Sustainable bra garments and improved bio-based open cell foam pad portions

Abstract

The present application describes a sustainable bra garment comprising a first cup portion and a second cup portion made of one or more recyclable flexible materials, and a first side flap and a second side flap extending from the first cup portion and the second cup portion, respectively, and a first cushioning support pad and a second cushioning support pad made of a bio-based foam material having a very soft open-cell structure. The first side flap and the second side flap are made of one or more recyclable flexible materials. The first cushioning support pad and the second cushioning support pad are configured to be connected to the first cup portion and the second cup portion, respectively, each pad having a front surface and a rear surface, the front surface of each pad having a substantially convex shape, and the rear surface of each pad having a substantially concave shape. Each pad is made of a bio-based material, such as a sugar cane-based open cell foam material, having hardness and density values that provide cushioning and support for the breasts of a wearer of the sustainable bra garment. The cushioning support pad may be used with brassiere garments, and may also be used with other garments, such as swimsuits and other garments where brassiere support pads may be incorporated.

Description

Background Art

[0001] The present application relates generally to a bra garment and, more particularly, to a bra garment including an improved bra padding portion made from a bio-based polymer open-cell foam material, as opposed to a petroleum-based foam padding material.

[0002] Women usually wear bras to provide support to the breasts and improve the shape and appearance of the breasts. Other garments have built-in bras that can provide the same function. Bras are essential for proper support of the wearer, which determines the type of materials that can be used for bras, especially the bra padding parts for shaping and support, which are usually made of non-recyclable petroleum-based polymer foams. Therefore, foam pads are usually attached to bras using glue. However, foam materials and glues are toxic to humans during their production process, and are also toxic to the wearer, and are non-recyclable and environmentally unfriendly. Therefore, it is necessary to provide an improved environmentally friendly bra garment, especially a bra garment with a foam padding part formed by recyclable and / or bio-based materials, so that bra products are more environmentally friendly and sustainable. The improved bio-based recyclable support pad of the present invention can be used with bra garments, and can also be used with other garments (such as swimwear and other clothing) that can be combined with bra support pads.

[0003] The contents of U.S. Patent No. 11,330,849 (granted on May 17, 2022) are incorporated herein by reference in their entirety, in which the same applicants and inventors as the present application describe and claim a bra garment having a cup portion made of bio-based ethylene vinyl acetate ("EVA") foam, the foam being essentially composed of a bio-based ethanol component, 60-85% of which is sugarcane-based ethanol, and the remainder being fossil fuel-based ethanol and vinyl acetate, thereby producing an EVA foam having a closed-cell structure ("closed-cell foam"). There is currently a need for a further improved bra cup portion, so that it is composed of a higher proportion of bio-based polymer materials having an open-cell structure (such as the "open-cell foam" provided by the present invention), so that a preferred proportion of bio-based EVA is combined with a preferred proportion of bio-based polyethylene ("bio-based PE") to form an open-cell foam, thereby producing a bra cup portion that is softer but has sufficient structural support than the bra cup portion described and claimed in Patent No. US11,330,849. The bio-based polymer material may also comprise only bio-based EVA in a preferred proportion to form an open-cell foam to create a softer yet sufficiently structurally supportive bra cup portion of the present invention. Summary of the invention

[0004] The present disclosure can provide a sustainable bra garment, which includes a first cup portion and a second cup portion and a first side wing piece and a second side wing piece, wherein the first cup portion and the second cup portion include a bra pad portion made of one or more bio-based open-cell foam materials, and the first side wing piece and the second side wing piece are made of a recyclable flexible material and extend from the first cup portion and the second cup portion, respectively. The first buffer support pad and the second buffer support pad are configured to be connected to the first cup portion and the second cup portion, respectively. Each bra pad portion has a front surface and a rear surface, wherein the front surface of each pad is generally convex in shape, and the rear surface of each pad is generally concave in shape. Each pad is made of a bio-based open-cell foam material, which has a hardness and density value that provides cushioning and support for the breasts of the wearer of the bra garment. The pad made of the bio-based open-cell foam material can also be used in other types of clothing and apparel, such as bras, maternity bras, sports bras, swimwear, camisole, corsets, T-shirts and other clothing that can be combined with bra support pads.

[0005] In some embodiments, the open-cell bio-based foam material is composed of a sugarcane-based polymer foam material made of a blend of bio-based EVA and bio-based PE (and other materials) that is non-toxic to the wearer. Each pad may be free of a lamination or glue layer at least on its back side; the one or more recyclable materials of the first and second cup portions and the first and second side wing pieces are one or more recyclable fabrics; and / or the first and second cup portions and the first and second side wing pieces are made of the same recyclable fabric.

[0006] In other embodiments, the bra garment further comprises elastic shoulder straps, which are respectively connected between the first cup portion and the first side wing piece and between the second cup portion and the second side wing piece, and the elastic shoulder straps are made of recyclable materials; each shoulder strap comprises an adjustable element for adjusting the length of the shoulder strap, and the adjustable element is made of a sustainable material, and the hardness value of the sustainable material is greater than the hardness value of the sustainable material of the pad; the first cup portion and the second cup portion both have a steel ring channel; further comprising a bridge piece connecting the first cup portion and the second cup portion, and the bridge piece is made of recyclable materials; and / or the free ends of the first side wing piece and the second side wing piece comprise corresponding fastening elements for fastening the free ends together.

[0007] The present disclosure generally provides a first cushioning support pad and a second cushioning support pad composed of a bio-based open-cell foam, which are respectively retained in a receiving area of ​​a first cup portion and a second cup portion of a bra garment. Each pad has a front surface and a rear surface, and the front surface and the rear surface correspond to the outer sheet and the inner sheet of the first cup portion and the second cup portion, respectively. The front surface of each pad is generally convex in shape, and the rear surface of each pad is generally concave in shape. Each pad is made only of a bio-based material having a hardness and density value that can provide cushioning and support for the breasts of a wearer of a sustainable bra garment.

[0008] In a preferred embodiment, the padding portion can be made of environmentally friendly materials, such as sugar cane-based polymers, which are known in the art as green or bio-based EVA materials. Bio-based EVA materials are known in the art and have been previously developed and used to produce soles for certain specialty footwear products [see https: / / www.forbes.com / sites / veenamccoole / 2018 / 08 / 01 / allbirds-launches-flip-flops-made-from-sustainable-sugarcane / ?sh=55cd98913672 and https: / / materialdistrict.com / article / flip-flops-sugarcane-foam / ]. However, in the present invention, it has been discovered that bio-based EVA materials can be further refined and processed to produce a foam polymer material that is softer and structurally strong enough to be used as a bra pad. In the present invention, preferred foaming methods are disclosed for forming molded bra pad products from bio-based EVA that have the flexibility and structural properties of petroleum-based EVA, but are recyclable after the end of the useful life of a typical bra pad product. In addition, the outer sheet of each cup portion can be made of renewable nylon and the inner sheet of each cup portion is made of renewable polyester; the bra garment also includes elastic shoulder straps, which are respectively connected between the first cup portion and the first side wing piece and between the second cup portion and the second side wing piece, and the elastic shoulder straps are made of renewable fabric; and / or the first cup portion and the second cup portion each have an underwire channel and a bridge piece, the bridge piece connecting the first cup portion and the second cup portion, and the underwire channel and the bridge piece are both formed of renewable materials.

