Sustainable bra garment and improved bio-based open cell foam pad portion

Abstract

To provide a bra garment including an improved bra pad portion made of a bio-based polymer open cell foam material.SOLUTION: A sustainable bra garment includes first and second cup portions formed of one or two or more flexible recycled materials and first and second side wing panels extending from the first and second cup portions and has first and second cushioning support pads formed of a bio-based foam materials having a very soft open cell structure. The first and second side wing panels are formed of one or two or more recyclable soft materials. The first and second cushioning support pads are configured to be coupled with the first and second cup portions, and each pad has a front face and a back face. The front face of each pad has a generally convex shape and a back face of each pad has a generally concave shape. Each pad is formed of an environmentally friendly bio-based material such as sugarcane-based open cell foam material.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] This application relates generally to bra garments, and more particularly to bra garments that include improved bra padding portions formed from a bio-based polymeric open cell foam material as opposed to petroleum-based foam padding materials. [Background technology]

[0002] Generally, women wear bras to support and improve the shape and appearance of their breasts. Other garments may have built-in bras to provide the same function. It is important for the bra to provide proper support to the wearer, which in turn dictates the type of material that can be used for the bra padding, which is typically made of petroleum-based polymer foams that are not renewable or biodegradable, among other things, to provide the desired shape and support. Thus, foam padding is typically attached to the bra using adhesives. However, foam materials and adhesives can be harmful to humans during the manufacturing process as well as to the wearer, and are not renewable or environmentally friendly. Thus, there is a need for improved environmentally friendly bra garments, especially bra garments with foam padding portions made of renewable and / or bio-based materials that make the bra product environmentally friendly and sustainable. The improved bio-based renewable support padding of the present invention can be used with bra garments or with other garments, such as swimwear and other garments that can incorporate bra support padding.

[0003] The applicant and the present inventors have described and claimed in U.S. Patent No. 11,330,849 (issued May 17, 2022) a bra garment formed of a bio-based ethylene vinyl acetate ("EVA") foam consisting essentially of a bio-based ethanol component having 60-85% sugarcane-based ethanol, with the remaining EVA foam utilizing a cup portion having fossil fuel-based ethanol and vinyl acetate resulting in an EVA foam having a closed-cell structure ("Closed Cell Foam"), which is incorporated herein by reference. There is a need for further improved bra cup portions that include an increased percentage of bio-based polymeric material having an open cell structure ("closed cell foam") as shown in the present invention, such that a preferred percentage of bio-based EVA is combined with a preferred percentage of bio-based polyethylene ("bio-based PE") to form an open cell foam for forming the bra cup portion that is softer yet provides sufficient structural support than that described and claimed in U.S. Patent No. 11,330,849. The bio-based polymeric material can also include a preferred percentage of bio-based EVA alone to form an open cell foam for forming the bra cup portion of the present invention that is softer yet provides sufficient structural support. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Pat. No. 11,330,849 Summary of the Invention

[0005] The present disclosure may provide a sustainable bra garment including first and second cup portions including bra pad portions formed from one or more bio-based open cell foam materials, and first and second side wing panels extending from the first and second cup portions, respectively, formed from a flexible recycled material. The first and second cup portions are configured to have first and second cushioning support pads coupled thereto, respectively. Each bra pad portion has a front and a back surface, the front surface of each pad having a generally convex shape, and the back surface of each pad having a generally concave shape. Each pad is formed from a bio-based open cell foam material having hardness and density values ​​that provide both cushioning and support to the breasts of a wearer of the bra garment. Pads formed from bio-based open cell foam materials may also be used in other types of garments and garments, such as bras, maternity bras, sports bras, swimwear, camisoles, bustiers, t-shirts, and other garments that may incorporate bra support pads.

[0006] In some embodiments, the open cell bio-based foam material is comprised of a sugarcane-based polymeric foam material formed from a blend of bio-based EVA and bio-based PE (among other materials) that are not harmful to the wearer. Each pad may also not include a lamination or adhesive layer on at least its rear surface, and one or more recycled materials of the first and second cup portions and the first and second side wing panels are one or more recycled fabrics, and / or the first and second cup portions and the first and second side wing panels are formed of the same recycled fabrics.

