafing and poking, provide flexibility and adaptability via two-layer insert pockets over the breasts that may selectively contain a foam insert, and provide lift and support via wires in underwire channels. The seamless underwire bra and seamless underwire nursing garment fall uniquely into a middle ground between being highly structured and minimally structured. For nursing women, the seamless underwire nursing garment includes slings and clasps that allow the insert pockets to be partially removed to facilitate breastfeeding and/or pumping above the wire channels.

[0005] In accordance with an example, an underwire nursing garment includes a unitary exterior layer, an interior layer, a first wire channel and a second wire channel, a first insert pocket and a second insert pocket, and a first clasp and a second clasp. The unitary exterior layer has a first exterior breast cover, a second exterior breast cover, a bottom band, and an exterior back portion. The interior layer is integral with and seamlessly connected to the unitary exterior layer by the bottom band, and the interior layer has a first interior breast cover, a second interior breast cover, and an interior back portion. The first wire channel is connected only to the interior layer, and a first wire is contained within the first wire channel. The second wire channel is connected only to the interior layer, and a second wire is contained within the second wire channel. The first insert pocket is formed between the first exterior breast cover and the first interior breast cover above the first wire channel, and a first foam insert is adapted for selective placement within the first insert pocket. The second insert pocket is formed between the second exterior breast cover and the second interior breast cover above the second wire channel, and a second foam insert is adapted for selective placement within the second insert pocket. The first clasp connected by a first shoulder strap to the exterior back portion or interior back portion and is connected by a first sling to the interior layer. The first insert pocket is configured to selectively connect to the first clasp. The second clasp is connected by a second shoulder strap to the exterior back portion or the interior back portion and is connected by a second sling to the interior layer. The second insert pocket is configured to selectively connect to the second clasp.

[0006] In some forms, a perimeter of the first insert pocket may extend along the first wire channel, and a perimeter of the second insert pocket may extend along the second wire channel. The unitary exterior layer may have a first exterior armpit edge and a second exterior armpit edge. The interior layer may have a first interior armpit edge and a second interior armpit edge. The first interior armpit edge may be partially connected along the first exterior armpit edge to form a first combined armpit edge, and the second interior armpit edge may be partially connected along the second exterior armpit edge to form a second combined armpit edge. The first combined armpit edge may include a first pocket opening where the first exterior armpit edge is not connected along the first interior armpit edge, and the first pocket opening may be configured to provide access to an interior of the first insert pocket. The second combined armpit edge may include a second pocket opening where the second exterior armpit edge is not connected along the second interior armpit edge, and the second pocket opening may be configured to provide access to an interior of the second insert pocket. The unitary exterior layer may have an exterior neck edge, and the interior layer may have an interior neck edge.

The exterior neck edge may be connected along the interior neck edge to form a combined neck edge. The first wire channel may extend from the first combined armpit edge to the combined neck edge, and the second wire channel may extend from the second combined armpit edge to the combined neck edge.

[0007] In further forms, the unitary exterior layer may have a first channel cover region adjacent the first exterior breast cover and on top of the first wire channel, a second channel cover region adjacent the second exterior breast cover and on top of the second wire channel, and an exterior sub-cup region below the first channel cover region, below the second channel cover region, and above the bottom band. The unitary exterior layer may have first material properties at the first exterior breast cover and at the second exterior breast cover, second material properties at the first channel cover region and at the second channel cover region, and third material properties at the exterior sub-cup region. The first material properties may include a first modulus of elasticity, the second material properties may include a second modulus of elasticity, and the third material properties may include a third modulus of elasticity, each of the first modulus of elasticity, the second modulus of elasticity, and the third modulus of elasticity being different. The interior layer may have an interior sub-cup region below the first wire channel, below the second wire channel, and above the bottom band, the interior sub-cup region having the third material properties. The bottom band may have fourth material properties. The fourth material properties may include a fourth modulus of elasticity that differs from the first modulus of elasticity, the second modulus of elasticity, and the third modulus of elasticity.