[0009] Conventional fossil fuel-based foams, such as polyurethane foams, are produced through sheeting, molding, and extrusion processes of compounded rubber and are formulated using a variety of raw materials, including chemicals, liquid polymers (such as polyols, polyisocyanates, toluene diisocyanate), additives (used as catalysts to increase production speed), and blowing agents (which create bubbles during the foam formulation process). Surfactants such as silicones or polyethers are also used to control the size of the bubbles. The physical properties of conventional fossil fuel-based foams depend on the alloy composition and reaction temperature during the production stage.

[0010] The present disclosure provides a sustainable bra garment, which includes a first cup portion and a second cup portion, wherein the first cup portion and the second cup portion have a cushioning support pad formed by a bio-based open-cell foam, and the bio-based open-cell foam is substantially free of fossil fuel-based materials. The first cup portion and the second cup portion both have an outer sheet and an inner sheet. The inner sheet and the outer sheet are connected to each other at their respective peripheries, thereby forming a pad receiving area between them. The inner sheet and the outer sheet are formed by one or more recyclable fabrics. The first side wing piece and the second side wing piece extend from the first cup portion and the second cup portion, respectively. The first side wing piece and the second side wing piece are formed by one or more recycled fabrics. The first cushioning support pad and the second cushioning support pad are respectively retained in the receiving area of ​​the first cup portion and the second cup portion. Each pad has a front surface and a rear surface, and the front surface and the rear surface correspond to the outer sheet and the inner sheet of the first cup portion and the second cup portion, respectively. The front surface of each pad generally presents a convex shape, and the rear surface of each pad generally presents a concave shape. As disclosed herein, each pad is made of a bio-based open-cell foam having a hardness and density value that provides cushioning and support to the breasts of a wearer of the sustainable bra garment and is non-toxic to the wearer. Essentially, every part of the sustainable bra garment is made of recycled or bio-based materials.

[0011] In some embodiments, the bra garment further comprises elastic shoulder straps, the elastic shoulder straps being connected between the first cup portion and the first side wing piece and between the second cup portion and the second side wing piece, respectively, and the elastic shoulder straps can be made of renewable fabric; each shoulder strap comprises an adjustable element for adjusting the length of the shoulder strap, the adjustable element being made of a sustainable material having a stiffness value greater than the stiffness value of the sustainable material of the pad; and / or the first cup portion and the second cup portion can both have an underwire channel. A bridge piece connects the first cup portion and the second cup portion, and the free ends of the first side wing piece and the second side wing piece can include corresponding fastening elements for fastening the free ends together, wherein the underwire channel, the bridge piece and the fastening elements can be made of renewable materials.

[0012] This summary is not intended to identify essential features of the claimed subject matter, nor is it intended to be used to determine the scope of the claimed subject matter. It should be understood that both the general description above and the detailed description below are exemplary and are intended to provide an overview or framework for understanding the essence and character of the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The accompanying drawings are incorporated into and constitute a part of this specification. It should be understood that the accompanying drawings only illustrate some examples of the present disclosure, and other examples or combinations of various examples not shown in the accompanying drawings may still fall within the scope of the present disclosure. The examples will now be described in more detail by using the accompanying drawings, in which:

[0014] Figure 1 is a front or exterior elevation view of an exemplary sustainable bra garment of the present invention;

[0015] Figure 2 yes Figure 1 A rear view or interior elevation view of the sustainable bra garment shown;

[0016] Figure 3 is a front view or exterior elevation view of another exemplary sustainable bra garment of the present application;

[0017] Figure 4 yes Figure 3 A rear view or interior elevation view of the sustainable bra garment as shown; and

[0018] Figure 5 is an enlarged partial cross-sectional view of a cup of the sustainable bra garment of the present invention.

[0019] Figure 6a is a side perspective view of a molten mixture of bio-based foam material being formed into a shape from the mixture in a single screw extrusion step.

[0020] Figure 6b is a perspective view of a foam block (or foam gum block) of a bio-based foam material before it is subjected to multiple breaking steps through a roller process to convert the foam into an open-cell structure.

[0021] Figure 6c is a perspective view of a foam block (or foam gum block) of a bio-based foam material being heated in an oven to restore the thickness of the foam block after a crushing process.

[0022] Figure 6d is a front perspective view of a bio-based open-cell foam sheet used to form one or more cushions of the present invention.

[0023] Figure 7 is a front perspective view of a cushion portion formed in part from a bio-based open-cell foam sheet of the present invention (as shown in FIG. 6 ).

[0024] Figure 8 It is a front view or elevation view of the finished liner of the present invention. DETAILED DESCRIPTION

[0025] Referring to the accompanying drawings, the present disclosure generally relates to a bra garment 100 made of sustainable and recyclable materials, which is environmentally friendly, non-toxic to the wearer, and can promote the health and wellness of the wearer. The bra garment 100 can be, for example, a bra, a sports bra, a maternity bra, a bra, a bikini top, a camisole, other underwear tops, or other breast covering garments, such as a swimsuit.

[0026] Bra garment 100 generally comprises cup portion 102a, 102b, side wing pieces 104a, 104b extending from corresponding cup portion 102a, 102b respectively and pad 108 of cup portion 102a, 102b. Bra garment 100 also can provide shoulder strap 106a, 106b, makes shoulder strap 106a connected between cup portion 102a and side wing piece 104a, shoulder strap 106b connected between cup portion 102b and side wing piece 104b. Pad 108 is made of bio-based material, and it provides cushioning and support for wearer's breast. The rest of bra garment 100 can be made of renewable material and / or sustainable material. Therefore, whole or substantially whole bra garment 100 can only be made of sustainable bio-based and renewable material.

[0027] The sustainable material of the present disclosure is a bio-based open-cell foam material that is non-toxic to the wearer and may also be free of fossil fuel-based foam materials, etc. For example, the sustainable material used to form the pad 108 may have a hardness and density value sufficient to provide cushioning and support to the wearer. Furthermore, the sustainable material of the bra garment 100 may be manufactured through a sustainable and environmentally friendly process.

[0028] The bio-based materials disclosed herein are eco-friendly, climate-friendly, green, environmentally friendly, environmentally safe, fuel-efficient, energy-efficient, pollution-free, organic, energy-saving materials. Bio-based materials are vital, continuous, sustainable, viable, uninterrupted, livable, supportable, immortal, everlasting, renewable, green materials. Bio-based materials are produced from existing resources to meet current needs while ensuring sufficient resources for future generations. In certain embodiments, the bio-based materials can be sugar cane, soy or corn-based polymers. In addition, biodegradable additives can also be added to the foam.

[0029] The cup portions 102a and 102b and the side panels 104a and 104b can be made of recyclable materials, such as recycled fabrics. According to the present disclosure, the recycled materials of the present invention refer to materials that can convert waste into usable materials. Recycled fabrics refer to waste products, fabrics and textiles that can be sorted, graded and used again to make recycled fabrics, such as synthetic fibers such as polyester and nylon.

[0030] Each cup portion 102a, 102b of the bra garment 100 has an outer sheet 120 and an inner sheet 122, which can be connected to each other at their respective peripheries by sewing or the like, thereby forming a pad receiving area 124 therebetween, and the pad receiving area 124 contains a corresponding pad 108, such as Figure 5 As shown. The outer sheet 120 can have a generally convex shape selected from a plurality of available cup sizes. The inner sheet can have a generally concave shape selected from a plurality of available cup sizes. The outer layer 120 and the inner layer 122 are made of one or more flexible materials. In one embodiment, the outer layer can be made of nylon or recycled nylon, and the inner layer can be made of polyester or recycled polyester. The polyester can be brushed to increase softness to the wearer's skin.