[0007] In other embodiments, the bra garment further includes elastic shoulder straps attached between the first cup portion and the first side wing panel and between the second cup portion and the second side wing panel, respectively, the elastic shoulder straps being formed from recycled materials, each of the shoulder straps including an adjustable element for adjusting a length of the shoulder strap, the adjustable element being formed from a sustainable material having a hardness value higher than a hardness value of the sustainable material of the pad, each of the first and second cup portions having an underwire channel, the bra garment further includes a bridge panel connecting the first and second cup portions, the bridge panel being formed from recycled materials, and / or free ends of the first and second side wing panels including corresponding fastening elements for fastening the free ends to one another.

[0008] The present disclosure primarily provides first and second cushioning support pads comprised of bio-based open cell foam that are retained in receiving areas of first and second cup portions, respectively, of a bra garment. Each pad has a front and a rear surface that correspond to the outer and inner elements of the first and second cup portions, respectively. The front surface of each pad has a generally convex shape, and the rear surface of each pad has a generally concave shape. Each pad is formed exclusively from bio-based materials that have hardness and density values ​​that provide both cushioning and support to the breasts of a wearer of the sustainable bra garment.

[0009] In a preferred embodiment, the padding portion can be manufactured from environmentally friendly materials such as sugarcane-based polymers, known in the art as green or bio-based EVA materials. Bio-based EVA materials are well known in the art and have already been developed and used to produce soles for several 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, the present invention has discovered that bio-based EVA materials can be more specifically formulated and processed to produce a flexible and structurally stable foamed polymeric material suitable for use as a bra pad. The present invention discloses a preferred foaming method used in forming molded bra pad products from bio-based EVA that have the flexibility and structural qualities of petroleum-based EVA, but are renewable after the useful life of the padding of a typical bra pad product has been reached. Also, an outer element of each cup portion can be formed from recycled nylon and an inner element of each cup portion is formed from recycled polyester, the bra garment includes elastic shoulder straps attached between the first cup portion and the first side wing panel and between the second cup portion and the second side wing panel, respectively, the elastic shoulder straps being formed from recycled fabric, and / or each of the first and second cup portions has an underwire channel and a bridge panel joins the first and second cup portions, both of which are formed from recycled materials.

[0010] Traditional fossil-based foams (such as polyurethane foams) are produced from compounded gum rubber by sheeting, molding and extrusion processes and are formulated using a number of ingredients including chemicals, liquid polymers such as polyols, polyisocyanates, toluene diisocyanates, additives that act as catalysts to increase production rates, and blowing agents to form cells during foam formation. Surfactants such as silicones or polyethers are also used to control the size of the cells. The physical properties of traditional fossil-based foams depend on the alloy composition and reaction temperature during production.

[0011] The present disclosure provides a sustainable bra garment including a first cup portion and a second cup portion having a cushioning support pad formed from a bio-based open cell foam that is substantially free of fossil fuel-based materials. Each of the first and second cup portions has an outer element and an inner element. The inner and outer elements are attached to each other at their respective peripheries to form a pad receiving area therebetween. The inner and outer elements are formed from one or more recycled fabrics. First and second side wing panels extend from the first and second cup portions, respectively. The first and second side wing panels are formed from one or more recycled fabrics. The first and second cup portion receiving areas hold first and second cushioning support pads, respectively. Each pad has a front surface and a rear surface corresponding to the outer and inner elements of the first and second cup portions, respectively. The front surface of each pad has a generally convex shape and the rear surface of each pad has a generally concave shape. As disclosed herein, each pad is formed from a bio-based open cell foam that is non-toxic to the wearer and has firmness and density values ​​that provide both cushioning and support to the chest of the wearer of the sustainable bra garment. Substantially each portion of the sustainable bra garment is formed from either recycled or bio-based materials.

[0012] In some embodiments, the bra garment further includes elastic shoulder straps attached between the first cup portion and the first side wing panel and between the second cup portion and the second side wing panel, respectively, the elastic shoulder straps may be formed of recycled fabric, each of the shoulder straps includes an adjustable element for adjusting a length of the shoulder strap, the adjustable element is formed of a sustainable material having a hardness value higher than a hardness value of the sustainable material of the pad, and / or each of the first and second cup portions may have an underwire channel, the first and second cup portions are connected by a bridge panel, the free ends of the first and second side wing panels include corresponding fastening elements for fastening the free ends together, the underwire channel, the bridge panel and the fastening element may be formed of recycled material.