[0008] In accordance with an example, an underwire bra includes a unitary exterior layer, an interior layer, a first wire channel and a second wire channel, a first insert pocket and a second insert pocket, and a first clasp and a second clasp. The unitary exterior layer has a first exterior breast cover, a second exterior breast cover, a bottom band, and an exterior back portion. The interior layer is integral with and seamlessly connected to the unitary exterior layer by the bottom band, and the interior layer has a first interior breast cover, a second interior breast cover, and an interior back portion. The first wire channel is connected only to the interior layer, and a first wire is contained within the first wire channel. The second wire channel is connected only to the interior layer, and a second wire is contained within the second wire channel. The first insert pocket is formed between the first exterior breast cover and the first interior breast cover above the first wire channel, and a first foam insert is adapted for selective placement within the first insert pocket. The second insert pocket is formed between the second exterior breast cover and the second interior breast cover above the second wire channel, and a second foam insert is adapted for selective placement within the second insert pocket.

[0009] In some forms, a perimeter of the first insert pocket may extend along the first wire channel, and a perimeter of the second insert pocket may extend along the second wire channel. The unitary exterior layer may have a first exterior armpit edge and a second exterior armpit edge. The interior layer may have a first interior armpit edge and a second interior armpit edge. The first interior armpit edge may be partially connected along the first exterior armpit edge to form a first combined armpit edge, and the second interior armpit edge may be partially connected along the second exterior armpit edge to form a second combined armpit edge. The first combined armpit edge may include a first pocket opening where the first exterior armpit edge is not connected along the first interior armpit edge, and the first pocket opening may be configured to provide access to an interior of the first insert pocket. The second combined armpit edge may include a second pocket opening where the second exterior armpit edge is not connected along the second interior armpit edge, and the second pocket opening may be configured to provide access to an interior of the second insert pocket. The unitary exterior layer may have an exterior neck edge, and the interior layer may have an interior neck edge.

[0010] In further forms, the unitary exterior layer may have a first channel cover region adjacent the first exterior breast cover and on top of the first wire channel, a second channel cover region adjacent the second exterior breast cover and on top of the second wire channel, and an exterior sub-cup region below the first channel cover region, below the second channel cover region, and above the bottom band. The unitary exterior layer may have first material properties at the first exterior breast cover and at the second exterior breast cover, second material properties at the first channel cover region and at the second channel cover region, and third material properties at the exterior sub-cup region. The first material properties may include a first modulus of elasticity, the second material properties may include a second modulus of elasticity, and the third material properties may include a third modulus of elasticity, each of the first modulus of elasticity, the second modulus of elasticity, and the third modulus of elasticity being different. The interior layer may have an interior sub-cup region below the first wire channel, below the second wire channel, and above the bottom band, the interior sub-cup region having the third material properties. The bottom band may have fourth material properties. The fourth material properties may include a fourth modulus of elasticity that differs from the first modulus of elasticity, the second modulus of elasticity, and the third modulus of elasticity.

[0011] In accordance with an example, a method of manufacturing an underwire garment includes producing a tubular knit piece of material, cutting or casting off the tubular knit piece of material circumferentially, and folding the tubular knit piece of material along a bottom band to create a unitary exterior layer and an interior layer, the interior layer integral with and seamlessly connected to the unitary exterior layer by the bottom band. The method includes attaching a first wire channel to the interior layer, a first wire sewn into the first wire channel, and attaching a second wire channel to the interior layer, a second wire sewn into the second wire channel. The method further includes sewing the unitary exterior layer to the interior layer along a neckline edge, a bound portion of a first armpit edge, and a bound portion of a second armpit edge, while leaving a free portion of the first armpit edge and a free portion of the second armpit edge unbound. The method still further includes providing a first foam insert adapted for placement between the exterior layer and the interior layer above the first wire channel, and providing a second foam insert adapted for placement between the exterior layer and the interior layer above the second wire channel.