[0031] Each pad 108 has a front surface 110 and a rear surface 112, which correspond to the outer sheet 120 and the inner sheet 122 of the cup parts 102a, 102b, respectively. The front surface 110 of each pad 108 has a generally convex shape, and the rear surface 112 of each pad 108 has a generally concave shape, such as Figure 5 The pad 108 may be sized to any breast cup size and generally correspond to the size of the outer and inner panels 120, 122 of the cup portions 102a, 102b.

[0032] Each pad 108 is made of a sustainable material, which is a bio-based open-cell foam material, whose hardness, resilience and density values ​​are sufficient to provide cushioning and support for the breasts of the wearer of the sustainable bra garment, and is non-toxic to the wearer. For example, the bio-based material of the pad 108 can be composed of about 40% to 85% bio-based EVA and PE open-cell foam, or about 40% to 85% EVA open-cell foam. This ratio of bio-based materials provides the pad 108 with the required flexibility and provides comfort, cushioning and sufficient support for the wearer.

[0033] The open-cell foam used in the gasket 108 of the present invention is made of a bio-based resin compound through a multi-step process of mixing, extrusion, tableting and molding. The bio-based resin compound can be formulated using a variety of raw materials, including bio-based EVA alone or a combination of bio-based EVA and PE as a resin base, as well as additives as catalysts to increase production speed and foaming agents to generate bubbles during the foam formulation process. The physical properties of the bio-based open-cell foam depend on its composition and the reaction temperature of the production stage.

[0034] As a specific example of a preferred embodiment of the present invention, the liner 108 is formed by a bio-based material, which uses 25% to 85% of bio-based EVA and 5% to 45% of bio-based polyethylene ("PE"), both of which are mainly composed of sugarcane-based ethanol converted into ethylene. A small amount of olefin block copolymers (such as Dow Infuse 9107 olefin block copolymers) can also be mixed with bio-based EVA and PE, which helps to control shrinkage and improve the elastic recovery of the resulting bio-based open-cell foam. Bio-based EVA (bio-based ethylene from sugarcane and vinyl acetate) is mixed with bio-based PE and olefin block copolymers, and then combined with initiators (such as hydrogen peroxide (or double peroxide)) and foaming agents (such as azodicarbonamide) and other chemicals and additives known in the art (such as titanium dioxide that can be used as a white coloring pigment). The preferred formula of the bio-based EVA and PE composition used to form the liner 108 of the present invention is shown in the following table:

[0035]

[0036] *PHR is the abbreviation for "parts per hundred resin"

[0037] The preferred formulations of the bio-based EVA and PE compositions and olefin block copolymers and other reference components used to form the liner 108 of the present invention are shown in the following table:

[0038]

[0039] *PHR is the abbreviation for "parts per hundred resin"

[0040] According to an additional formulation of a preferred embodiment of the present invention, a bio-based material consisting only of bio-based EVA, which is mainly composed of sugarcane-based ethanol converted into ethylene, can be used to form the liner 108. The following table shows a preferred formulation of bio-based EVA materials and other reference ingredients for forming the liner 108 of the present invention:

[0041]

[0042] Bio-based materials consisting only of bio-based EVA can also be used in combination with olefin block copolymers (such as Dow Infuse 9107 olefin block copolymers). The preferred formula of bio-based EVA materials, olefin block copolymers and other reference components used to form the liner 108 of the present invention is shown in the following table:

[0043]

[0044] A preferred method of forming a bio-based open-cell foam for use in the liner 108 of the present invention includes heating the bio-based EVA / PE formulation from room temperature to about 105°C (about 221°F) to about 130°C (about 266°F) to produce a molten mixture similar to dough consistency. This mixture is then extruded in a single screw extruder. The preferred extrusion temperature range can be between about 80°C (about 176°F) and about 90°C (about 194°F) to form the mixture as shown in FIG. Figure 6a The shape 113 is shown. The shape 113 is preferably maintained at a temperature of about 60°C (about 140°F) to about 90°C (about 194°F) during the remainder of the extrusion process to maintain the extruded shape, after which the shape is compressed using a through-type pressing belt to form a substantially flat sheet. The volumetric shape of the substantially flat sheet is then expanded by a two-step heating process, the two-step heating process comprising: 1) heating the sheet to a temperature between about 135°C (about 275°F) and about 150°C (about 300°F) for a duration of about 30 to 45 minutes to obtain a substantially cross-linked foam material, preferably with a cross-linking rate of 100%, to achieve a moderate volume expansion; 2) heating the sheet to a temperature between about 160°C (about 320°F) and about 185°C (about 365°F) for a duration of about 90 to about 150 minutes to obtain a substantial volume expansion. The volume expansion of the foam shape can reach about 36-38 times the original shape, thereby forming a foam sheet. After the second heating process, the bio-based foam sheet is preferably subjected to a cooling process in the mold. The preferred cooling process may use cold water at about 15°C (about 59°F) for about 70 to 90 minutes. After the second step (heating) of the above two-step process is completed, a foam block 114a having a preferred size of about 2.4 meters long, 1 meter wide and 90 mm thick will be obtained.

[0045] The foam block (or foam rubber block) 114a is preferably placed at room temperature for about 24 hours and then Figure 6bThe illustrated rolling process performs multiple crushing steps to obtain an open-cell structure within the foam block 114a. The preferred rolling process is performed by subjecting the foam block 114a to approximately two back-and-forth cycles in the rolling machine, so that the foam block 114a is crushed at least four times between the rollers to release as much air as possible from the foam interior. The foam block may then be heated in an oven at a temperature between approximately 165° and 175° C. for 40 to 50 minutes, which serves to restore the thickness of the foam block and produce a porous structure such as shown after the crushing process. Figure 6c Open cell foam block 114b is shown.

[0046] The open-cell foam block is then cut or sliced ​​into thinner sheets, preferably in the range of about 4 mm to about 13 mm thick. Figure 6d As shown, this material may be used as a material for preparing one or more gaskets 108 .

[0047] The hardness of the foam sheet 115 is in the range of about 3 to about 50 Shore 00 hardness, preferably about 6 to 25 Shore 00 hardness, as measured according to ASTM D2240.

[0048] Using the ISO 845 test standard as the preferred method, the density of the foam sheet 115 is about 0.020 to about 0.045 g / cm 3 , preferably in the range of about 0.025 to about 0.035 g / cm 3 The ISO 845 test standard is commonly used to characterize the performance of solid plastic samples such as sheets, rods, tubes or open-cell foam sheets such as the one described herein. Figure 6d )Determination of specific gravity (relative density) and density of molded articles.

[0049] The bio-based foam sheet 115 can then be laminated with a fabric such as polyester, polyamide, nylon, a polyester and nylon blend, or the like. A preferred embodiment of the fabric is a 100% polyester, double-sided 72D microfine brushed fabric. In a preferred lamination process, the fabric is secured to the foam sheet using an adhesive such as NEL-1018 hot melt polyurethane adhesive, preferably with a viscosity of 10,000 (±2,000 cps ("centipoise")) / 100°C. The preferred amount of adhesive is 25 grams per square meter of foam sheet, and the fabric lamination temperature is 95°C. The duration of the lamination process to complete, including curing and drying of the laminated foam sheet, is preferably about 24 hours.