[0013] This summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining the scope of the claimed subject matter. It should be understood that both the foregoing summary and the following detailed description are exemplary and intended to provide an overview or framework for understanding the nature and character of the present disclosure.

[0014] The accompanying drawings are incorporated in and constitute a part of this specification. The drawings show only some examples of the present disclosure, and it is to be understood that other embodiments or combinations of various embodiments not specifically shown are also included within the scope of the present disclosure. The embodiments are described in more detail below using the drawings. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 is a front or exterior elevation view of an exemplary sustainable bra garment according to the present disclosure. [Diagram 2] FIG. 2 is a rear or inner elevation view of the sustainable bra garment shown in FIG. 1. [Diagram 3] 1 is a front or exterior elevation view of another exemplary sustainable bra garment according to the present disclosure. FIG. [Figure 4] FIG. 4 is a rear or inner elevation view of the sustainable bra garment shown in FIG. 3. [Diagram 5] FIG. 2 is an enlarged partial cross-sectional view of a cup of a sustainable bra garment according to the present disclosure. [Figure 6a] FIG. 1 is a side perspective view of a molten mixture of bio-based foam material during a single screw extrusion step that forms the mixture into a shape. [Figure 6b] FIG. 1 is a perspective view of a foam block (or bun) of bio-based foam material before undergoing multiple crushing steps through a compression roller process that transitions the foam into an open cell structure. [Figure 6c] FIG. 2 is a perspective view of a foam block (bun) of bio-based foam material after the crushing process and heating in an oven to restore the thickness of the foam block. [Figure 6d] FIG. 1 is a front perspective view of a bio-based open cell foam sheet used to form one or more pads made in accordance with the present disclosure. [Figure 7] FIG. 7 is a front perspective view of a pad portion formed in part from the bio-based open cell foam sheet shown in FIG. 6 made in accordance with the present disclosure. [Figure 8] FIG. 2 is a front or elevation view of a finished pad made in accordance with the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Referring to the figures, the present disclosure generally relates to a bra garment 100 formed from sustainable recycled materials that are environmentally friendly and non-harmful to the wearer to promote health and wellness. The bra garment 100 can be, for example, a bra, a sports bra, a maternity bra, a brassiere, a bikini top, a camisole, other lingerie top, or other garment such as a swimsuit that covers the breasts.

[0017] The bra garment 100 may generally include cup portions 102a, 102b, side wing panels 104a, 104b extending from the respective cup portions 102a, 102b, and padding 108 for the cup portions 102a, 102b. Shoulder straps 106a, 106b may also be provided connecting between the cup portions 102a and the side wing panels 104a and connecting between the cup portions 102b and the side wing panels 104b. The padding 108 is formed from a bio-based material that provides both cushioning and support to the wearer's breasts. The remainder of the bra garment 100 may be formed from recycled and / or sustainable materials. Thus, the bra garment 100 may be formed entirely or substantially entirely from sustainable bio-based and recycled materials.

[0018] The sustainable materials according to the present disclosure are bio-based open cell foam materials that are not harmful to the wearer, and may be free of fossil fuel-based foam materials, etc. The sustainable materials used to form the padding 108 may have, for example, sufficient hardness and density values ​​to provide both cushioning and support to the wearer. Additionally, the sustainable materials of the bra garment 100 may be manufactured by processes that are both sustainable and environmentally friendly.

[0019] The bio-based materials according to the present disclosure are eco-friendly, easy to use, climate adaptable, green, eco-conscious, eco-friendly, fuel-efficient, energy-efficient, non-polluting, organic, and energy-saving materials. Bio-based materials can be viable, continuous, sustainable, viable, perpetual, symbiotic, supportable, immortal, limitless, renewable, and environmentally friendly. Bio-based materials are produced based on available resources that meet the current needs while ensuring that sufficient resources are available for future generations. In some examples, the bio-based materials can be sugarcane, soy, or corn-based polymers. Biodegradable additives can also be added to the foam.

[0020] The cup portions 102a and 102b and the side wing panels 104a and 104b can be formed from recycled materials, such as recycled fabrics. Recycled materials according to the present disclosure are waste converted materials into usable materials. Recycled fabrics are waste materials or fabrics and textiles that can be sorted, graded and reused to re-form recycled fabrics, such as synthetic fibers like polyester and nylon.

