Bra and method of manufacturing the same

Abstract

The present disclosure relates to support members for use in bras and other garments. The support members can be manufactured through additive manufacturing, subtractive manufacturing methods, and injection molding techniques, among others. The support members can include a thickness gradient designed to support a breast. The support members can be customized according to the anatomical configuration of a particular user. The support members can include one or more biometric sensors.

Description

[0001] This application is a divisional application of the invention patent application entitled "Bra and Method of Manufacturing Thereof", with an international filing date of May 7, 2018, international application number PCT / US2018 / 031428, and national application number 201880029733.4.

[0002] Cross-references to related applications

[0003] This patent application is a continuation in part of International Patent Application No. PCT / US17 / 32026, filed May 10, 2017, entitled “Molded Bra and Method of Manufacturing Thereof,” which claims priority to U.S. Provisional Patent Application No. 62 / 502,511, filed May 5, 2017, entitled “Molded Bra and Method of Manufacturing Thereof.” This application claims priority to each of the foregoing patent applications, the entire contents of which are incorporated herein by reference. Background Technology

[0004] Underwire bras are described in the prior art. These underwires are often uncomfortable, as they are close to the wearer's body, and wear points are present where the underwire protrudes from the channel at either end, which significantly shortens the bra's lifespan. Summary of the Invention

[0005] This invention relates to bras and other garments, and methods of manufacturing thereof. In one method, the bra or other garment has a mesh-like support member disposed between each of a first cup and a second cup. In one embodiment, the cups of the bra or other garment can be formed by forcing and heating to fuse the first cup, the mesh-like support member, and the second cup together, achieving a volumetric bulge in the cups specifically adapted to the anatomy of the user. The application of heat and force is sometimes referred to as forging in this application. In another embodiment, the mesh-like support member is initially manufactured to a suitable size and / or shape (e.g., by additive manufacturing) and used in the bra or other garment. In these embodiments, the mesh-like support member can be simply inserted into the garment (e.g., without physical connection to the inner or outer cups).

[0006] Similarly, considering the custom production of bra cups for specific users, scans or other image acquisitions of the user's anatomy can render digital images, which can be converted to provide 3D imaging and production parameters for a specially sized mesh support member. This specially sized mesh support member can, for example, be initially manufactured in an appropriate size and / or shape (e.g., a dome shape), or positioned between cups of a set size to create volumetric bulges through the application of force and heat to achieve a specific volume suitable for a particular user. Furthermore, each cup of the bra can be individually sized and manufactured to produce a custom bra. Each cup can have its own custom mesh support member. In addition to a dome shape, the mesh support member can be produced in a warped plane or other suitable topological configuration.

[0007] On the one hand, bras and their manufacturing methods enable garments to support and lift one or more of a user's breasts without the need for underwires or their associated channels. Bras and their manufacturing methods also allow for custom cups to conform to the specific anatomy of particular users and enable custom garments to be produced on demand.

[0008] For example, the bra and its manufacturing method of the present invention may include a polymer-based additively printed (additively manufactured) mesh support member having an arcuate first edge and an arcuate second edge. The first edge diverges from the second edge at a proximal vertex, defining a mesh matrix along one side, and converges with the second edge at a distal vertex. Thus, the mesh matrix defined by the first and second edges comprises an angled arrangement of a plurality of staggered members, the staggered structure defining a plurality of voids in the mesh support member. In one embodiment, the mesh support member has a substantially uniform thickness. In another embodiment, the mesh support member has one or more selectively customized thickness gradients.

[0009] For example, a mesh-like support member may include a maximum thickness disposed at the middle of a first edge and a minimum thickness disposed at a second edge. A thickness gradient may be used, and may be configured from the maximum thickness at the first edge toward each of the proximal and distal vertices and the minimum thickness at the second edge. Therefore, the mesh-like matrix may include a stiffness gradient configured in proportion to the aforementioned thickness gradient. In one embodiment, the mesh-like support member has a substantially uniform thickness. In another embodiment, the mesh-like support member has one or more selective, customized thickness gradients.

[0010] A mesh support member may be embedded between a first cup (e.g., an outer cup) and a second cup (e.g., an inner cup). The bra cup may be at least partially defined by each of the first and second cups, wherein one or more mesh support members are disposed between the first and second cups. In one embodiment, the mesh support member is initially manufactured in an appropriate size and / or shape (e.g., by additive manufacturing). In these embodiments, the mesh support member can be simply inserted into clothing (e.g., not physically attached to the inner and / or outer cups). In these embodiments, the mesh support member may be manufactured as a non-flat substrate (e.g., dome-shaped). In one embodiment, the mesh support member is initially formed as a dome-shaped mesh support member and can be easily inserted into the cup, thereby giving the bra a dome shape (e.g., to fit the wearer's breasts). In another embodiment, the mesh support member is stretched and bulged by applying heat and force, thereby forming the mesh support member and each of the first and second cups into a single-volume cup, the mesh support member disposed between the first and second cups.

[0011] Custom-sized cups can also be considered, as described in detail below, with parameters derived from images of the user's anatomy. Image acquisition of a specific user enables the generation of a digital profile of that user. Therefore, additive printing (manufacturing) is suitable for producing mesh-like support members sized to accommodate individual anatomical variations. Mesh-like support members of specific dimensions can be produced based on acquired images, such members being embedded between a first (outer) cup and a second (inner) cup, and one or both of the first and second cups can also be specifically sized according to the wearer's anatomy to form a specific volume cup for a bra or other garment. Such customized sizes may be useful for users with anatomical differences or irregularities (e.g., due to postoperative surgery such as mastectomy, breast augmentation, or other reconstructive, hyperplastic, or reductive procedures). In embodiments using forging, at least a portion of the mandrel and corresponding mold used to form the cups can also be produced as needed, with the specific shape of the customized mesh-like support member affected. Therefore, bra cups of a specific shape can be made, formed, and designed to fit the anatomy of any particular user, and can be produced as needed.

[0012] The mesh support member can be any suitable shape to facilitate support and / or lift one or both breasts of a person. In one embodiment, the mesh support member is anchor-shaped. In another embodiment, the mesh support member is hook-shaped. In another embodiment, the mesh support member is eye-shaped. In yet another embodiment, the mesh support member is cross-shaped. Multiple different mesh support members of the same shape or multiple different shapes can be used within a single cup of clothing.

[0013] The mesh support member can be polymer-based and can be manufactured by any suitable method, such as additive manufacturing, subtractive manufacturing, and / or injection molding. In one embodiment, the mesh support member is manufactured by additive manufacturing. In another embodiment, the mesh support member is manufactured by subtractive manufacturing. In yet another embodiment, the mesh support member is manufactured by injection molding. Attached Figure Description

[0014] Figure 1 This is a top view of an embodiment of the grid-like support member.

[0015] Figure 2 This is an isometric view of an embodiment of the grid-like support member.

[0016] Figure 3 This is a front view of an embodiment of a molded bra that is about to be pressed, showing a mesh-like support member disposed on top of the first cup.

[0017] Figure 4A It is a front view of a raised bra cup, in which a mesh-like support member inside the cup maintains the shape of the cup, and each of the associated first and second cups has cohesion.

[0018] Figure 4B This is a front view of a cup with a grid-like support structure raised within it.

[0019] Figure 5 This is a graphical representation of an exemplary thickness gradient from the first edge of the mesh support member to the second edge of the mesh support member.

[0020] Figure 6 This is a graphical representation of an exemplary stiffness gradient from the first edge of the mesh support member to the second edge of the mesh support member.

[0021] Figure 7 It is a top view of a mesh support member having a mesh-like base of variable thickness disposed between its first and second edges.

[0022] Figure 8This is a flowchart of an exemplary method for manufacturing one or more molded cups to create a custom molded bra for a specific user to wear.

[0023] Figure 9 This is a flowchart of an exemplary method for manufacturing one or more molded cups to create a custom molded bra for a specific user to wear.

[0024] Figure 10 This is an embodiment of a molded bra, wherein one or more cups include a mesh-like support member.

[0025] Figure 11A This is a top view of an embodiment of an eye-shaped mesh support member.

[0026] Figure 11B yes Figure 11A Isometric view of the grid-like support structure.

[0027] Figure 12 This is a top view of an embodiment of a cross-shaped grid-like support member.

[0028] Figure 13 It is a front view of a pair of natural breasts and a pair of augmented breasts.

[0029] Figure 14 It is a side view of a pair of natural breasts and augmented breasts, showing each type of cup (100).