[0012] In some forms, the method may include attaching a first shoulder strap to the unitary exterior layer or the interior layer, attaching a first sling to the interior layer adjacent the first wire channel, and securing a first clasp to the first shoulder strap and the first sling. The method may further include attaching a second shoulder strap to the unitary exterior layer or the interior layer, attaching a second sling to the interior layer adjacent the second wire channel, and securing a second clasp to the second shoulder strap and the second sling.

BRIEF DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 is a front view of a seamless underwire nursing garment of the present disclosure in a fastened configuration. [0014] FIG. 2 is a back view of the seamless underwire nursing garment of FIG. 1 in a fastened configuration.

[0015] FIG. 3 is a front view of inserts for the seamless underwire nursing garment of FIGS. 1 and 2.

[0016] FIG. 4 is an exterior view of the seamless underwire nursing garment of FIGS. 1 and 2 in an unfastened configuration.

[0017] FIG. 5 is an interior view of the seamless underwire nursing garment of FIGS. 1-3 in an unfastened configuration.

[0018] FIG. 6 is a front view of a seamless underwire bra of the present disclosure in a fastened configuration.

[0019] FIG. 7 is a back view of the seamless underwire bra of FIG. 6 in a fastened configuration.

[0020] FIG. 8 is an exterior view of the seamless underwire bra of FIGS. 6 and 7 in an unfastened configuration.

[0021] FIG. 9 is an interior view of the seamless underwire bra of FIGS. 6-8 in an unfastened configuration.

[0022] FIG. 10 is a front view of a tubular knit piece of material for manufacture of the seamless underwire nursing garment of FIGS. 1 , 2, 4, and 5 or the seamless underwire bra of FIGS. 6-9.

[0023] FIG. 11 is a schematic illustration of a method of manufacturing an underwire garment of the present disclosure.

DETAILED DESCRIPTION OF THE DRAWINGS

[0024] An aspect of the present disclosure is directed to a seamless underwire nursing garment 100. As shown in FIG. 1 , the nursing garment 100 includes a unitary exterior layer 102 having a first exterior breast cover 104, a second exterior breast cover 106, and a bottom band 108. As shown in FIG. 2, the nursing garment 100 also has an exterior back portion 110. The unitary exterior layer is integral with and seamlessly connected to an interior layer 112. That is, as discussed with respect to manufacturing the nursing garment 100 below, the unitary exterior layer 102 and the interior layer 112 are constituent parts of a single piece of fabric that is folded to create the unitary exterior layer 102 and the interior layer 112. The unified nature of the unitary exterior layer 102 and the interior layer 112 is beneficial because stitching, adhesive, ultrasonic welding, or other connection means are not necessary, resulting in fewer rough or abrasive parts of the nursing garment 100 that can cause chafing.

[0025] As shown in FIG. 2, the interior layer 112 has a first interior breast cover 114 and a second interior breast cover 116. A first wire channel 118 and a second wire channel 120 are connected only to the interior layer 112. A first wire 122 (indicated by dotted lines) is contained within the first wire channel 118, and a second wire 124 (indicated by dotted lines) is contained within the second wire channel 120. Because the first wire channel 118 and the second wire channel 120 are not connected to the unitary exterior layer 102, the unitary exterior layer 102 has a smooth and uninterrupted appearance. Optimally, the first wire 122 and the second wire 124 have a diameter and to be made of a material that provides a degree of malleability compatible with the flexibility provided by the unitary exterior layer 102 and the interior layer 112.

[0026] As also shown in FIG. 2, a first insert pocket 126 is formed between the first exterior breast cover 104 and the first interior breast cover 114 above the first wire channel 118, and a second insert pocket 128 is formed between the second exterior breast cover 106 and the second interior breast cover 116 above the second wire channel 120. A perimeter 127 of the first insert pocket 126 extends along the first wire channel 118, and a perimeter 129 of the second insert pocket 128 extends along the second wire channel 120. In this way, the first wire channel 118 and the second wire channel 120 play an important role in defining the size of and providing support for the first insert pocket 126 and the second insert pocket 128.