[0050] The bio-based open-cell foam sheet 115 is then formed into partial cushion portions 115a and 115b (eg, Figure 7). A preferred molding method for forming a standard cushioning cup portion comprises: 1) heating a portion of the bio-based open-cell foam sheet in a mold to between about 70°C (160°F) and about 120°C (248°F) for a first pressing, the duration of which is about 80 seconds to about 160 seconds; 2) heating the bio-based open-cell foam sheet in the mold to between about 20°C (68°F) and about 60°C (140°F) for a second pressing, the duration of which is about 60 seconds to about 120 seconds; 3) cooling the bio-based open-cell foam in the press at room temperature for about 30 seconds to about 70 seconds; so that each of the partial cushion portions (115a and 115b) forms an inner surface having a generally convex shape and an outer surface having a generally concave shape in the mold, and the cushion portion has a Shore 00 hardness value of about 20 to about 70, preferably a Shore 00 hardness value of about 35 to about 55. Examples of cushion cup portions 115a and 115b formed using the preferred molding method described above are as follows: Figure 7 shown.

[0051] An example of a finished gasket portion 108 made according to the above-described processing method is as follows: Figure 8 In addition to the above preferred molding methods, a variety of molding methods with different times and temperatures can also be used to produce pad parts with various cup sizes and styles. The different methods for manufacturing various styles are shown in the following table:

[0052]

[0053] Several such pad portion samples were tested using the ASTM test method to evaluate the preferred range of pad material hardness properties. The samples were hardness tested using the Shore00 durometer using the ASTM D2240 test method to determine the material hardness at various surface points for each sample with cup sizes ranging from 32A to 44G (U.S. standard sizes). After such hardness testing, it was observed that the Shore00 hardness values ​​ranged from about 20 to about 70, with the preferred Shore00 material hardness range being between about 35 and about 55, thereby providing appropriate cushioning and adequate support for the breasts of a wearer of a sustainable bra garment or other garment containing such pad 108.

[0054] It has been determined that the bio-based carbon content in the finished gasket portion 108 sample can reach 77%. The bio-based carbon content of the finished gasket portion sample is determined by standard ASTM D6866 (Method B) analysis, which indicates the percentage of carbon from "natural" (plant or animal byproduct) sources to "synthetic" (petrochemical) sources. For reference, 100% bio-based carbon means that the material is completely derived from plants or animal byproducts, while 0% bio-based carbon means that the material does not contain any carbon from plants or animal byproducts. Values ​​in between represent a mixture of natural and fossil fuel sources, such as the finished gasket portion 108 described herein.

[0055] The front surface 110 of each liner 108 may be laminated so that it can be attached to the outer sheet 120 of the cup portion 102a, 120b. The rear surface 112 of each liner 108 may not be laminated. Alternatively, each liner 108 may not be laminated at all, that is, no lamination is performed on its front surface 110 and rear surface 112.

[0056] Each side wing piece 104a, 104b is connected with the outer edge of corresponding cup part 102a, 102b.Side wing piece 104a, 104b can be made of one or more fabrics, such as nylon, regenerated nylon, etc.Side wing piece 104a, 104b can be made of the regenerated fabric that is the same or different from cup part 102a, 102b.In addition, regenerated yarn can be used for sewing the edge of any part or any piece of bra garment 100, such as around the edge 109 of side wing piece 104a, 104b.The free end of side wing piece 104a, 104b comprises corresponding fastening element 130 and 132 respectively, such as hook and buttonhole element, for free end being buckled together in a conventional manner.Fastening element 130 and 132 can be made of recyclable material, such as, can make hook with recyclable metal, make buttonhole with fabric or yarn.

[0057] The shoulder straps 106a, 106b may be made of recyclable materials, such as recyclable elastic materials, recyclable yarns, etc., to provide flexibility and comfort to the wearer. Each shoulder strap 106a and 106b may be adjusted using adjustable elements, such as corresponding loop members 134 and hook members 136, the functions of which are known in the art. The loop members 134 and hook members 136 may be made of sustainable materials, such as sugar cane polymers. The sugar cane polymers of the loop members 134 and hook members 136 will be harder and stronger than the sugar cane polymers that form the pad 108. That is, the sugar cane polymers of the loop members 134 and hook members 136 have sufficient hardness values ​​and rigidity to be connected to the shoulder straps 106a and 106b to allow the shoulder straps 106a and 106b to be adjusted.

[0058] The bra garment 100 may include an underwire, such as Figure 1 and2 As shown, or the bra garment 100 'may not have a steel ring, such as Figure 3 and 4 As shown. The bra garment 100 has underwire channels 140a, 140b at the bottom of the support members 102a, 102b, respectively. The underwire channels 140a, 104b can be made of recyclable fabrics (e.g., recyclable yarns) and are sized to receive conventional underwires. A bridge 138 extends between the underwire channels 140a, 140b to connect the cup portions 102a, 102b. The bridge 138 can be made of recyclable materials (e.g., recycled nylon).

[0059] like Figure 3 and 4 As shown, the bra garment 100' is similar to the bra garment 100 except that it does not have a steel ring and a steel ring channel. Figure 1 and 2 The bra garment 100 is substantially the same as in FIG. Figure 4 As shown, the cup portions 102a', 102b' of the bra garment 100' are identical to the cup portions 102a, 102b except that the cup portions 102a and 102b' are sewn together at the center line 150 and the bottom line 152 using recycled yarn. The tops of the cup portions 102a', 120b' may be provided with an optional lace trim 154. The lace trim 154 may be made of a renewable material, such as a renewable yarn, etc.

[0060] Some embodiments of the present invention are as follows:

[0061] Embodiment 1: A bio-based cushioning support pad for a bra garment or other garments, comprising:

[0062] a cushion portion formed from one or more bio-based foam materials including at least about 40-85% bio-based EVA and bio-based PE formed primarily from sugarcane-based ethylene;

[0063] The bio-based EVA and bio-based PE are combined with at least a peroxide-based initiator and a foaming agent;

[0064] The bio-based EVA, bio-based PE, peroxide-based initiator, and blowing agent mixture is formed into a substantially flat sheet by a method comprising: heating the mixture to a temperature between about 105° C. and about 130° C. to form a molten mixture, extruding the molten mixture to form the mixture into a shape, maintaining the shape at a temperature of at least about 60° C. to about 90° C. during extrusion, and compressing the shape to form a substantially flat sheet;

[0065] Expanding the volume of the substantially planar sheet by a heating method comprising:

[0066] heating the sheet to about 135° C. to about 150° C. for about 30 to 45 minutes to obtain a substantially cross-linked foam material with limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 to about 150 minutes to obtain a significant volume expansion to form a bio-based foam block;

[0067] The bio-based foam block is crushed by a multiple roller pressing process, which comprises:

[0068] squeezing the bio-based foam block between press rollers at least about 4 times to release a large amount of air from the interior of the bio-based foam block, thereby forming an open-cell foam block;

[0069] cutting the open-cell foam block into sheets;

[0070] forming the bio-based open-cell foam sheet into a cushioning portion,

[0071] The cushion portion is formed in a mold into a shape in which an inner surface is substantially concave and an outer surface is substantially convex.

[0072] Embodiment 2: The bio-based cushioning support pad according to embodiment 1, wherein the bio-based EVA and bio-based PE are further combined with an olefin block copolymer.

[0073] Embodiment 3: The bio-based cushioning support pad of Embodiment 1, wherein the bio-based foam material comprises at least about 40-85% bio-based EVA, wherein the bio-based EVA is substantially made of sugarcane-based ethylene.

[0074] Embodiment 4: The bio-based cushioning support pad of Embodiment 3, wherein the bio-based EVA is combined with an olefin block copolymer.