[0030] Figure 15 This is a perspective view of an embodiment of a mesh support member, wherein the thickness of the mesh support member decreases radially from the center position.

[0031] Figures 16A to 16C This is a top view of an embodiment of a mesh support member having an internal mesh support base portion having multiple arms extending between the outer periphery of the mesh support member and the internal mesh support base portion.

[0032] Figure 17 This is a top view of another embodiment of a mesh support member having an internal mesh support base portion, wherein the mesh support base portion is generally honeycomb-shaped.

[0033] Figure 18 This is a top view of another embodiment of a mesh support member having an internal mesh support base portion, wherein the mesh support base portion is elliptical. Detailed Implementation

[0034] This bra and its manufacturing method contemplate an underwear for women or men that can be worn to support the breasts and, where appropriate, does not require underwires or underwire channels. Furthermore, this bra and its manufacturing method enable the custom cups to conform to the breasts of any particular wearer, including wearers who have undergone breast augmentation, breast lump removal, mastectomy, plastic surgery, or any other surgery that alters the breast's volume, including natural changes such as those resulting from pregnancy and / or breastfeeding.

[0035] Examples of molded bras in Figure 1-3 and Figure 10 The text describes a process where heat and / or force are used to produce molded cups. (As described in the original text...) Figure 1-3 and Figure 10 As shown, the molded bra (10) typically includes a mesh-like support member (20) disposed between the first cup (50) and the second cup (52). Figure 1 As shown, before the cup (100) is formed, the mesh support member (20) can be generally flat. After the cup (100) is formed, the mesh support member (20) can be dome-shaped. The mesh support member (20) includes a first edge (22) and a second edge (24). Figure 1-2 As shown, a mesh-like base (30) is provided between the first edge (22) and the second edge (24) of the support member (20). The mesh-like support member (20) may also include a first (e.g., maximum) thickness (40) realized at the middle of the first edge (22) and a second (e.g., minimum) thickness (42) realized at the second edge (24). Therefore, the mesh-like support member (20) may typically include a gradient cross section across the mesh-like base (30), which gradually decreases from the maximum thickness (40) toward the minimum thickness (42).

[0036] Now for reference Figure 3 , Figures 4A-4B and Figure 10 In the illustrated embodiment, a mesh support member (20) is disposed between the first cup (50) and the second cup (52). The first edge (22) of the mesh support member (20) provides support for the wearer below the breast near the inframammary fold and eliminates the need for underwires and / or their associated channels. The mesh base (30) can be formed into a suitable shape to conform to the anatomy of a particular wearer. For example, a second edge (24) having a minimum thickness (42) can taper gradually within the molded cup (100) (e.g., a bra cup) close to the wearer's pectoralis major muscle. Thus, the mesh support member (20) can be positioned centrally within the cup (100) and can at least partially define the shape of the cup (100) and facilitate proper support for the wearer.

[0037] As described above, this molded bra (10) or other garment can be produced by additive printing (manufacturing) of a mesh support member (20). For example, the mesh support member (20) can be printable, polymer-based, and can be formed between the boundaries described by the first edge (22) and the second edge (24). The mesh support member (20) can be printed to conform to the anatomy of a particular wearer, for example, by adapting to an individual wearer through image acquisition of a particular user, wherein the mesh support member (20) can be printed to fit a particular person.

[0038] The mesh support member (20) can be printed as a flat substrate. The printed substrate (20) may include a maximum thickness (40) and a minimum thickness (42). The printed substrate (20) can be fitted between a first (outer) cup (50) and a second (inner) cup (52), after which the material can be heated and fused to form a cup (100). In this respect, the material can be heated (e.g., below the melting point or glass transition temperature of the mesh support member (20)) so that the cup (100) can be shaped into a desired cup shape. Thus, the bulge of the cup (100) is achieved during cup formation (e.g., when the mesh support member (20) is inserted between each of the first (outer) cup (50) and the second (inner) cup (52) and heated to form the desired cup shape). In other embodiments, as described in more detail below, the mesh support member can be made as a non-flat substrate, which eliminates the need to form (e.g., forge) the mesh support member.

[0039] The second cup (52) is conceived as a soft material (e.g., foam) and is arranged to contact the wearer's breasts when the bra (10) is worn. The second cup (52) may overlap the mesh support member (20) and remain positioned externally, covering the wearer's breasts. Thus, although both the first cup (50) and the second cup (52) may have similar bulges and volume forms (though there are still small differences in size due to their position relative to the mesh support member (20), the second cup (52) may be recessed relative to the support member (20) to accommodate and contact the wearer's breasts, while the first cup (50) may be protruding to overlap externally and cover the wearer's breasts.

[0040] Now for reference Figure 1 and Figure 2The illustrated mesh support member (20) typically includes an arcuate first edge (22) and an opposing arcuate second edge (24). Each of the arcuate first edge (22) and second edge (24) radiates from a proximal vertex (26), crosses the boundary of the mesh substrate (30), and converges at a distal vertex (28). The mesh substrate (30) is arranged at an angle between the first edge (22) and the second edge (24) with staggered members (32). The staggered members (32) typically define a plurality of voids (37).

[0041] exist Figures 1 to 2 In the illustrated embodiment, the gradient of the second edge (24) is positive starting from the near vertex (26), then turns negative into an inverted pocket (34), and then turns positive again to rise through the S-shaped section (36), reaching a vertex at the top arc (38) at the distance furthest from the first edge (22). The second edge (22) maintains symmetry reflected by the central axis of the mesh support member (20) and defines a similar perimeter between the top arc (38) and the far vertex (28).

[0042] like Figure 1 and Figure 2 As shown, the maximum thickness (40) can be achieved at the middle of the first edge (22), while the minimum thickness (42) can be achieved at the second edge (24). Therefore, the cross-section of the mesh support member (20) can gradually decrease from the maximum thickness (40) to the minimum thickness (42) from the first edge (22) toward the second edge (24) and toward each of the proximal vertex (26) and the distal vertex (28). In this respect, a reduction in stiffness between the maximum thickness (40) and the minimum thickness (42) can be achieved (e.g., as...). Figure 6 (As shown). The first edge (22) can be at its maximum rigidity at the midpoint relative to the second edge (24), while the second edge (24) can be at its minimum rigidity. Therefore, the deformation of the mesh support member (20) can be achieved by applying controlled forces and heat to it, with the forces distributed across the entire mesh matrix (30) between the maximum thickness (40) and the minimum thickness (42).

[0043] In other embodiments, the mesh support member (20) may be initially manufactured as a non-planar substrate. In one embodiment, the non-planar mesh support member is manufactured as a mesh product or a near-mesh product, wherein its final product form is obtained during its manufacturing process (e.g., by additive manufacturing, by injection molding). Such a mesh support member can be used as a replacement component for, for example, clothing (e.g., bra cups). In such applications, the mesh support member can initially be manufactured to fit the size and shape of the clothing (e.g., to fit the wearer's breasts when used in a bra), thus eliminating the need to apply force and / or heat to form a dome shape. Therefore, in one embodiment, the bra cup is manufactured using a non-planar mesh support member and at least one of an inner cup and an outer cup, and there is no deformation of the non-planar mesh support member.

[0044] Figure 5 and Figure 6 The thickness profile is shown. Figure 5 ) and corresponding stiffness profile ( Figure 6 Graphical representation of related embodiments. (e.g.) Figure 5 As shown, the maximum thickness (40) gradually decreases along a gradient proportional to the distance from the midpoint set on the first edge (22) (gradients A, B, or C are shown as examples of thickness curves). Similarly, as Figure 6 As shown, the stiffness gradually decreases along a gradient proportional to the distance from the midpoint set on the first edge (22) (gradients A, B, or C are shown as examples of stiffness curves).

[0045] Figure 7 An embodiment of a support member (20) with discrete portions of variable thickness is shown. A maximum thickness (40) is positioned along a first edge (22) and has a maximum thickness (43a). The gradient gradually decreases from the maximum thickness portion (43a) to the minimum thickness portion (43f). The first portion (43a) includes the maximum thickness, and the sixth portion (43f) includes the minimum thickness. The second portion (43b), third portion (43c), fourth portion (43d), and fifth portion (43e) may each have a different thickness from each other and have different thicknesses from the first portion (43a) and the sixth portion (43f). The thickness in each intermediate portion (43b-43d) can decrease monotonically.