[0027] FIG. 3 shows a first foam insert 130 adapted for selective placement within the first insert pocket 126 and a second foam insert 132 adapted for selective placement within the second insert pocket 128. Because the first foam insert 130 and the second foam insert 132 are removable from the nursing garment 100, a wearer can determined whether or not the additional padding and coverage provided by the first foam insert 130 and the second foam insert 132 is desirable during any given period of wear. For example, wearing the first foam insert 130 and the second foam insert 132 may be beneficial under certain clothing, for additional nipple coverage in the cold, or as a means by which to prevent milk from leaking through the nursing garment 100. On the other hand, removal of the first foam insert 130 and the second foam insert 132 may be beneficial if less padding is desired, to improve the breathability of the nursing garment when the wearer is hot, or to launder the first foam insert 130 or the second foam insert 132. Furthermore, the first insert pocket 126 and the second insert pocket 128 may selectively hold other items. For example, an ice pad or a hot pad could be placed within the first insert pocket 126 or the second insert pocket 128 to ease mastitis or breast discomfort caused by nursing. The first wire channel 118 and the second wire channel 120 would provide structural support for the weight of an ice pad or a hot pad.

[0028] As shown in FIG. 4, the first insert pocket 126 is configured to selectively connect to a first clasp 130, and the second insert pocket 128 is configured to selectively connect to a second clasp 132. As shown in FIG. 5, the interior layer 112 has an interior back portion 134. The first clasp 130 is connected by a first shoulder strap 136 to the exterior back portion 110 or the interior back portion 134, and the second clasp 132 is connected by a second shoulder strap 138 to the exterior back portion 110 or the interior back portion 134. In addition, the first clasp 130 is connected to a first sling 140, and the second clasp 132 is connected to a second sling 142. The first sling 140 and the second sling 142 are connected, respectively, at a first location 141 adjacent the first wire channel 122 on the interior layer 112 and a second location 143 adjacent the second wire channel 124 on the interior layer 112. The first sling 140 and the second sling 142 enable the first insert pocket 126 and the second insert pocket 128 to be disconnected from the first clasp 130 and the second clasp 132 and pulled down to breastfeed while the seamless nursing garment 100 is kept secure on a wearer by the first sling 140, the second sling 142, the first shoulder strap 136, and the second shoulder strap 138.

[0029] As shown in FIG. 4, the unitary exterior layer 102 has a first exterior armpit edge 144, a second exterior armpit edge 146, and an exterior neck edge 148. As shown in FIG. 5, the interior layer 112 has a first interior armpit edge 150, a second interior armpit edge 152, and an interior neck edge 154. The first interior armpit edge 150 is partially connected along the first exterior armpit edge 144 to form a first combined armpit edge 156. Similarly, the second interior armpit edge 152 is partially connected along the second exterior armpit edge 146 to form a second combined armpit edge 158. The exterior neck edge 148 is connected to the interior neck edge 154 to form a combined neck edge 160. The first wire channel 122 extends from the first combined armpit edge 156 to the combined neck edge 160, and the second wire channel 124 extends from the second combined armpit edge 158 to the neck edge 160.

[0030] As shown in FIG. 5, the first combined armpit edge 156 includes a first pocket opening 162 where the first exterior armpit edge 144 is not connected to the first interior armpit edge 150. The first pocket opening 162 provides access to an interior of the first insert pocket 126. Likewise, the second combined armpit edge 158 includes a second pocket opening 164 where the second exterior armpit edge 146 is not connected to the second interior armpit edge 152. The second pocket opening 164 provides access to an interior of the second insert pocket 128. The first pocket opening 162 and the second pocket opening 164 are large enough to permit the first foam insert 130 and the second foam insert 132 (shown in FIG. 3) to be inserted into the first insert pocket 126 and the second insert pocket 128. To facilitate identifying the location of the first pocket opening 162 and the second pocket opening 164, the first pocket opening 162 and the second pocket opening 164 may curve inwardly away from the first combined armpit edge 156 and the second combined armpit edge 158, respectively.