[0075] Embodiment 5: The bio-based buffer support pad according to embodiment 1, wherein after the rolling process, the foam block is heated to between about 165° C. and about 175° C. for about 40 to about 50 minutes to substantially restore the thickness of the foam block.

[0076] Embodiment 6: The bio-based cushioning support pad of Embodiment 1, wherein the pad portion has a Shore 00 hardness value of at least about 20 to 70.

[0077] Embodiment 7: The bio-based cushioning support pad of embodiment 1, wherein the pad portion has a bio-based carbon content of about 40-90%.

[0078] Embodiment 8: The bio-based cushioning support pad according to embodiment 1, wherein the sheet formed by the cutting method is composed of open-cell foam, and the density of the sheet is about 0.020 to 0.045 g / cm 3 .

[0079] Embodiment 9: The bio-based cushioning support pad according to embodiment 1, wherein the pad portion is formed by molding, the method comprising:

[0080] The bio-based open-cell foam board is heated in a mold to about 70° C. to about 120° C., and a first pressing is performed for a duration of about 80 to about 140 seconds;

[0081] The bio-based foam board is reheated in the mold to about 20° C. to about 60° C. and pressed a second time for about 60 to about 120 seconds, and

[0082] Cooling the bio-based foam board in the mold to about room temperature for a duration of about 30 seconds to about 70 seconds;

[0083] Part of the cushion portion is formed in the mold with an inner surface substantially presenting a concave shape and an outer surface substantially presenting a convex shape.

[0084] Embodiment 10: The bio-based buffer support pad according to embodiment 1, wherein the bio-based open-cell foam sheet layer is laminated on at least one side thereof, and the laminated layer comprises:

[0085] natural or synthetic fabrics;

[0086] The adhesive attaching the fabric to the foam sheet had a curing and drying time of approximately 24 hours per laminated foam sheet.

[0087] Embodiment 11: The bio-based cushioning support pad according to Embodiment 10, wherein the fabric used for laminating the foam sheet is composed of double-sided 72D ultra-fine brushed fabric.

[0088] Embodiment 12: The bio-based cushioning support pad of Embodiment 10, wherein the fabric used to laminate the foam sheet is composed of 100% polyester.

[0089] Embodiment 13: The bio-based cushioning support pad according to embodiment 10, wherein the adhesive glue is composed of NEL-1018 hot melt polyurethane adhesive, which preferably has a viscosity of about 8,000 to about 12,000 cps / 100°C.

[0090] Embodiment 14: The bio-based cushioning support pad according to embodiment 10, wherein the adhesive is applied to the foam sheet in an amount of about 25 grams per square meter.

[0091] Embodiment 15: The bio-based cushioning support pad of Embodiment 10, wherein each of the foam sheets is laminated using a fabric lamination roller maintained at a temperature of about 95°C.

[0092] Embodiment 16: The bio-based buffer support pad according to Embodiment 1, wherein each of the buffer support pads has no lamination layer or adhesive layer at least on the back side thereof.

[0093] Embodiment 17: A method for manufacturing a bio-based cushioning support pad for a bra garment or other garments, comprising:

[0094] at least one cushion portion made from one or more bio-based foam materials, the material comprising at least about 40-85% bio-based EVA and bio-based PE formed primarily from sugarcane-based ethylene;

[0095] The bio-based EVA and bio-based PE are combined with at least a peroxide-based initiator and a foaming agent;

[0096] The mixture of bio-based EVA, bio-based PE, peroxide-based initiator and blowing agent is formed into a substantially flat sheet by the following method, the method comprising:

[0097] heating the mixture to a temperature between about 105° C. and about 130° C. to form a molten mixture, extruding the molten mixture to form the mixture into a shape, maintaining the shape at a temperature of at least about 60° C. to about 90° C. during extrusion, and compressing the shape to form a substantially flat sheet;

[0098] The volume of the substantially flat sheet is expanded by a heating method, the heating method comprising: heating the sheet to about 135° C. to about 150° C. for about 30 to 45 minutes to obtain a substantially cross-linked foam material with limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 to about 150 minutes to obtain a significant volume expansion to form a bio-based foam block; comminuting the bio-based foam block by a multiple roller pressing process, which comprises:

[0099] squeezing the bio-based foam block between press rollers at least about 4 times to release a large amount of air from the interior of the bio-based foam block, thereby forming an open-cell foam block;

[0100] cutting the open-cell foam block into sheets;

[0101] forming the bio-based open-cell foam sheet into a cushioning portion,

[0102] The cushion portion is formed in a mold into a shape in which an inner surface is substantially concave and an outer surface is substantially convex.

[0103] Embodiment 18: The method of Embodiment 17, wherein the bio-based EVA and bio-based PE are further combined with an olefin block copolymer.

[0104] Embodiment 19: The method of Embodiment 17, wherein the bio-based foam material comprises at least about 40%-85% bio-based EVA, wherein the bio-based EVA is substantially made of sugarcane-based ethylene.

[0105] Embodiment 20: The method of Embodiment 19, wherein the bio-based EVA is combined with an olefin block copolymer.

[0106] Embodiment 21: The method according to embodiment 17, wherein after the rolling process, the foam block is heated to between about 165°C and about 175°C for about 40 to about 50 minutes to substantially restore the thickness of the foam block.

[0107] Embodiment 22: The method of Embodiment 17, wherein the pad portion has a Shore 00 hardness value of at least about 25 to 65.

[0108] Embodiment 23: The method of Embodiment 17, wherein the bio-based carbon content of the liner portion is about 50-90%.

[0109] Embodiment 24: The method according to embodiment 17, wherein the cushion portion is formed by molding, the method comprising:

[0110] The bio-based open-cell foam board is heated in a mold to about 70° C. to about 120° C., and a first pressing is performed for a duration of about 80 to about 140 seconds;

[0111] The bio-based foam board is reheated in the mold to about 20° C. to about 60° C. and pressed a second time for about 60 to about 120 seconds, and

[0112] Cooling the bio-based foam board in the mold to about room temperature for a duration of about 30 seconds to about 70 seconds;

[0113] Part of the cushion portion is formed in the mold with an inner surface substantially presenting a concave shape and an outer surface substantially presenting a convex shape.

[0114] Embodiment 25: A bra garment, comprising:

[0115] a first cup portion and a second cup portion made of one or more recyclable flexible materials;

[0116] First and second side wing panels extending from the first and second cup portions, respectively; and

[0117] a first cushioning support pad and a second cushioning support pad configured to be connected to the first cup portion and the second cup portion, respectively, each of the pads having a front surface and a rear surface, the front surface of each pad having a generally convex shape and the rear surface of each pad having a generally concave shape;

[0118] Each of said pads is made of a bio-based open-cell foam material having a hardness and density value that provides cushioning and support to the breasts of a wearer of the bra garment;

[0119] The bio-based open-cell foam material comprises at least about 60-85% of a bio-based EVA and bio-based PE blend formed primarily of sugarcane-based ethylene;

[0120] The bio-based EVA and bio-based PE mixture is combined with at least a peroxide-based initiator and a blowing agent;

[0121] The bio-based EVA, bio-based PE, peroxide-based initiator and blowing agent mixture is formed into a substantially flat sheet by the following method, the method comprising:

[0122] heating the mixture to a temperature between about 105° C. and about 130° C. to form a molten mixture, extruding the molten mixture to form the mixture into a shape, maintaining the shape at a temperature of at least about 60° C. to about 90° C. during extrusion, and compressing the shape to form a substantially flat sheet;

[0123] Expanding the volume of the substantially planar sheet by a heating method comprising:

[0124] heating the sheet to about 135° C. to about 150° C. for about 30 to 45 minutes to obtain a substantially cross-linked foam material with limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 to about 150 minutes to obtain a significant volume expansion to form a bio-based foam block;

[0125] The bio-based foam block is crushed by a multiple roller pressing process, which comprises:

[0126] squeezing the bio-based foam block between press rollers at least about 4 times to release a large amount of air from the interior of the bio-based foam block, thereby forming an open-cell foam block;

[0127] cutting the open-cell foam block into sheets;

[0128] forming the bio-based open-cell foam sheet into a cushioning portion,

[0129] The cushion portion is formed in a mold into a shape in which an inner surface is substantially concave and an outer surface is substantially convex.