[0046] As shown, the new support member (20) may include a maximum thickness (e.g., along a first edge (22)) and a minimum thickness (e.g., along a second edge (24)). In these embodiments, a thickness gradient may exist between the maximum and minimum thickness of the support member (20). In one approach, the gradient may include one or more portions of the thickness that are variable between the maximum and minimum thicknesses. Additionally, the gradient may be a monotonic gradient (i.e., strictly decreasing from the maximum thickness to the minimum thickness) or a non-monotonic gradient. Furthermore, the gradient may be uniform (e.g., linear) or non-uniform. In one embodiment, the gradient between the maximum and minimum thicknesses is a continuous gradient. In another embodiment, the gradient between the maximum and minimum thicknesses is a discrete gradient, including one or more portions of the thickness that are variable between the maximum and minimum thicknesses. In one embodiment, the gradient may be linear and monotonic. In another embodiment, the gradient may be non-linear and monotonic. In yet another embodiment, the gradient may be non-linear and non-monotonic. As described above, a thickness gradient can produce a support member (20) with a stiffness gradient, wherein the stiffness gradient is generally proportional to the thickness gradient.

[0047] Now for reference Figure 15 In one embodiment, the mesh support member (200) may include a maximum thickness (M) of the central region near the mesh base portion (220). t (below) Figures 16A-16C Additional structures related to the illustrated embodiment are described. In one embodiment, a thickness gradient is employed, wherein the thickness of the mesh support member (200) increases with the maximum distance from the center (M). t The thickness decreases as the distance increases. In one embodiment, the thickness reduction is continuous and / or uniform. In another embodiment, the thickness reduction is discontinuous and / or non-uniform (e.g., discrete reduction; step reduction). In one embodiment, the thickness reduction is linear. In another embodiment, the thickness reduction is non-linear (e.g., polynomial reduction; exponential reduction; logarithmic reduction). In one embodiment, another portion of the mesh support member (200) includes a minimum thickness (L). t (not shown). In one embodiment, the minimum thickness may be associated with the outer perimeter 210. In one embodiment, L t With M t The ratio is not greater than 0.90, or not greater than 0.75, or not greater than 0.60, or not greater than 0.50, or not greater than 0.40, or not greater than 0.35, or not greater than 0.30, or not greater than 0.25 or less than 0.25. In other embodiments (not shown), the minimum thickness location (L) t The maximum thickness (Mt) and the maximum thickness position (Mt) can be switched, where the maximum thickness (Mt) t) is associated with the outer periphery (210) of the grid-like support member, and wherein the minimum thickness (L) t This is associated with the mesh-like base portion (220). Any thickness method described in this application can be used with any mesh-like support member described or shown in this application.

[0048] Continue to refer to Figure 15 In one embodiment, a radial thickness gradient can be used, wherein the gradient increases with increasing distance from the maximum thickness (M). t As the distance between the positions increases, the thickness of the mesh support member (200) decreases approximately uniformly in each direction. A radial thickness gradient can be used, for example, to facilitate the appropriate distribution of the user's weight (e.g., breast weight distribution in a bra).

[0049] Now for reference Figure 3 When using the molding operation, the first cup (50) can be positioned below the mesh support member (20), while the second cup (52) can be positioned above the mesh support member (20). Once properly positioned, the cup (100) can be formed by applying heat and force to mold the cup (100) into the desired shape and fusing the mesh support member (20) with the first (outer) cup (50) and the second (inner) cup (52) into a single cup (100). The mesh support member can be fused to one or both of the first and second cups. Thus, the cup (100) can be molded into the desired shape, thereby achieving the abrasion resistance of the bra (10).

[0050] Now for reference Figure 3 , Figure 4A and Figure 4B When using a forming operation, the mandrel (62) can be used to force the cup (100) to bulge by applying force and heat below the melting point (for crystalline and semi-crystalline polymers) or glass transition temperature (for amorphous polymers) of the mesh support member (20). The mandrel (62) can apply force to cause the mesh support member to bulge into the mold (60), thereby causing the cup (100) to form a dome. Thus, the mesh support member (20) can fuse the first (outer) cup (50) and the second (inner) cup (52) together and can maintain the special shape produced by forcing the mandrel (62) into the mold (60) at a certain temperature.

[0051] Now for reference Figure 8This illustrates an embodiment of a method for producing a bra or other garment (500) with encapsulated custom support members. As described above, the construction of one or more specific cups designed for a particular user to fit a unique anatomical structure can be produced by utilizing image acquisition of the particular user's anatomy. For example, a user can scan (510) one or more portions of their anatomy using a digital (or analog) camera or multiple digital (or analog) cameras. The scan can be used to acquire a 3D image (520) of the user's anatomy. This 3D image can be used to determine the user's anatomical features, where a custom support member (530) can be printed (additively manufactured) to fit the user's specific anatomical features. For example, an anatomical feature could be the weight distribution of the user's breasts. For example, the weight distribution of the user's breasts can be adapted by producing a support member (20) with a custom gradient, wherein areas of the support member (20) can have increased thickness to accommodate areas with higher breast weight distribution. In one embodiment, a custom support member can be fused between the first and second cups (550) by forming a first cup and a second cup (540), and then one or more cups can be forged to form a cup (560). The cup can be fitted to a bra or other garment component (e.g., suspenders, wings, straps, and bridges) to ultimately define the wearer's bra or other garment.

[0052] Now for reference Figure 9This illustrates one embodiment of a method (600) for producing a bra or other garment with a custom-fitted support member (20). As described above, a specific cup designed to fit the unique anatomy of a particular user can be produced by utilizing image acquisition of the user's anatomy. For example, a user can scan (510) their anatomy using a digital (or analog) camera or multiple digital (or analog) cameras. The scan can be used to acquire 3D images (520) of one or more portions of the user's anatomy. The user's digital profile (625) can then be rendered. The digital profile can include 3D measurement data of the altered breast, a portion of the breast removed surgically, and a completely removed breast, etc. For example, the digital profile of the breast can be of a breast removed by mastectomy, or a portion removed by mastectomy. As described in more detail below, the digital profile can be used to produce one or more restorative volume blocks (e.g., implants) that can be manufactured to fill the negative volume created by breast surgery. One or more restorative volumetric blocks can be additively manufactured using suitable materials, as described in more detail below. The one or more restorative volumetric blocks can be manufactured individually and then sewn into bra cups, encapsulated between the first and second cups, or printed onto a support member to encapsulate between the first and second cups, etc. The support member can be printed using digital contouring (630). As described in more detail below, one or more restorative volumetric blocks can be incorporated into the support member, wherein the support member serves as a substrate for the restorative volumetric block(s). The first and second cups can be formed (640). When using a forging operation, custom support members and / or restorative volumetric blocks can utilize optional custom mandrels and corresponding molds. As described in more detail below, custom mandrels and corresponding molds can be produced by printing (additively manufacturing) the mandrels and molds (680). In one embodiment, one or more cups are formed by inserting a mesh-like support member into the bra. When using a forging operation, one or more cups can be formed by fusing a support member, optionally one or more restorative volume blocks, between a first cup and a second cup (650), and then forging (660) to form one or more cups. One or more cups can be fitted to a bra or other garment component (e.g., suspenders, wings, straps, and bridges) to ultimately define the wearer's bra or other garment. The forging step (660) may optionally include the use of a custom mandrel and a corresponding mold.

[0053] Still referencing Figure 8 and Figure 9The construction of specific cups is conceived and shaped to fit the unique anatomy of a specific user by acquiring images of the user's anatomical structure. The acquisition of images of the user's anatomical structure enables 3D modeling of the user's anatomy as a digital profile, facilitating the additive printing of customized mesh support components. Therefore, mesh support components of appropriate sizes can be printed using additive printing with suitable polymer-based materials. Like the mesh support components, the first (outer) cup and / or the second (inner) cup can be produced (e.g., stamped from foam blanks; additive manufacturing). When forging is used, one or more cups can be formed to bulge in volume, fusing the mesh support components inside the cup between the first (outer) cup and the second (inner) cup. One or more cups can be fitted onto straps and blanks to create bras or other garments for a specific user as needed.

[0054] When forging is used, the mandrel itself can be additively manufactured or otherwise customized and produced. In one embodiment, at least a portion of the mandrel (e.g., the outer covering) can be produced on demand according to the specific anatomy of a particular user, for example, to accommodate a breast that may have an irregular shape as a result of surgery (e.g., mastectomy and partial mastectomy). Similarly, at least a portion of the mold (e.g., the outer covering) can also be produced according to the needs representing the specific anatomy of a particular user.