[0031] The material properties of the underwire nursing garment 100 may vary in different regions in order to provide optimal levels of support, compression, and give in various areas.

For example, as shown in FIG. 4, the unitary exterior layer 102 may have a first channel cover region 166 adjacent the first exterior breast cover 104 and on top of the first wire channel 122. The unitary exterior layer 102 may also have a second channel cover region 168 adjacent the second exterior breast cover 106 and on top of the second wire channel 124. Additionally, the unitary exterior layer 102 may have an exterior sub-cup region 170 below the first channel cover region 166, below the second channel cover region 168, and above the bottom band 108. Similarly, as shown in FIG. 5, the interior layer 112 may have an interior sub-cup region 172 below the first wire channel 122 and the second wire channel 124 and above the bottom band 108. Each of these regions, or subsets of these regions, may have different material properties.

[0032] In particular, the unitary exterior layer 102 may have first material properties at the first exterior breast cover 104 and at the second exterior breast cover 106, second material properties at the first channel cover region 166 and at the second channel cover region 168, and third material properties at the exterior sub-cup region 170. The interior sub-cup region 170 may also have the third material properties. The first interior breast cover 114, the second exterior breast cover 116, the exterior back portion 110, and the interior back portion 134 may all also have the first material properties. The bottom band 108 may have fourth material properties. The first material properties may include a first modulus of elasticity, the second material properties may include a second modulus of elasticity, the third material properties may include a third modulus of elasticity, and the fourth material properties may include a fourth modulus of elasticity, each of the first modulus of elasticity, the second modulus of elasticity, the third modulus of elasticity, and the fourth modulus of elasticity being different.

[0033] For example, the first exterior breast cover 104, the first interior breast cover 114, the second exterior breast cover 106, and the second interior breast cover 116 may all be formed from a jersey knit. The exterior sub-cup region 170 and the interior sub-cup region 172 may be formed from a ribbed knit having a low stretch. The first channel cover region 166 and the second channel cover region 168 may be formed from a pique knit having a moderate stretch. The bottom band 108 may be formed from a flat and smooth pique knit.

[0034] FIGS. 6-9 illustrate an alternate garment, specifically a non-nursing seamless underwire bra 200, having features in common with the seamless underwire nursing garment 100. The elements illustrated in FIGS. 6-9 are designated by the same reference numbers indicated on the arrangements illustrated in FIGS. 1-5, increased by one hundred. Accordingly, features common to all figures will not be described in substantial detail. Further, it is appreciated that any combination or sub-combination of features described in regard to the seamless underwire nursing garment 100 in FIGS. 1-5 may be incorporated into the seamless underwire bra 200 shown in FIGS. 6-9 , and vice-versa.

[0035] The seamless underwire bra 200 does not include an equivalent to first clasp 130, second clasp 132, first sling 140, or second sling 142. Instead, as shown in FIG. 9, the seamless underwire bra 200 has a first shoulder strap 236 that extends from the exterior back portion 210 or the interior back portion 234 to a first meeting point 274 between the first combined armpit edge 256 and the combined neck edge 260. Similarly, the seamless underwire bra 200 has a second shoulder strap 238 that extends from the exterior back portion 210 or the interior back portion 234 to a second meeting point 276 between the second combined armpit edge 258 and the combined neck edge 260.

[0036] FIG. 10 illustrates a tubular knit piece of material 300 used to manufacture the seamless underwire nursing garment 100 or the seamless underwire bra 200. The elements illustrated in FIG. 10 are designated by the same reference numbers indicated on the arrangements illustrated in FIGS. 1-9, increased by one hundred or two hundred. Accordingly, features common to all figures will not be described in substantial detail.