[0130] Embodiment 26: The bra garment of Embodiment 25, wherein the bio-based EVA and bio-based PE are further combined with an olefin block copolymer.

[0131] Embodiment 27: The bra garment of Embodiment 25, wherein the bio-based foam material comprises at least about 40-85% bio-based EVA, wherein the bio-based EVA is made essentially of sugarcane-based ethylene.

[0132] Embodiment 28: The bra garment of Embodiment 27, wherein the bio-based EVA is combined with an olefin block copolymer.

[0133] Embodiment 29: The bra garment of Embodiment 25, wherein after the rolling process, the foam block is heated to between about 165°C and about 175°C and maintained for about 40 to about 50 minutes to substantially restore the thickness of the foam block.

[0134] Embodiment 30: The bra garment of Embodiment 25, wherein the first cushioning support pad and the second cushioning support pad have a Shore 00 hardness value of at least about 20-70.

[0135] Embodiment 31: The bra garment of Embodiment 25, wherein the first cushioning support pad and the second cushioning support pad have a bio-based carbon content of about 40%-90%.

[0136] Embodiment 32: The bra garment of Embodiment 25, wherein the sheet formed by the cutting process is composed of open-cell foam, and the density of the sheet has a value of about 0.020 to 0.045 g / cm3.

[0137] Embodiment 33: The bra garment of Embodiment 25, wherein the bio-based open-cell foam sheet is laminated on at least one side thereof, the laminate comprising:

[0138] natural or synthetic fabrics;

[0139] The adhesive attaching the fabric to the foam sheet had a curing and drying time of approximately 24 hours per laminated foam sheet.

[0140] Embodiment 34: The bra garment according to Embodiment 33, wherein the fabric used to laminate the foam sheet is composed of double-sided 72D ultra-fine brushed fabric.

[0141] Embodiment 35: The bra garment of Embodiment 33, wherein the fabric used to laminate the foam sheet consists of 100% polyester.

[0142] Embodiment 36: The bra garment of Embodiment 33, wherein the adhesive consists of NEL-1018 hot melt polyurethane adhesive, which preferably has a viscosity of about 8,000 to about 12,000 cps / 100°C.

[0143] Embodiment 37: The bra garment of Embodiment 33, wherein the adhesive is applied to the foam sheet in an amount of about 25 grams per square meter.

[0144] Embodiment 38: The bra garment of Embodiment 33, wherein each of the foam sheets is laminated using a fabric laminating roller maintained at a temperature of about 95°C.

[0145] Embodiment 39: The bra garment of Embodiment 25, wherein each of the cushioning support pads has no laminate or adhesive layer on at least a back side thereof.

[0146] Embodiment 40: A method of making a bio-based open-cell foam block for use in a cushioning support pad for a bra garment or other garment, comprising:

[0147] One or more bio-based foam materials, the materials comprising at least about 40-85% bio-based EVA and bio-based PE, the bio-based EVA and bio-based PE being made primarily from sugarcane-based ethylene;

[0148] The bio-based EVA and bio-based PE are combined with at least a peroxide-based initiator and a blowing agent;

[0149] The bio-based EVA, bio-based PE, peroxide-based initiator and blowing agent mixture is formed into a substantially flat sheet by the following method, the method comprising:

[0150] heating the mixture to a temperature between about 105° C. and about 130° C. to form a molten mixture, extruding the molten mixture to form the mixture into a shape, maintaining the shape at a temperature of at least about 60° C. to about 90° C. during extrusion, and compressing the shape to form a substantially flat sheet;

[0151] Expanding the volume of the substantially planar sheet by a heating method comprising:

[0152] heating the sheet to about 135° C. to about 150° C. for about 30 to 45 minutes to obtain a substantially cross-linked foam material with limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 to about 150 minutes to obtain a significant volume expansion to form a bio-based foam block;

[0153] The bio-based foam block is crushed by a multiple roller pressing process, which comprises:

[0154] The bio-based foam block is pressed between press rollers at least about 4 times to release a large amount of air from the interior of the bio-based foam block, thereby forming an open-cell foam block.

[0155] Embodiment 41: The method according to embodiment 40, wherein after the rolling process, the foam block is heated to between about 165°C and about 175°C for about 40 to about 50 minutes to substantially restore the thickness of the foam block.

[0156] Embodiment 42: The method of Embodiment 40, wherein the bio-based EVA and bio-based PE are also combined with an olefin block copolymer.

[0157] Embodiment 43: The method of Embodiment 40, wherein the bio-based foam material comprises at least about 40-85% bio-based EVA, wherein the bio-based EVA is substantially made of sugarcane-based ethylene.

[0158] Embodiment 44: The method of Embodiment 43, wherein the bio-based EVA is further combined with an olefin block copolymer.

[0159] It is obvious to those skilled in the art who benefit from the teachings presented in the foregoing description and the related drawings that various modifications, combinations, recombinations and changes can be made without departing from the spirit or scope of the present disclosure. Similarly, the various examples described in this application can be used alone or in combination with other examples. It will be understood by those skilled in the art that various combinations of examples not specifically described or shown herein still fall within the scope of the present disclosure. In this regard, it should be understood that the present disclosure is not limited to the specific examples set forth, and the examples of the present disclosure are only used for illustration and do not constitute any limitation.

[0160] The following are some definitions and terms used in this disclosure:

[0161] EVA: In this disclosure, "EVA" is "ethylene vinyl acetate" as known and used in the art

[0162] (ethylene-vinyl-acetate), is a flexible, petroleum-based polymer that can be used to make materials and products with rubber-like softness and flexibility.

[0163] Bio-based EVA: In this disclosure, "bio-based EVA" is used to describe a carbon-negative material made primarily from sugar cane (sugar cane ethanol) that is used as a replacement and / or substitute for petroleum-based polymers. Existing bio-based EVA materials are commercially available and supplied by Braskem as EVA resins. Preferred resins are EVA Evance SVT 2145 and SVT 2180, which are typically supplied in the form of foam sheets for use in soles of footwear products, or for use in toys and furniture.

[0164] Polyethylene ("PE"): In this disclosure, "polyethylene" or "PE" is used to describe a synthetic resin made by polymerizing ethylene. Polyethylene is an important member of the polyolefin resin family and is one of the most widely used plastics in the world, being made into a variety of products ranging from transparent food packaging and shopping bags to detergent bottles and automobile fuel tanks. It can also be cut or spun into synthetic fibers, or modified to have the elasticity of rubber.

[0165] Bio-based PE: In this disclosure, "bio-based PE" is used to describe polyethylene synthetic resins that use a high proportion of renewable raw materials (such as sugar cane) as raw materials.