[0055] Now for reference Figure 10 Bras (10) or other garments may include accessories to fit additional components to the cups (100). For example, such as Figure 10 As shown, the bra (10) may further include one or more straps, one or more wings, and one or more bridges. Bridges (or other connectors) may be used to connect the first cup (100) adjacent to the second cup (100). Zippers and / or Velcro fasteners may also be used, or alternatively, to connect the cups. Additionally, in Figure 10Components not shown may include straps (e.g., compression bands for post-surgical wear). It is understood that a bra or other garment (10) may include a single cup (100) comprising a polymer-based mesh support member disposed between an inner cup and an outer cup. The inner and outer cups may define pockets for the mesh support member. In another embodiment, at least one of the inner and outer cups is forged from the mesh support member to form the final cup shape. The bra or other garment (10) may further include a second cup (100) having a second inner cup and a second outer cup. In some embodiments, the second cup (100) includes a second polymer-based mesh support member disposed between the second inner cup and the second outer cup. As described above, pockets may be used for the second mesh support member, or the second mesh support member may be forged together with the inner cup and / or the outer cup. In other embodiments, the second cup does not have any mesh support member. As described in further detail below, a bra (10) or other garment may include various combinations of a first cup design and a second cup design, wherein at least one of the first cup or the second cup includes an encapsulated support member.

[0056] Although the above embodiments generally relate to bras without underwires, the novel support member (20) described in this application can also be used with underwire bras and / or other underwire garments (e.g., for additional support and / or enhancement of elegance as described in further detail below).

[0057] Although the above embodiments typically involve encapsulating a single support member (20) in a bra cup (100), it is understood that at least two support members (20) may be encapsulated in a bra cup (100) to provide support for one or both breasts of an individual and to enhance a sense of dignity, etc.

[0058] Clothing types

[0059] As described above, the new support member (20) can be used with bras and other suitable garments. For example, the new support member (20) can be used for underwear, evening wear, swimwear, sportswear (e.g., sportswear and athleisure wear), post-surgical garments, maternity wear, bridal wear, and protective clothing, etc. The support member (20) can be used for aesthetic garments (e.g., with more aesthetic qualities than functional qualities), such as underwear, evening wear, and bridal wear. Alternatively, the support member can be used for functional garments (e.g., with more functional qualities than aesthetic qualities), such as sportswear and swimwear. Non-limiting examples of underwear include close-fitting underwear, sleepwear, bras, and shapewear. Non-limiting examples of evening wear include strapless bras, strapless bras, dip bras, wire-free thin bras, tights, and close-fitting underwear. Non-limiting examples of swimwear include bikini tops, wetsuits, drysuits, one-piece swimsuits, swimwear, and vests. Non-limiting examples of athletic wear include fitness bras, sports bras, and fitness tops (e.g., vests, T-shirts, long-sleeved shirts). Non-limiting examples of post-surgical clothing include bras with implant stabilizer bands and compression bras (e.g., to enhance recovery). Transitional clothing includes bras for wearers who may be transitioning from breast surgery (e.g., breast augmentation, breast lump removal, mastectomy, and bilateral mastectomy) to plastic surgery. One non-limiting example of transitional clothing is a compression bra. Non-limiting examples of maternity wear include nursing bras and maternity bras. Non-limiting examples of bridal gowns include corsets, bridal corsets, gowns, and postpartum corsets. Non-limiting examples of protective clothing include bulletproof vests (e.g., bulletproof clothing).

[0060] Enhance humility

[0061] In addition to providing support for the wearer's breasts, the new support structure (20) can promote garments that enhance a sense of elegance. Figure 3 As shown, the support member (20) is located between the first cup (50) and the second cup (52). It is understood that the areola and / or nipple of the breast are typically located in the middle of the support member. Therefore, the support member (20) can cover the areola and / or nipple area of ​​the breast, thereby concealing unwanted protrusion of these areas when clothing is worn. In other words, the combined support member (20) can distribute the force applied to the areola and / or nipple across the area including the support member (20), thus resulting in the unnecessary protrusion of the areola and / or nipple being concealed.

[0062] Manufacturing of supporting components

[0063] As described above, among other methods, the new support member (20) can be manufactured by additive manufacturing. As defined in ASTM F2792-12a, entitled “Standard Terminology for Additive Manufacturing Techniques,” “additive manufacturing” as used herein refers to “a process, in contrast to subtractive manufacturing methods, of generally combining materials layer by layer to manufacture an object from 3D model data.” In one embodiment, the additive manufacturing process includes continuous liquid phase printing (“CLIP”) using, for example, the method described in U.S. Patent No. 9,360,757 entitled “Continuous Liquid Phase Printing,” the disclosure of which is incorporated herein by reference in its entirety.

[0064] Typically, the new support member (20) is manufactured using a polymer-based material. The polymer-based material can be a thermoplastic, an elastomer, or a thermoplastic elastomer. The polymer-based material can also be a combination of an elastomer and a thermoplastic material, which can be considered a thermoplastic elastomer. A thermoplastic elastomer can be formed, for example, by physically mixing a thermoplastic and an elastomer or by forming chemical bonds between the thermoplastic and elastomer materials, and combinations thereof. Non-limiting examples of thermoplastics include polypropylene, acrylonitrile-butadiene-styrene (ABS), polystyrene, polyvinyl chloride, polylactic acid (PLA), polyethylene terephthalate (PET), polyetherimide, nylon, polycarbonate, polyacrylonitrile, and combinations thereof. Non-limiting examples of elastomers include polyisoprene, polybutadiene, chloroprene, butyl rubber, silicone rubber, chlorosulfonated polyethylene, fluorinated elastomers (e.g., fluororubber), and combinations thereof. As described above, thermoplastic elastomers can be formed by physical mixing or chemical bonding between at least one of the aforementioned thermoplastic plastics and at least one of the aforementioned elastomers.

[0065] Suitable materials for manufacturing the new support member (20) may have specific properties or qualities. For example, the material may include a polymer or polymer blend that is formable, flexible, but strong enough to support the breast. Additionally, the material may include polymers or polymer blends that respond well to different temperatures. For example, forming the cup (100) may involve subjecting the material to temperatures greater than 400°F during a forging step. Therefore, suitable materials have a melting temperature (e.g., for semi-crystalline or crystalline polymers) or glass transition temperature (e.g., for amorphous polymers) that is at least 400°F (204°C) and higher than the forging temperature. The support member material may be suitable for both commercial and domestic laundry washing and drying operations. Commercial or domestic laundry and drying operations may include conditions to which the support member material may be resistant, such as high temperatures, exposure to water, exposure to soap, and exposure to bleach. Furthermore, the temperature of commercial or domestic dryers may not exceed 200°F (93°C), so the material can retain its shape memory properties up to 200°F (93°C).

[0066] In one embodiment, the new support member (20) comprises a polymer or polymer mixture with a melting temperature or glass transition temperature of at least 500°F (260°C). In another embodiment, the new support member (20) comprises a polymer or polymer mixture with a melting temperature or glass transition temperature of at least 600°F (316°C). In yet another embodiment, the new support member (20) comprises a polymer or polymer mixture with a melting temperature or glass transition temperature of at least 700°F (371°C).

[0067] In one embodiment, the new support member (20) is made of thermoplastic. In another embodiment, the new support member (20) is made of elastomer. In another embodiment, the new support member (20) is made of thermoplastic elastomer. In one embodiment, the new support member (20) is made of thermoplastic elastomer containing nylon-6. In another embodiment, the new support member (20) is made of thermoplastic elastomer containing polyurethane. In another embodiment, the new support member (20) is made of thermoplastic plastic containing nylon-6. In another embodiment, the new support member (20) is made of thermoplastic plastic containing polyurethane.

[0068] In addition to additive manufacturing, new support components (20) can also be manufactured using subtractive manufacturing. For example, a suitable subtractive manufacturing method for producing new support components (20) could be CNC (Computer Numerical Control) machining. CNC machining involves using a computer to control machining tools to manufacture a product. A CNC machine can perform a series of operations on a precursor material, such as cutting, carving, milling, drilling, laser cutting, etc., to remove parts to form a product. CNC machining can include the use of 3D model data, which can allow manufacturers to flexibly produce customizable support components (20) for bras and clothing. As another example, injection molding (e.g., rapid injection molding) can be used to produce new support components (20), where injection molding can be suitable for producing new support components (20) that do not require customization (e.g., support parts for commercial bras or clothing).