[0021] As shown in FIG. 5, each of the cup portions 102a, 102b of the bra garment 100 has an outer element 120 and an inner element 122 that can be attached to one another at their respective edges, such as by sewing, to form a pad receiving area 124 therebetween in which the respective pads 108 are contained. The outer element 120 can have a generally convex shape selected from a number of available breast cup sizes. The inner element can have a generally concave shape selected from a number of available cup sizes. The outer and inner elements 120 and 122 are formed of one or more flexible materials. In one example, the outer element can be formed of nylon or recycled nylon, and the inner element can be formed of polyester or recycled polyester. The polyester can be brushed to increase softness against the wearer's skin.

[0022] Each of the pads 108 has a front surface 110 and a rear surface 112 that correspond to the outer and inner elements 120, 122, respectively, of the cup portions 102a, 102b. As best seen in Figure 5, 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. The size of the pads 108 can be any breast cup size and will generally correspond to the size of the outer and inner elements 120, 122, of the cup portions 102a, 102b.

[0023] Each of the pads 108 is formed of a sustainable material that is non-toxic to the wearer and that has hardness, rebound and density values ​​that provide both cushioning and support to the chest of the wearer of the sustainable bra garment. For example, the bio-based material of the pads 108 can be comprised of about 40%-85% bio-based EVA and PE open cell foam, or about 40%-85% EVA open cell foam. This proportion of bio-based material provides the pads 108 with the desired flexibility while providing comfort, cushioning and sufficient support to the wearer.

[0024] The open cell foam used in the pad 108 of the present invention is produced by a multi-step process of mixing, extruding, sheeting and molding from bio-based resin compounds that contain essentially bio-based EVA alone or a combination of bio-based EVA and PE as the resin base, and can be compounded using many ingredients, including additives that act as catalysts to increase the production rate, and blowing agents that form cells during compounding. The physical properties of the bio-based open cell foam depend on its composition and the reaction temperatures during the production steps.

[0025] As a further example of a preferred embodiment according to the present invention, the pad 108 is formed of a bio-based material using 25%-85% bio-based EVA and 5%-45% bio-based polyethylene ("PE"), both of which are essentially composed of sugarcane-based ethanol converted to ethylene. A small percentage of an olefin block copolymer, such as Dow Infuse 9107 Olefin Block Copolymer, can also be mixed with the bio-based EVA and PE to help control shrinkage and improve the elastic recovery of the resulting bio-based open cell foam. The bio-based EVA (bio-based ethylene and vinyl acetate from sugarcane) is mixed with the bio-based PE and olefin block copolymer, and then mixed with an initiator, such as hydrogen peroxide (or bis peroxide), and a blowing or foaming agent, such as azodicarbonamide, as well as other chemicals and additives known in the art, such as titanium dioxide, which can be used as a white color pigment. The following table shows a preferred formulation of the combination of bio-based EVA and PE used to form the pad 108 of the present invention, as well as other reference ingredients. TIFF2025079330000002.tif65150*PHR- is an acronym for "per hundred parts resin."

[0026] The following table shows the preferred formulations of the combination of bio-based EVA and PE, as well as the olefin block copolymers and other reference ingredients used to form the pad 108 of the present invention. TIFF2025079330000003.tif76150*PHR- is an acronym for "Percent Resin".

[0027] Further formulations for preferred embodiments according to the present invention can be used to form the pad 108 using bio-based materials having only bio-based EVA composed of sugarcane-based ethanol that is substantially converted to ethylene. The following table shows a preferred formulation of the bio-based EVA material and other reference ingredients used to form the pad 108 of the present invention. TIFF2025079330000004.tif62150

[0028] A bio-based material having only bio-based EVA can be combined with an olefin block copolymer, such as Dow Infuse 9107 Olefin Block Copolymer. The following table shows a preferred formulation of the bio-based EVA material, as well as the olefin block copolymer and other reference ingredients, used to form the pad 108 of the present invention. TIFF2025079330000005.tif79150