[0166] Open Cell Foam: In this disclosure, "open cell foam" is used to describe a foam material that consists of a series of interconnected open structure cells, which enhances the resilience of the cells. When compressed, the cells collapse tightly together in any direction, and when the compression is released, the air enters to allow the cushion to quickly return to its original state. The open cells are less prone to rupture, so they have excellent performance over long-term use. Open cell foams are generally less dense than closed cell foams, but depending on the application, the composition of the cushion can be changed to increase the density.

[0167] Closed Cell Foam: As used in this disclosure, “closed cell foam” consists of a series of closed air pockets, similar to a small balloon or rubber ball compressed within a rubber membrane. When compressed, the air is released through the cell walls and the air pockets are squeezed into a small disk shape. When the compression is released, the air re-enters through the cell walls at a slower rate than the open cells. Because of this property, closed cells tend to be harder or stronger, resulting in excellent moisture resistance, making them ideal for use in wet applications such as gaskets and insulation. Similar to open cell fillers, the composition of closed cell foams can be varied to adjust their density, rigidity, compression resistance, and other properties. Hydrogen Peroxide or Bis(trifluoromethyl) Peroxide: As used in this disclosure, “hydrogen peroxide” or “bisperoxide” is used to describe chemicals used as initiators (or catalysts) for unsaturated ethylene-based molecules in the production of stable polymer materials, including initiators used when using bio-based EVA and PE to prepare cross-linked open cell foams with enhanced mechanical properties. Examples of suitable open cell foam cross-linking peroxides are BC-FF (Nouryon) and 802 (Arkema). Blowing agent or foaming agent: In this disclosure, "blowing agent" or "foaming agent" is used to describe a chemical composition used in state-of-the-art polymerization processes, usually azodicarbonamide, which is capable of producing a porous structure through a foaming process to reduce the density of the matrix polymer and increase the relative stiffness of the matrix polymer. It has been determined that more environmentally friendly compositions, such as sodium bicarbonate (Alve-One TM , commercially available from Solvay), can also be used as an effective blowing agent or foaming agent to form bio-based EVA and PE open-cell foams. Another example of a suitable commercially available foaming agent is Hydrocerol (Avient).

[0168] Zinc Oxide - In this disclosure, "zinc oxide" is used to describe substances known in the art as "accelerators" which are typically added to formulations to assist in heat flow distribution within the foam and to reduce the temperature of the blowing or foaming agent (e.g., azodicarbonamide) during the blowing or foaming process.

[0169] Titanium Dioxide or Titanium IV Oxide [TiO2] - In this disclosure, "titanium dioxide" or "titanium IV oxide" is used to describe a material commonly used as a pigment in paints and polymers (also known as "titanium white").

[0170] Shore Hardness / Asker Hardness - In this disclosure, "Shore Hardness" and "Asker Hardness" are terms used to describe the hardness measurement of a given material (or its resistance to permanent indentation), usually measured as the depth of the indentation produced by applying a specific force to the material. The commonly used measuring instrument is called a durometer, and different scales for measuring hardness (such as Asker, Shore, Rockwell scales) are known in the art. Different hardness scales are used to measure the firmness of materials with different properties, such as rubbers, polymers, and elastomers. The most commonly used scale for measuring the hardness of rubber materials is the Asker C for softer materials.

[0171] The A and Shore 00 or A scales, and the Shore D scale for harder materials. The ASK C, ASK F, and Shore 00 scales are often used to measure the hardness of more flexible foam or rubber materials.

[0172] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Similarly, the adjective "another," when used to introduce an element, is intended to mean one or more elements. The terms "comprising," "including," "having," and similar terms are intended to be inclusive, and thus there may be additional elements in addition to the listed elements.

[0173] Furthermore, if the method described above does not explicitly require that its steps follow a certain order, or if a certain order is not required by the description or claim language, no particular order should be inferred. Similarly, if the following method claim does not explicitly recite a step mentioned in the above description, it should not be assumed that the step is required by the claim.

[0174] It should be noted that geometric or relational terms may be used in the specification and claims. These terms are not intended to limit the present disclosure and are generally used only for convenience of description so that the description can be made based on the examples in the drawings. In addition, geometric or relational terms may not be precise. For example, due to surface roughness, tolerances allowed during manufacturing, etc., the walls may not be completely vertical or parallel to each other, but may still be considered vertical or parallel.

Claims

1. A bio-based cushioning support pad for a bra garment or other garments, comprising: a cushion portion formed from one or more bio-based foam materials, the material comprising at least about 40-85% bio-based EVA and bio-based PE, the bio-based EVA and bio-based PE being primarily formed from sugarcane-based ethylene; The bio-based EVA and bio-based PE are combined with at least a peroxide-based initiator and a blowing agent; The bio-based EVA, bio-based PE, peroxide-based initiator, and blowing agent mixture is formed into a substantially flat sheet by a method comprising: heating the mixture to a temperature between about 105° C. and about 130° C. to form a molten mixture, extruding the molten mixture to form the mixture into a shape, maintaining the shape at a temperature of at least about 60° C. to about 90° C. during extrusion, and compressing the shape to form a substantially flat sheet; Expanding the volume of the substantially planar sheet by a heating method comprising: heating the sheet to about 135° C. to about 150° C. for about 30 to 45 minutes to obtain a substantially cross-linked foam material with limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 to about 150 minutes to obtain a significant volume expansion to form a bio-based foam block; The bio-based foam block is crushed by a multiple roller pressing process, which comprises: squeezing the bio-based foam block between press rollers at least about 4 times to release a large amount of air from the interior of the bio-based foam block, thereby forming an open-cell foam block; cutting the open-cell foam block into sheets; forming the bio-based open-cell foam sheet into a cushioning portion, The cushion portion is formed in a mold into a shape in which an inner surface is substantially concave and an outer surface is substantially convex.

2. The bio-based cushioning support pad of claim 1, wherein the bio-based EVA and bio-based PE are further combined with an olefin block copolymer.

3. The bio-based cushioning support pad of claim 1, wherein the bio-based foam material comprises at least about 40-85% bio-based EVA, the bio-based EVA being made substantially of sugarcane-based ethylene.

4. The bio-based cushioning support pad of claim 3, wherein the bio-based EVA is combined with an olefin block copolymer.

5. The bio-based cushioning support pad of claim 1, wherein after the rolling process, the foam block is heated to between about 165°C and about 175°C and maintained for about 40 to about 50 minutes to substantially restore the thickness of the foam block.

6. The bio-based cushioning support pad of claim 1, wherein the pad portion has a Shore 00 hardness value of at least about 20 to 70.

7. The bio-based cushioning support pad of claim 1, wherein the pad portion has a bio-based carbon content of about 40% to about 90%.

8. The bio-based cushioning support pad of claim 1, wherein the sheet formed by the cutting method is composed of open-cell foam, and the density of the sheet is about 0.020 to 0.045 g / cm 3 .

9. The bio-based cushioning support pad of claim 1, wherein the pad portion is formed by molding, the method comprising: The bio-based open-cell foam board is heated in a mold to about 70° C. to about 120° C., and a first pressing is performed for a duration of about 80 to about 140 seconds; The bio-based foam board is reheated in the mold to about 20° C. to about 60° C. and pressed a second time for about 60 to about 120 seconds, and Cooling the bio-based foam board in the mold to about room temperature for a duration of about 30 seconds to about 70 seconds; Part of the cushion portion is formed in the mold to have an inner surface that is substantially concave and an outer surface that is substantially convex.