[0069] As described above, the new support member (20) may include a mesh-like base (30) comprising an angled arrangement of interlaced members (32) defining a plurality of gaps (37), such as Figure 1 As shown. The staggered members (32) can create gaps (37) of various shapes. As shown, the staggered members form square or rectangular patterns. In other embodiments, at least some of the staggered members may be non-perpendicular, thus forming parallelogram or rhombus patterns. In practice, any suitable arrangement of the staggered members can be used. In one embodiment, the staggered members are typically linear, such as... Figure 1 As shown. However, the staggered members can be non-linear, including one or more curved / arc sections. Therefore, the resulting gaps can have any suitable shape, including rectangular, rhomboid, olive-shaped, circular, elliptical, triangular, honeycomb-shaped, or other shapes. Furthermore, one or more staggered members can have a uniform thickness or a varying thickness. Similarly, one or more staggered members can have a uniform width or a varying width (e.g., see...). Figure 17 Similarly, one or more interlaced members can have a uniform length or a varying length.

[0070] The support member can have any suitable shape. In one embodiment, such as... Figure 1 and Figure 2 As shown, the support member (20) allows the bra cup (100) to have smooth inner and outer surfaces (e.g., the support member does not fold) and the support member is an anchor-shaped form. Another example of the support member shape could be an eye shape, such as... Figure 11A and 11B As shown. Another example of the shape of a support member can resemble a symmetrical cross shape with arms of equal length that extend non-linearly from the center, such as... Figure 12 As shown. In another embodiment, the support member is hook-shaped.

[0071] Now for reference Figures 16A to 16C In another embodiment, the mesh-like support member (200) includes an outer periphery (210), a mesh-like base portion (220), and one or more support arms (230) extending from the outer periphery (210) to the mesh-like base portion (220). The one or more support arms (230) define a gap (234) between the outer periphery (210) and the mesh-like base portion (220). This embodiment may be useful, for example, in situations where ease of manufacture and / or less material is required to produce an acceptable support member.

[0072] In the illustrated embodiment, the outer periphery (210) includes a top (250), a left bottom portion (252), a right bottom portion (254), a left side portion (256), and a right side portion (258). The left bottom portion and the right bottom portion (252, 254) are separated by an optional lower gap (280) that has a notch in the outer periphery (210). The optional lower gap (280) is partially defined by a first lower edge portion (282) and a second lower edge portion (284). The first and second lower edge portions (282, 284) converge at a vertex (286). The first and second lower edges (282, 284) partially define the outer periphery (210). The optional lower gap (280) may, for example, allow the mesh support member (200) to flex. In other embodiments, this gap is absent and a continuous bottom is used (see, for example, see...). Figure 11A ).

[0073] The top (250) of the outer periphery (210) may include a curved outer edge (251). In the illustrated embodiment, the top (250) connects to the left portion (256) and the right portion (258). The top (250) transitions to the left portion (256) at a first transition point (270) and to the right portion (258) at a second transition point (272). The left portion (256) may include a flat surface (257). Similarly, the right portion (258) may include a flat surface (259). The use of flat surfaces can, for example, facilitate the fabrication of a mesh support member (200) by CLIP-plate additive manufacturing. The left portion (256) may transition to the left bottom portion (252) at a third transition point (274). The right portion (258) may transition to the right bottom portion at a fourth transition point (276). The left bottom portion (252) may include a curved outer edge (253). Similarly, the bottom right portion (253) may include an arc-shaped outer edge (255).

[0074] In the illustrated embodiment, the mesh-like support member (200) includes a mesh-like base portion (220). The mesh-like base portion (220) is disposed between the top (250) and one or more bottom portions (252, 254) of the outer periphery (210). The mesh-like base portion (220) generally includes a first longitudinal side (rib) (226) and an opposing second longitudinal side (rib) (228). The first longitudinal side (226) is located inside the outer periphery (210) and generally extends from the top (250) of the outer periphery (210) to the left bottom portion (252). In the illustrated embodiment, the first longitudinal side (226) has a generally concave shape (e.g., crescent-shaped). The second longitudinal side (228) is also located inside the outer periphery (210) and generally extends from the top (250) of the outer periphery (210) to the right bottom portion (254). In the illustrated embodiment, the second longitudinal side (226) has a generally concave shape. In the illustrated embodiment, the mesh-like base portion (220) is symmetrical about its vertical axis but asymmetrical about its horizontal axis. In the illustrated embodiment, the upper portion of the mesh-like base (220) includes a first width (W1), the middle portion includes a second width (W2), and the lower portion includes a third width (W3), where W2 < W1 < W3. The mesh-like base portion (220) can therefore include a bottle shape and / or an hourglass shape. For example, this shape may be useful when using a mesh support member (200) in a bra.

[0075] One or more support arms (230) may extend from the first longitudinal side (226) to the left bottom portion (252). One or more support arms (230) may extend from the first longitudinal side (226) to the left side portion (256). One or more support arms (230) may extend from the second longitudinal side (228) to the right bottom portion (254). One or more support arms (230) may extend from the second longitudinal side (228) to the right side portion (258).

[0076] The mesh-like matrix portion (220) typically includes a plurality of interlaced members (222) defining a plurality of voids (224). The interlaced members can be any interlaced members described herein, and can be linear or non-linear, thus defining rectangular, square, oval, or circular voids (224). For example, this is shown in... Figure 17-18 In. Figure 17 In the middle, the grid-like support member 200' includes a plurality of interlaced members having a generally honeycomb structure, and defines a plurality of generally hexagonal or partially hexagonal voids. Figure 18 In the middle, the grid-like support member 200” includes a plurality of interlaced members having a generally sinusoidal structure and defines a plurality of generally elliptical or partially elliptical gaps.

[0077] As previously mentioned, the interlaced members may also have varying lengths, widths, and / or thicknesses. One embodiment is shown in... Figure 17 In this embodiment, the width of the interlacing members located near the bottom of the grid-like support member 200' is greater than the width of the interlacing members located near the top of the grid-like support member 200". Therefore, at least some of the interlacing members can define a first geometry having a first perimeter, while other interlacing members can define a second geometry having a second perimeter. In one embodiment, the first geometry is the same as the second geometry. In another embodiment, the first geometry is different from the second geometry. In one embodiment, the first perimeter has a first thickness, while the second perimeter has a second thickness. In one embodiment, the first thickness is different from the second thickness. In one embodiment, the first thickness is uniform. In one embodiment, the first thickness is non-uniform. In one embodiment, the second thickness is uniform. In one embodiment, the second thickness is non-uniform.

[0078] Back Figure 15 The various portions of the mesh-like support member (200) may include variable thicknesses. In the illustrated embodiment, the mesh-like substrate (220) includes a variable thickness, and the support member (230) includes a variable thickness, while the outer periphery (210) includes a generally uniform thickness. In one embodiment, the outer periphery (210) includes a variable thickness. In one embodiment, the mesh-like substrate portion (220) includes a uniform thickness, while the support member (230) and / or the outer periphery (210) include variable thicknesses. In another embodiment, the support member (230) includes a uniform thickness, while the mesh-like substrate portion (220) and / or the outer periphery includes a variable thickness. In another embodiment, the outer periphery (210) includes a generally uniform thickness, while the support member (230) and / or the mesh-like substrate portion (220) includes a variable thickness.

[0079] In one embodiment, the average thickness of the mesh-like base portion (220) is greater than (a) the average thickness of the support member (230), (b) the average thickness of the outer periphery (210), or (c) the average thickness of both the support member (230) and the outer periphery (210). In some of these embodiments, the average thickness of the support member (230) is greater than the average thickness of the outer periphery (210). In other embodiments, the average thickness of the support member (230) is less than the average thickness of the outer periphery (210). In still some of these embodiments, the average thickness of the support member (230) is the same as the average thickness of the outer periphery (210).

[0080] In another embodiment, the average thickness of the outer periphery (210) is greater than (a) the average thickness of the support member (230), (b) the average thickness of the mesh-like base portion (220), or (c) the average thickness of both the support member (230) and the mesh-like base portion (220). In some of these embodiments, the average thickness of the support member (230) is greater than the average thickness of the mesh-like base portion (220). In some of these embodiments, the average thickness of the support member (230) is less than the average thickness of the mesh-like base portion (220). In some of these embodiments, the average thickness of the support member (230) is the same as the average thickness of the mesh-like base portion (220).