[0037] As shown in FIG. 10, an axis A runs through the bottom band 308. The portion of the tubular knit piece of material 300 that will become the unitary exterior layer 302 is located on one side of the axis A and the portion of the tubular knit piece of material 300 that will become the interior layer 312 is located on the other. The tubular knit piece of material 300 is substantially symmetrical across the axis A. For example, the first exterior armpit edge 344 is generally symmetrical across axis A to the first interior armpit edge 350, the second exterior armpit edge 346 is generally symmetrical across axis A to the second interior armpit edge 352, and the exterior neck edge 348 is generally symmetrical across axis A to the interior neck edge 354. During manufacture, as discussed below, the tubular knit piece of material 300 is folded along the axis A. The first exterior armpit edge 344 can then be connected to the first interior armpit edge 350, the second exterior armpit edge 346 can be connected to the second interior armpit edge 352, and the exterior neck edge 348 can be connected to the interior neck edge 354.

[0038] As discussed above and shown in the tubular knit piece of material 300 in FIG. 10, various regions of the unitary exterior layer 302 and the interior layer 312 may have different material properties (shown in FIG. 10 by different shading). For example, the unitary exterior layer 302 may have material at the first channel cover region 366 and the second channel cover region 368 that is thicker or abrasion-resistant because the first channel cover region 366 and the second channel cover region 368 may, through the interior layer 312, rub against the first wire channel and second wire channel (118, 120, 218, and 220 in FIGS. 2 and 7) and the first wire and second wire (122, 124, 222, and 224 in FIGS. 2 and 7) once those components are attached to the tubular knit piece of material 300.

[0039] FIG. 11 illustrates schematically a method 400 of manufacturing an underwire garment, such as seamless underwire nursing garment 100 or seamless underwear bra 200. The method includes, at box 402, producing a tubular knit piece of material (such as tubular knit piece of material 300). At box 404, the method includes cutting or casting off the tubular knit piece of material circumferentially. At box 406, the method includes folding the tubular knit piece of material along a bottom band to create a unitary exterior layer and an interior layer, the interior layer integral with and seamlessly connected to the unitary exterior layer by the bottom band. At box 408, the method includes attaching a first wire channel to the interior layer, a first wire sewn into the first wire channel. At box 410, the method includes attaching a second wire channel to the interior layer, a second wire sewn into the second wire channel. At box 412, the method includes sewing the unitary exterior layer to the interior layer along a neckline edge, a bound portion of a first armpit edge, and a bound portion of a second armpit edge, while leaving a free portion of the first armpit edge and a free portion of the second armpit edge unbound. At box 414, the method includes providing a first foam insert adapted for placement between the exterior layer and the interior layer above the first wire channel. At box 416, the method includes providing a second foam insert adapted for placement between the exterior layer and the interior layer above the second wire channel.

[0040] When manufacturing a seamless underwire nursing garment 100, the method 400 may further include attaching a first shoulder strap to the unitary exterior layer or the interior layer, attaching a first sling to the interior layer adjacent the first wire channel, and securing a first clasp to the first shoulder strap and the first sling. The method 400 would then also include attaching a second shoulder strap to the unitary exterior layer or the interior layer, attaching a second sling to the interior layer adjacent the second wire channel, and securing a second clasp to the second shoulder strap and the second sling.

Claims

CLAIMS What is claimed is:

1 . An underwire nursing garment comprising: a unitary exterior layer having a first exterior breast cover, a second exterior breast cover, a bottom band, and an exterior back portion; an interior layer integral with and seamlessly connected to the unitary exterior layer by the bottom band, the interior layer having a first interior breast cover, a second interior breast cover, and an interior back portion; a first wire channel connected only to the interior layer, a first wire contained within the first wire channel; a second wire channel connected only to the interior layer, a second wire contained within the second wire channel; a first insert pocket formed between the first exterior breast cover and the first interior breast cover above the first wire channel; a second insert pocket formed between the second exterior breast cover and the second interior breast cover above the second wire channel; a first clasp connected by a first shoulder strap to the exterior back portion or interior back portion and connected by a first sling to the interior layer, the first insert pocket configured to selectively connect to the first clasp; and a second clasp connected by a second shoulder strap to the exterior back portion or the interior back portion and connected by a second sling to the interior layer, the second insert pocket configured to selectively connect to the second clasp.