10. A method for making a bio-based cushioning support pad for a bra garment or other garments, comprising: at least one cushion portion made from one or more bio-based foam materials, the material comprising at least about 40% to 85% bio-based EVA and bio-based PE, the bio-based EVA and bio-based PE being formed primarily from sugarcane-based ethylene; The bio-based EVA and bio-based PE are combined with at least a peroxide-based initiator and a foaming agent; The mixture of bio-based EVA, bio-based PE, peroxide-based initiator and blowing agent is formed into a substantially flat sheet by the following method, the method comprising: heating the mixture to a temperature between about 105° C. and about 130° C. to form a molten mixture, extruding the molten mixture to form the mixture into a shape, maintaining the shape at a temperature of at least about 60° C. to about 90° C. during extrusion, and compressing the shape to form a substantially flat sheet; Expanding the volume of the substantially planar sheet by a heating method comprising: heating the sheet to about 135° C. to about 150° C. for about 30 to 45 minutes to obtain a substantially cross-linked foam material with limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 to about 150 minutes to obtain a significant volume expansion to form a bio-based foam block; The bio-based foam block is crushed by a multiple roller pressing process, which comprises: squeezing the bio-based foam block between press rollers at least about 4 times to release a large amount of air from the interior of the bio-based foam block, thereby forming an open-cell foam block; cutting the open-cell foam block into sheets; forming the bio-based open-cell foam sheet into a cushioning portion, The cushion portion is formed in a mold into a shape in which an inner surface is substantially concave and an outer surface is substantially convex.

11. The method of claim 10, wherein the bio-based EVA and bio-based PE are further combined with an olefin block copolymer.

12. The method of claim 10, wherein the bio-based foam material comprises at least about 40%-85% bio-based EVA, the bio-based EVA being made substantially from sugarcane-based ethylene.

13. The method of claim 12, wherein the bio-based EVA is combined with an olefin block copolymer.

14. The method according to claim 10, wherein: After the rolling process, the foam block is heated to between about 165° C. and about 175° C. for about 40 to about 50 minutes to substantially restore the thickness of the foam block.

15. The method of claim 10, wherein the pad portion has a Shore 00 hardness value of at least about 25 to 65.

16. The method of claim 10, wherein the liner portion has a bio-based carbon content of about 50% to about 90%.

17. The method of claim 10, wherein the cushion portion is formed by molding, the method comprising: The bio-based open-cell foam board is heated in a mold to about 70° C. to about 120° C., and a first pressing is performed for a duration of about 80 to about 140 seconds; The bio-based foam board is reheated in the mold to about 20° C. to about 60° C. and pressed a second time for about 60 to about 120 seconds, and Cooling the bio-based foam board in the mold to about room temperature for a duration of about 30 seconds to about 70 seconds; Part of the cushion portion is formed in the mold to have an inner surface that is substantially concave and an outer surface that is substantially convex.

18. A bra garment, comprising: a first cup portion and a second cup portion made of one or more recyclable flexible materials; a first side panel and a second side panel extending from the first cup portion and the second cup portion, respectively; as well as a first cushioning support pad and a second cushioning support pad configured to be connected to the first cup portion and the second cup portion, respectively, each of the pads having a front surface and a rear surface, the front surface of each pad having a generally convex shape and the rear surface of each pad having a generally concave shape; Each of said pads is made of a bio-based open-cell foam material having a hardness and density value that provides cushioning and support to the breasts of a wearer of the bra garment; The bio-based open-cell foam material comprises at least about 60-85% of a bio-based EVA and a bio-based PE blend, wherein the bio-based EVA and the bio-based PE blend is primarily formed from sugarcane-based ethylene; The bio-based EVA and bio-based PE mixture is combined with at least a peroxide-based initiator and a blowing agent; The bio-based EVA, bio-based PE, peroxide-based initiator and blowing agent mixture is formed into a substantially flat sheet by the following method, the method comprising: heating the mixture to a temperature between about 105° C. and about 130° C. to form a molten mixture, extruding the molten mixture to form the mixture into a shape, maintaining the shape at a temperature of at least about 60° C. to about 90° C. during extrusion, and compressing the shape to form a substantially flat sheet; Expanding the volume of the substantially planar sheet by a heating method comprising: heating the sheet to about 135° C. to about 150° C. for about 30 to 45 minutes to obtain a substantially cross-linked foam material with limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 to about 150 minutes to obtain a significant volume expansion to form a bio-based foam block; The bio-based foam block is crushed by a multiple roller pressing process, which comprises: squeezing the bio-based foam block between press rollers at least about 4 times to release a large amount of air from the interior of the bio-based foam block, thereby forming an open-cell foam block; cutting the open-cell foam block into sheets; forming the bio-based open-cell foam sheet into a cushioning portion, The cushion portion is formed in a mold into a shape in which an inner surface is substantially concave and an outer surface is substantially convex.

19. The bra garment of claim 18, wherein the bio-based EVA and bio-based PE are further combined with an olefin block copolymer.

20. The bra garment of claim 18, wherein the bio-based foam material comprises at least about 40-85% bio-based EVA, the bio-based EVA being made substantially from sugarcane-based ethylene.

21. The bra garment of claim 20, wherein the bio-based EVA is combined with an olefin block copolymer.

22. The bra garment of claim 18, wherein after the rolling process, the foam block is heated to between about 165°C and about 175°C for about 40 to about 50 minutes to substantially restore the thickness of the foam block.

23. The bra garment of claim 18, wherein the first cushioning support pad and the second cushioning support pad have a Shore 00 hardness value of at least about 20 to 70.

24. The bra garment of claim 18, wherein the first cushioning support pad and the second cushioning support pad have a bio-based carbon content of about 40%-90%.

25. The bra garment of claim 18, wherein the sheet formed by the cutting process is comprised of open-cell foam, the sheet having a density value of about 0.020 to about 0.045 g / cm 3 .

26. A method of making a bio-based open-cell foam block for use in a cushioning support pad for a bra garment or other garment, comprising: One or more bio-based foam materials, the materials comprising at least about 40-85% bio-based EVA and bio-based PE, the bio-based EVA and bio-based PE being made primarily from sugarcane-based ethylene; The bio-based EVA and bio-based PE are combined with at least a peroxide-based initiator and a blowing agent; The mixture of bio-based EVA, bio-based PE, peroxide-based initiator and blowing agent is formed into a substantially flat sheet by the following method, the method comprising: heating the mixture to a temperature between about 105° C. and about 130° C. to form a molten mixture, extruding the molten mixture to form the mixture into a shape, maintaining the shape at a temperature of at least about 60° C. to about 90° C. during extrusion, and compressing the shape to form a substantially flat sheet; Expanding the volume of the substantially planar sheet by a heating method comprising: heating the sheet to about 135° C. to about 150° C. for about 30 to 45 minutes to obtain a substantially cross-linked foam material with limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 to about 150 minutes to obtain a significant volume expansion to form a bio-based foam block; The bio-based foam block is comminuted by a multiple roller pressing process, comprising: The bio-based foam block is pressed between press rollers at least about 4 times to release a large amount of air from the interior of the bio-based foam block, thereby forming an open-cell foam block.

27. The method of claim 26, wherein after the rolling process, the foam block is heated to between about 165°C and about 175°C for about 40 to about 50 minutes to substantially restore the thickness of the foam block.

28. The method of claim 26, wherein the bio-based EVA and bio-based PE are further combined with an olefin block copolymer.

29. The method of claim 26, wherein the bio-based foam material comprises at least about 40%-85% bio-based EVA, the bio-based EVA being made substantially from sugarcane-based ethylene.

30. The method of claim 29, wherein the bio-based EVA is further combined with an olefin block copolymer.

Images