[0081] In another embodiment, the average thickness of the support member (230) is greater than (a) the average thickness of the outer periphery (210), (b) the average thickness of the mesh-like base portion (220), or (c) the average thickness of both the outer periphery (210) and the mesh-like base portion (220). In some of these embodiments, the average thickness of the outer periphery (210) is greater than the average thickness of the mesh-like base portion (220). In other embodiments of these embodiments, the average thickness of the outer periphery (210) is less than the average thickness of the mesh-like base portion (220). In still other embodiments of these embodiments, the average thickness of the outer periphery (210) is the same as the average thickness of the mesh-like base portion (220).

[0082] Refer back Figures 16A-16C At least some interlacing members (222) are typically connected to and disposed between the first longitudinal side (226) and the second longitudinal side (228). In the illustrated embodiment, at least some interlacing members (222) are connected to the arcuate surfaces (227, 229) of the first and second longitudinal sides (226, 228), respectively. In the illustrated embodiment, at least some interlacing members (222) are connected to the top (250) of the outer periphery (210), for example at the inner arcuate edge (296). In the illustrated embodiment, at least some interlacing members (222) are connected to the bottom (252, 254) of the outer periphery (210), for example at the inner arcuate edge (292, 294).

[0083] The mesh support member (200) may include an optional positioning arm (240). In the illustrated embodiment, the optional positioning arm (240) extends from the outer periphery (210) and away from the mesh base portion (220). In the illustrated embodiment, the positioning arm (240) is partially located within a gap (280) (notch) associated with the outer periphery (210). In other embodiments, the positioning arm (240) may be completely located within the gap (280) (notch) associated with the outer periphery (210). In other embodiments, for example when the optional gap (280) is not present, the positioning arm (240) may extend from the outer edge of the outer periphery (210).

[0084] The positioning arm (240) can conveniently position the mesh support member (200) inside clothing (e.g., inside a pocket). Once positioned inside the clothing, the positioning arm (240) can be removed from the mesh support member (200), for example, by fatigue of the joint associated with the positioning arm (240) (e.g., a joint located at or near the apex (286)) and / or by cutting off the positioning arm (240) (e.g., by cutting). In another embodiment, the positioning arm (240) is used to position the mesh support member (200) between at least one of an inner cup and an outer cup (not shown). When using a forging operation, the positioning arm (240) may be cut off during or concurrent with the forging process by a die or mandrel.

[0085] exist Figures 16A-16C In the illustrated embodiment, first and second side portions (256, 258) are included. In other embodiments, one or both of these side portions may be omitted. Thus, in some embodiments, the mesh-like support member (200) may include a generally eye-shaped outer periphery (210) (see, for example, [link to relevant documentation]). Figure 17 ).

[0086] Bra cup manufacturing

[0087] As described above, the first cup (50) can be positioned below the support member (20), and the second cup (52) can be positioned above the support member (20). In a forging embodiment, once properly positioned, the cup (100) can be formed by applying heat and force to mold the cup (100). Forming the cup (100) may also include applying an adhesive between the first and second cups prior to formation. In one embodiment, the adhesive is a cornstarch-based adhesive. In another embodiment, the adhesive is a natural cornstarch-based adhesive. In other embodiments, a mesh support member can be inserted into a pocket of the bra. The pocket may be defined at least partially by the first cup (50) and the second cup (52).

[0088] The first cup (50) and the second cup (52) may be made of a material suitable for direct contact with the wearer's breasts. When used as part of a pocket, conventional fabrics may be used for the first cup (50) and / or the second cup (52). When a forging step is used, the cup material may include, for example, foam (e.g., synthetic and natural materials). Synthetic materials may include polymer-based materials such as polyurethane, polyester, Lycra (a polyurethane and polyester copolymer, commonly referred to as spandex elastic fiber). Natural materials may include pure natural cornstarch foam, a mixture of pure natural cornstarch and sugar, or hemp and combinations thereof. In one embodiment, the first cup (50) and / or the second cup (52) are made of polyurethane foam. In another embodiment, the first cup (50) and / or the second cup (52) are made of all-natural cornstarch foam. In another embodiment, the first cup (50) and / or the second cup (52) are made of a mixture of all-natural cornstarch and sugar. In another embodiment, the first cup (50) and / or the second cup (52) are made of polyester. In yet another embodiment, the first cup (50) and / or the second cup (52) are made of a mixture of polyester and polyurethane.

[0089] On the other hand, one of the first and second cups is manufactured by additive manufacturing. For example, the first and / or second cups may also be additively manufactured during the production of the mesh support member, thereby producing an integral mesh support member and cup arrangement. In another embodiment, the first and / or second cups may be additively manufactured separately from the mesh support member. The cups may include a first polymeric material having first properties, and the mesh support member may include a second polymeric material different from the first polymeric material and therefore having second properties. Using different polymers and properties can facilitate an improved combination of properties. For example, an improved combination of at least two of comfort, breathability, and support can be achieved (e.g., when the first polymer is more comfortable / softer and / or more "breathable" than the second polymer, but the second polymer is more rigid than the first polymer).

[0090] Biological characteristics

[0091] The features and manufacturing method of the new support member (20) allow the new support member (20) to be used as a substrate. For example, the new support member (20) can be used as a substrate for one or more biometric sensors. For example, the biometric sensor can be incorporated into the new support member (20) by additive manufacturing. In one embodiment, a method of incorporating a biometric sensor into the support member (20) includes: (a) placing the biometric sensor in a substrate after at least some portions of the support member (20) have been manufactured; and (b) manufacturing one or more other portions of the support member (20) (e.g., manufacturing the remaining portion of the support member) to embed the biometric sensor, wherein the sides of the biometric sensor are encapsulated by the support member (20). In another embodiment, a method of incorporating a biometric sensor into the support member (20) includes additively manufacturing the support member (20) onto one or more biometric sensors to partially encapsulate the biometric sensor. For example, another method may include stitching (e.g., weaving) the biometric sensor into the support member (20). In one embodiment, a method of incorporating a biometric sensor into a support member (20) includes suturing the biometric sensor, wherein the suturing includes: (a) modifying one or more biometric sensors to include a thread hole; and (b) passing a needle and thread through the thread hole to attach one or more biometric sensors to the support member (20). The method of incorporating one or more biometric sensors can be applied such that the one or more biometric sensors are positioned adjacent to an inner cup (52) or an outer cup (50) and combinations thereof.

[0092] As described above, the new support member (20) may have one or more biometric sensors integrated therein. The new support member (20) with such integrated biometric sensors can be used to generate biometric data. For example, one or more integrated biometric sensors can generate biometric data by monitoring vital signs. Some non-limiting examples of vital signs that can be monitored include body temperature, pulse (heart rate), respiratory rate, and / or blood pressure.

[0093] The support structure (20) which incorporates one or more biometric sensors can generate biometric data via electrophysiological signals. Some non-limiting examples of electrophysiological signals that can be monitored include electrocardiogram (ECG) signals (electrical activity of the heart) and electromyogram (EMG) signals (electrical activity of muscle tissue).

[0094] In one approach, a novel support member (20) incorporating such integrated biometric sensors can generate data about a disease. An example of a disease that can be monitored is diabetes (e.g., by measuring blood glucose levels; insulin levels). Another example is sleep apnea, which can be measured using pulse oximetry (a measure of oxygen saturation in the blood). In yet another example, the wearer can monitor pregnancy by detecting uterine muscle contractions. In yet another example, the wearer can monitor the condition of breast milk contained in the breasts (e.g., to determine the appropriate time to breastfeed an infant, or to determine how much milk is consumed during breastfeeding). In yet another example, the wearer can monitor frostbite exposure, for example, by monitoring water content and temperature. In yet another example, the wearer can monitor the menstrual cycle by monitoring basal body temperature (e.g., body temperature at rest), where ovulation and menstruation can be detected.

[0095] In one approach, a novel support member (20) having such a combination of biometric sensors can generate data about infection or disease. Non-limiting examples of diseases that can be monitored include cancer (e.g., monitoring tumor growth), which can be monitored by measuring blood flow (e.g., by measuring thermal conductivity), by tracking cancer biomarkers (e.g., by measuring alpha-fetoprotein (AFP)), and / or by measuring heat distribution (e.g., by infrared radiation). Examples of infections that can be monitored include viral and / or bacterial infections (e.g., monitoring fever by body temperature; monitoring white blood cell count by pulse oximetry).