2. The underwire nursing garment of claim 1 , a perimeter of the first insert pocket extending along the first wire channel, and a perimeter of the second insert pocket extending along the second wire channel.

3. The underwire nursing garment of claim 1 , the unitary exterior layer having a first exterior armpit edge and a second exterior armpit edge, the interior layer having a first interior armpit edge and a second interior armpit edge, the first interior armpit edge partially connected along the first exterior armpit edge to form a first combined armpit edge, and the second interior armpit edge partially connected along the second exterior armpit edge to form a second combined armpit edge, the first combined armpit edge including a first pocket opening where the first exterior armpit edge is not connected along the first interior armpit edge, the first pocket opening configured to provide access to an interior of the first insert pocket, the second combined armpit edge including a second pocket opening where the second exterior armpit edge is not connected along the second interior armpit edge, the second pocket opening configured to provide access to an interior of the second insert pocket.

4. The underwire nursing garment of claim 1 , the unitary exterior layer having a first exterior armpit edge, a second exterior armpit edge, and an exterior neck edge, the interior layer having a first interior armpit edge, a second interior armpit edge, and an interior neck edge, the first interior armpit edge partially connected along the first exterior armpit edge to form a first combined armpit edge, the second interior armpit edge partially connected along the second exterior armpit edge to form a second combined armpit edge, and the exterior neck edge connected along the interior neck edge to form a combined neck edge, the first wire channel extending from the first combined armpit edge to the combined neck edge, the second wire channel extending from the second combined armpit edge to the combined neck edge.

5. The underwire nursing garment of claim 1 , the unitary exterior layer having a first channel cover region adjacent the first exterior breast cover and on top of the first wire channel, a second channel cover region adjacent the second exterior breast cover and on top of the second wire channel, and an exterior sub-cup region below the first channel cover region, below the second channel cover region, and above the bottom band, the unitary exterior layer having first material properties at the first exterior breast cover and at the second exterior breast cover, second material properties at the first channel cover region and at the second channel cover region, and third material properties at the exterior sub cup region.

6. The underwire nursing garment of claim 5, where the first material properties include a first modulus of elasticity, the second material properties include a second modulus of elasticity, and the third material properties include a third modulus of elasticity, each of the first modulus of elasticity, the second modulus of elasticity, and the third modulus of elasticity being different.

7. The underwire nursing garment of claim 5, the interior layer having an interior sub-cup region below the first wire channel, below the second wire channel, and above the bottom band, the interior sub-cup region having the third material properties.

8. The underwire nursing garment of claim 5, the bottom band having fourth material properties.

9. The underwire nursing garment of claim 6, the bottom band having fourth material properties that include a fourth modulus of elasticity that differs from the first modulus of elasticity, the second modulus of elasticity, and the third modulus of elasticity.

10. An underwire bra comprising: a unitary exterior layer having a first exterior breast cover, a second exterior breast cover, and a bottom band; an interior layer integral with and seamlessly connected to the unitary exterior layer by the bottom band, the interior layer having a first interior breast cover and a second interior breast cover; a first wire channel connected to the interior layer, a first wire contained within the first wire channel; a second wire channel connected to the interior layer, a second wire contained within the second wire channel; a first insert pocket formed between the first exterior breast cover and the first interior breast cover above the first wire channel; and a second insert pocket formed between the second exterior breast cover and the second interior breast cover above the second wire channel.

11 . The underwire bra of claim 10, a perimeter of the first insert pocket extending along the first wire channel, and a perimeter of the second insert pocket extending along the second wire channel.