[0096] In another approach, a novel support member (20) with such integrated biometric sensors can be used to generate environmental data. Some non-limiting examples of environmental data that can be monitored include pollution data (e.g., concentrations of polluting compounds found in the atmosphere, such as ozone, carbon monoxide, NOx compounds, and SOx compounds) or data on harmful gases that may be found in hazardous work environments (e.g., concentrations of hydrogen sulfide, carbon monoxide, hydrocarbon gases, SOx, and NOx). Another non-limiting example of environmental data that can be monitored includes pollen levels, which could be useful for wearers with allergies.

[0097] The new support member (20) may have at least two integrated biometric sensors. For example, at least two different categories of biometric data (e.g., vital signs, electrophysiological signals, condition, infection, disease, or environmental data) and variations within the biometric data category (e.g., measuring body temperature and pulse as vital signs) may be measured in one or more cups (100). For example, it may be preferable to place at least two biometric sensors in a single cup (100) of a bra (10) or other garment, such that the biometric sensors can be positioned adjacent to an accessory (e.g., a transmission device; a battery). Alternatively, at least two different categories of biometric data, such as condition and environmental data, may be measured in a single cup (100). Furthermore, at least two integrated biometric sensors may be placed in a single cup, which may produce data on a single variation. For example, a wearer may monitor the development of breast cancer by integrating an array of biometric sensors into the support member (20). Alternatively, at least two integrated biometric sensors may be placed in a single cup, which may produce data on a single variation. One or more biometric sensors placed in the first cup can be interconnected (e.g., via components such as wires, batteries, or transmission devices) to one or more biometric sensors placed in the second cup. An exemplary array of biometric sensors can generate three-dimensional data measuring blood flow (e.g., via thermal conductivity measurements), which can thus diagnose whether breast cancer is present and the approximate location of any diagnosed breast cancer (e.g., due to changes in blood flow). For example, for those who have undergone prior cancer treatment (e.g., radiation, mastectomy, mastectomy), one or more biometric sensors can be used in one or more cups of the garment described in this application to detect biometrics associated with potential cancer recurrence. In the case of mastectomy or mastectomy, one or more biometric sensors can be used in combination with one or more prosthetic components and the garment described in this application to detect biometrics associated with potential cancer recurrence.

[0098] It is understood that one or more of the aforementioned biometric sensors can also be incorporated into the bra cup (100), for example, into the inner cup (52). Incorporating one or more biometric sensors into the inner cup (52) allows for skin contact (e.g., the biometric sensor contacts the wearer's breast), which can allow for the collection of certain biometric data (e.g., electrophysiological signals). Furthermore, skin contact with the biometric sensor can allow for the collection of certain biometric data with greater accuracy and precision. Skin contact with the wearer's breast can be achieved by incorporating one or more biometric sensors into the support member (20). For example, a bra cup (100) having a support member (20) enclosed by an outer cup (50) and an inner cup (52) can remove at least a portion of the inner cup (52) (e.g., a portion corresponding to the size and location of the biometric sensor), thereby exposing one or more biometric sensors to the wearer's skin.

[0099] Various combinations of cups incorporating biometric sensors can be produced. One or more biometric sensors can be placed in one or more cups (100). One or more biometric sensors can be combined by various methods, such as by additively manufacturing the biometric sensors into a support member (20) (e.g., embedding the biometric sensors), or by stitching (e.g., weaving) the biometric sensors into the support member (20), and combinations thereof. One or more biometric sensors can generate one or more categories of data as described above (e.g., condition and environmental data, and many other combinations) and one or more types of data of variation (e.g., changes in body temperature in the category of vital signs), and combinations thereof. One or more biometric sensors can be used to generate data for one or more purposes other than those described above. For example, pulse oximetry can be used not only to monitor sleep apnea or detect infection, but also to monitor both sleep apnea and infection. One or more biometric sensors can be interconnected and can be interconnected in one or more cups, and combinations thereof. One or more biometric sensors can be positioned adjacent to the inner cup (52), adjacent to the outer cup (50), and combinations thereof.

[0100] A support member (20) incorporating one or more biometric sensors can be used with transmission devices and methods to transmit continuous and / or discrete data to a receiving device. The data can be received by a receiving device belonging to the wearer or a third party (e.g., a physician monitoring the wearer's health) and combinations thereof. The receiving device can utilize applications capable of analyzing, storing, and organizing the data. Non-limiting examples of receiving devices include smartphones and computers, etc. The transmission method can be wireless or wired, and combinations thereof. Wireless transmission methods can include Bluetooth, cellular, or wireless communication standards (e.g., the 802.11 standard defined by the IEEE (Institute of Electrical and Electronics Engineers)) and combinations thereof. Wired transmission methods can include the use of twisted-pair cables, coaxial cables, or fiber optic cables and combinations thereof.

[0101] Postoperative recovery bra

[0102] As described above, the new bra cups (100) may be useful for wearers who have undergone surgery (such as breast augmentation, breast lump removal, mastectomy, or bilateral mastectomy). After surgery, the wearer may experience a recovery period. Recovery bras or other garments (10) may include recovery materials in one or more cups (100) or other components, which may help support the breasts (e.g., through compression) and / or reduce susceptibility to infection to promote breast healing. Recovery bras or other garments may not have underwires. Recovery materials may include nylon, Lycra (spandex), and combinations thereof. Recovery bras or other garments may also be F5 certified compression garments.

[0103] Postoperative individual 3D imaging

[0104] As described above, the new bra cup (100) may be useful for wearers who have undergone surgery (e.g., breast augmentation, breast lump removal, mastectomy, or bilateral mastectomy). Wearers may experience psychological reactions due to the new appearance of their breasts after recovery from partial (e.g., breast lump removal) or total (e.g., mastectomy) mastectomy. A bra or other garment may restore the breasts to their pre-operative appearance, thus reducing the psychological impact. As described above, the construction of the bra cup (100) designed for a specific user can be shaped to adapt to the wearer's unique anatomy. The wearer's unique anatomy can be recorded via 3D image acquisition prior to breast surgery. For example, for an individual undergoing breast surgery, 3D image acquisition can be performed prior to surgery for medical purposes. The anatomical structure of the negative volume formed by the wearer's breast surgery can be reconstructed by using 3D image data collected before surgery and 3D imaging data collected after surgery. For example, a digital profile can be generated by calculating the difference between post-operative 3D image data and pre-operative 3D image data. Alternatively, a digital contour of a breast lacking 3D imaging data collected prior to surgery can be created using a mirror image of the unaltered breast. The negative volume can be digitally rendered to produce a digital contour that can be manufactured using additive manufacturing to create one or more restorative volumetric blocks. These restorative volumetric blocks can be incorporated into a bra cup (100) with supporting members (20) to restore the preoperative appearance of the breast and mitigate the psychological impact of the new appearance.

[0105] Restorative volumetric blocks can be incorporated into bra cups (100). In one approach, the restorative volumetric blocks can be sewn (e.g., woven) into a second cup (52) (the inner cup that contacts the breast). In another approach, one or more restorative volumetric blocks can be encapsulated between a custom-designed first cup (50) and a custom-designed second cup (52). Encapsulation of the restorative volumetric blocks between the custom-designed first cup (50) and the custom-designed second cup (52) may optionally include forging the cup (100) using a custom mandrel (62) and a custom mold (60). In yet another approach, a novel support member (20) can be used as a substrate for printing one or more restorative volumetric blocks, which, as described above, can be encapsulated by the first cup (50) and the second cup (52). For example, the voids (37) of a mesh-like substrate (30) can be a suitable structure for additively manufacturing restorative volumetric blocks. One or more restorative volumetric blocks can be encapsulated within the cup (100), adjacent to the inner cup (52) or the outer cup (50), and combinations thereof. In other embodiments, either cup (100) may be manufactured with one or more restorative volume blocks without a support member (20). For example, a woman who has undergone mastectomy may wear a bra (10) in which one cup (100) includes a restorative volume block having the size of the removed breast, while the other cup (100) is designed.

[0106] Restorative volume blocks can be made of materials that enhance the wearer's comfort and appearance. For example, restorative volume blocks can be additively manufactured from one or more materials with different densities and potentially other physical properties. Manufacturing restorative volume blocks from multiple materials allows for the customization of bras or other garments that mimic the weight and feel of the breast before surgery. Materials that can be used to manufacture restorative volume blocks may include thermoplastics, elastomers, thermoplastic elastomers, and combinations thereof. The material may, in particular, be in the form of foam or gel, etc. In one embodiment, one or more materials are thermoplastic elastomers comprising polyurethane. In another embodiment, one or more materials are thermoplastic elastomers comprising nylon-6. In another embodiment, one or more materials are thermoplastic elastomers. In another embodiment, one or more materials are elastomers comprising silicone gel. In another embodiment, one or more materials are gels comprising hydrogel.

[0107] The bra cup (100) can be manufactured using a support member (20) already incorporating one or more restorative volume blocks. In some embodiments, such as in the case of a wearer who has undergone mastectomy or bilateral mastectomy, the shape of the one or more restorative volume blocks may resemble the entire breast. In these embodiments, the bra cup (100) can be manufactured in a manner in which the inner cup (52) is not bulging in volume but is generally flat in order to comfortably rest against the chest of a wearer who has had their breasts removed through mastectomy.

[0108] Custom bra cups (100) can also be manufactured entirely additively. For example, the first cup (50), the second cup (52), and the support member (20) can be additively manufactured in the final shape of a bulky bra cup. The bulky first cup (50), the second cup (52), and the support member (20) can be realized as a continuum, or the entire bra cup (100) can be additively manufactured as a continuum. Thus, additive manufacturing of one or more bra cups (100) eliminates the need for a custom mandrel (62) or mold (60) in the production of custom bra cups (100).

[0109] Correcting cup shape for augmented breasts

[0110] Bra cups (100) in regular bras or clothing can be designed to support the weight of the breasts by supporting the bottom part of the breast (e.g., with underwire). Figure 13 and Figure 14 As shown, wearers who have undergone surgery such as breast augmentation (e.g., receiving breast implants) may have breasts that are more spherical than natural breasts. Supporting the spherical implant with an underwire on the augmented breast may cause the implant to shift and slow down postoperative recovery. A bra cup (100) that includes a support member (20) of appropriate size and / or shape and / or an inner cup and / or outer cup (50, 52) of appropriate size and / or shape can prevent implant shift and can improve recovery speed.

[0111] Custom molds and mandrels

[0112] As described above, this disclosure considers the construction (e.g., a custom bra cup) of a specific bra cup (100) designed for wear by a particular user, wherein a new support member (20) has been incorporated. The formation of the custom bra cup (100) may optionally include (see...) Figure 9A custom mold (60) and / or a custom mandrel (62) are produced prior to forging the appropriate bulge. At least a portion of the mandrel (62) may be customized to represent the specific anatomy of a wearer during forging. The custom mandrel (62) may include a non-custom mandrel (62) having a custom portion attached by some attachment means. The custom mandrel (62) or the custom portion of the mandrel (62) may be produced by additive manufacturing, wherein 3D imaging data is utilized when manufacturing in a manner similar to manufacturing a restorative volumetric block as described above. Similarly, the custom mold (60) or at least some portions thereof may be produced in the same manner as the custom mandrel (62).

[0113] It is understandable that each wearer may have a unique breast size, which traditional bras and other garments may not be able to represent. It might be considered impractical to create custom molds (60) and corresponding mandrels (62) for each individual wearer. However, a limited set of molds (60) and mandrels (62) representing, for example, 12 different breast shapes and corresponding cup (100) sizes is a practical method for customizing bra cups (100).

[0114] Bra cup combination

[0115] Bras and other garments can be manufactured using various combinations of the embodiments described above. For example, any cup (100) may include one or more mesh support members (20), or one or more restorative volume blocks. Furthermore, any cup (100) may be a conventional cup design. In one embodiment, a bra or other garment includes a first cup and a second cup, the first cup including one or more encapsulated mesh support members (20), and the second cup including a conventional bra cup design. In another embodiment, a bra or other garment includes a first cup and a second cup, the first cup including one or more encapsulated mesh support members (20), and the second cup including one or more restorative volume blocks. In yet another embodiment, a bra or other garment includes a first cup and a second cup, the first cup and the second cup each including one or more encapsulated mesh support members (20).

[0116] Other uses

[0117] As described above, currently disclosed bras and garments are generally intended for the purpose of supporting breasts (e.g., male or female breasts). In one embodiment, the bra or garment is intended to cover one or more male breasts. In another embodiment, the bra or garment is intended to cover one or more female breasts. Cups with support members can be designed for other anatomical features, such as for the purpose of covering, supporting, and / or protecting the penis and testicles. Male cups designed for the anatomical features of the penis and / or testicles may include a first cup, a second cup, and support members, which are suitably manufactured to cover the penis and / or testicles. For example, male cups can be used in sportswear, where their intended purpose may be to support and protect the wearer's penis and / or testicles during sports activities (e.g., football, baseball, soccer, skiing, hockey, cycling, running, or other athletic activities). Another purpose may be for use in men's underwear, where male cups can be used to enhance the visual aesthetics of the penis and / or testicles within the underwear. In one embodiment, male cups comprising a first cup, a second cup, and support members are used in sportswear. In another embodiment, a male bra cup, including a first cup, a second cup, and a support member, is used to enhance the visual aesthetics of the penis and / or testicles within the underwear. The male bra cup may include any of the biometric sensors described above. In one embodiment, the men's clothing includes sensors for detecting cancer (e.g., testicular cancer).

[0118] Although various embodiments of the present disclosure have been described in detail, modifications and variations of those embodiments will be apparent to those skilled in the art. However, it should be clearly understood that such modifications and variations fall within the spirit and scope of this disclosure.

Claims

1. A method for manufacturing clothing, the method comprising: (a) Manufacturing a polymer-based mesh support member, wherein the polymer-based mesh support member comprises: A breast support portion, comprising a plurality of angled, staggered members disposed between the arcuate edges of the polymer-based mesh support member; wherein the plurality of angled, staggered members define a plurality of gaps, at least some of which are uniformly shaped; and An outer periphery, wherein the bottom of the outer periphery is at least partially defined by a rigid polymer lower edge, some of the interlacing members being connected to the bottom of the outer periphery, wherein at least the rigid polymer lower edge is used to provide support for the wearer of the garment; (b) Positioning a polymer-based mesh support member between the first cup and the second cup; (c) A polymer-based mesh support member, a first cup, and a second cup are formed into a bra cup; wherein the mesh support member is completely encapsulated within the bra cup, and (d) Prepare the garment, wherein the garment includes the bra cup.

2. The method according to claim 1, comprising: A digital profile of the wearer is generated by scanning at least one of the wearer's breasts using a peripheral device. and Create a 3D digital image based on the wearer's digital profile; Manufacturing step (a) includes: First, the first layer of a polymer-based mesh support component is additively printed based on a 3D digital image; Then, based on the 3D digital image, the second layer of the polymer-based mesh support structure is additively printed; The second layer is set on top of the first layer.

3. The method according to claim 2, comprising: The size and thickness of the polymer-based mesh support member are customized based on the wearer's digital profile.

4. The method of claim 3, wherein the polymer-based mesh support member has a variable thickness based on the wearer's digital profile.

5. The method according to claim 1, wherein, Manufacturing step (a) includes: subtractive manufacturing relative to a polymer-based precursor material, the subtractive manufacturing including one or more of cutting, engraving, milling, and drilling of the polymer-based precursor material.

6. The method according to claim 5, wherein, The subtractive manufacturing process includes laser cutting of the polymer-based precursor material.

7. The method according to claim 1, wherein, Manufacturing step (a) includes injection molding.

8. The method of claim 1, wherein the bra cup is a first bra cup; The garment mentioned above includes a second bra cup; The first bra cup includes a first volume; The second bra cup includes a second volume; The volume of the first cup is different from that of the second cup.

9. The method of claim 8, wherein the garment is one of a breast augmentation bra, a breast lump removal bra, and a mastectomy bra.

10. The method according to claim 1, wherein, Manufacturing step (a) includes: The breast support portion of the polymer-based mesh support component is additively printed into a dome-shaped breast support portion; Positioning step (b) includes positioning the polymer-based mesh support member, which includes the dome-shaped breast support portion, between the first cup and the second cup; and The forming step (c) includes forming a polymer-based mesh support member, a first cup, and a second cup into a bra cup.

11. The method according to claim 1, wherein, The plurality of gaps includes at least one of the following: rectangular gap, square gap, parallelogram gap, triangular gap, hexagonal gap, oval gap, circular gap, or elliptical gap.

12. The method according to claim 1, wherein, At least some of the multiple gaps are of uniform size.

13. The method according to claim 1, wherein, At least some of the angled interlaced members are not perpendicular to each other, and at least some of the plurality of gaps include at least some parallelogram gaps.

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