12. The underwire bra of claim 10, the unitary exterior layer having a first exterior armpit edge and a second exterior armpit edge, the interior layer having a first interior armpit edge and a second interior armpit edge, the first interior armpit edge partially connected along the first exterior armpit edge to form a first combined armpit edge, and the second interior armpit edge partially connected along the second exterior armpit edge to form a second combined armpit edge, the first combined armpit edge including a first pocket opening where the first exterior armpit edge is not connected along the first interior armpit edge, the first pocket opening configured to provide access to an interior of the first insert pocket, the second combined armpit edge including a second pocket opening where the second exterior armpit edge is not connected along the second interior armpit edge, the second pocket opening configured to provide access to an interior of the second insert pocket.

13. The underwire bra of claim 10, the unitary exterior layer having a first exterior armpit edge, a second exterior armpit edge, and an exterior neck edge, the interior layer having a first interior armpit edge, a second interior armpit edge, and an interior neck edge, the first interior armpit edge partially connected along the first exterior armpit edge to form a first combined armpit edge, the second interior armpit edge partially connected along the second exterior armpit edge to form a second combined armpit edge, and the exterior neck edge connected along the interior neck edge to form a combined neck edge, the first wire channel extending from the first combined armpit edge to the combined neck edge, the second wire channel extending from the second combined armpit edge to the combined neck edge.

14. The underwire bra of claim 10, the unitary exterior layer having a first channel cover region adjacent the first exterior breast cover and on top of the first wire channel, a second channel cover region adjacent the second exterior breast cover and on top of the second wire channel, and an exterior sub-cup region below the first channel cover region, below the second channel cover region, and above the bottom band, the unitary exterior layer having first material properties at the first exterior breast cover and at the second exterior breast cover, second material properties at the first channel cover region and at the second channel cover region, and third material properties at the exterior sub cup region.

15. The underwire bra of claim 14, where the first material properties include a first modulus of elasticity, the second material properties include a second modulus of elasticity, and the third material properties include a third modulus of elasticity, each of the first modulus of elasticity, the second modulus of elasticity, and the third modulus of elasticity being different.

16. The underwire bra of claim 14, the interior layer having an interior sub-cup region below the first wire channel, below the second wire channel, and above the bottom band, the interior sub-cup region having the third material properties.

17. The underwire bra of claim 14, the bottom band having fourth material properties.

18. The underwire bra of claim 15, the bottom band having fourth material properties that include a fourth modulus of elasticity that differs from the first modulus of elasticity, the second modulus of elasticity, and the third modulus of elasticity.

19. A method of manufacturing an underwire garment comprising: producing a tubular knit piece of material; cutting or casting off the tubular knit piece of material circumferentially; folding the tubular knit piece of material along a bottom band to create a unitary exterior layer and an interior layer, the interior layer integral with and seamlessly connected to the unitary exterior layer by the bottom band; attaching a first wire channel to the interior layer, a first wire sewn into the first wire channel; attaching a second wire channel to the interior layer, a second wire sewn into the second wire channel; sewing the unitary exterior layer to the interior layer along a neckline edge, a bound portion of a first armpit edge, and a bound portion of a second armpit edge, while leaving a free portion of the first armpit edge and a free portion of the second armpit edge unbound; providing a first foam insert adapted for placement between the exterior layer and the interior layer above the first wire channel; and providing a second foam insert adapted for placement between the exterior layer and the interior layer above the second wire channel.

20. The method of claim 19, the method comprising attaching a first shoulder strap to the unitary exterior layer or the interior layer, attaching a first sling to the interior layer adjacent the first wire channel, and securing a first clasp to the first shoulder strap and the first sling, and attaching a second shoulder strap to the unitary exterior layer or the interior layer, attaching a second sling to the interior layer adjacent the second wire channel, and securing a second clasp to the second shoulder strap and the second sling.