[0029] A preferred method of forming the bio-based open cell foam used in the pad 108 of the present invention involves heating a bio-based EVA / PE blend from room temperature to a temperature of about 105° C. (221° F.) to about 130° C. (266° F.) to form a molten mixture similar to a dough consistency. Such a mixture is then extruded in a single screw extruder. A preferred extrusion temperature is about 80° C. (176° F.) to about 90° C. (194° F.), which forms the mixture into a shape 113 as shown in FIG. 6a. Preferably, this shape 113 should be kept at a temperature of about 60° C. (140° F.) to about 90° C. (194° F.) (during the remainder of the extrusion process) to maintain the extruded shape, after which the shape should be compressed using a pass-through pressing belt to form a substantially flat sheet. The volumetric shape of the substantially flat sheet is then expanded by a two-stage heating process that includes: 1) heating the sheet to a temperature of about 135° C. (about 275° F.) to about 150° C. (about 300° F.) for a period of about 30 to 45 minutes to obtain a substantially crosslinked, preferably 100% crosslinked, foamed material limited to a moderate volume expansion; and 2) heating the sheet to a temperature of about 160° C. (about 320° F.) to about 185° C. (about 365° F.) for a period of about 90 to 150 minutes to obtain a substantial volume expansion. The volume expansion of the foamed shape can be about 36 to 38 times the original shape to form a foamed sheet. After the second heating process, it is preferred to expose the bio-based foamed sheet to a cooling process in the mold. A preferred cooling process can use cold water at about 15° C. (about 59° F.) for about 70 to 90 minutes. After completion of the second stage (heating) of the two-stage process, a block 114a is obtained having preferred dimensions of approximately 2.4 meters in length, approximately 1 meter in width, and approximately 90 millimeters in thickness.

[0030] The foam block (or bun) 114a is preferably kept at room temperature for about 24 hours before undergoing multiple crushing steps through a compression roller process as shown in FIG. 6b to obtain an open cell structure in the foam block 114a. A preferred compression roller process is performed by passing the foam block 114a through a compression roller machine for about two passes, so that the foam block 114a is crushed between the rollers at least about four times to release as much air as possible from the interior of the foam. The foam block can then be heated in an oven at a temperature of about 165° C. to 175° C. for 40 to 50 minutes, which restores the thickness of the foam block and results in an open cell foam block 114b as shown in FIG. 6c after the crushing process.

[0031] The open cell foam block is then cut or sliced ​​into thin sheets, preferably having a thickness of about 4 mm to about 13 mm. Figure 6d shows an example of the resulting bio-based open cell foam sheet 115 according to the present invention that can be used as a material to form one or more pads 108.

[0032] The foam sheet 115 has a hardness range of about 3 to about 50 on the Shore 00 scale, preferably about 6 to 25 on the Shore 00 scale, as measured by the ASTM D2240 standard.

[0033] The density of the foam sheet 115 is about 0.020 to about 0.045 g / cm using the ISO 845 test standard as the preferred method. 3 is in the range of about 0.025 to about 0.035 g / cm 3 It has also been found that the preferred density range is 115. The ISO 845 test standard is commonly used to describe the determination of specific gravity (relative density) and density of solid plastic samples in the form of sheets, rods, tubes, or molded articles such as the open cell foam sheet 115 described herein (FIG. 6d).

[0034] The bio-based foam sheet 115 can then be laminated with fabrics such as polyester, polyamide, nylon, polyester and nylon blends. An example of a preferred fabric is a 100% polyester double-sided 72D superfine brushed fabric. In a preferred lamination process, the fabric is bonded to the foam sheet using an adhesive such as NEL-1018 hot melt polyurethane adhesive with a preferred viscosity of 10,000 (±2,000 cps ("centipoise")) / 100°C. The preferred amount of adhesive is 25 grams per square meter of foam sheet at a fabric lamination temperature of 95°C. The preferred time period for completion of the lamination process, including curing and drying of the laminated foam sheet, is about 24 hours.

[0035] Next, the bio-based open cell foam sheet 115 is formed into partial pad portions 115a and 115b (FIG. 7). A preferred molding method for forming a standard cushion cup portion includes 1) heating a portion of the bio-based open-cell foamed sheet in the mold to about 70°C (160°F) to about 120°C (248°F) over a first press for a period of about 80 seconds to about 160 seconds, followed by 2) heating the bio-based open-cell foamed sheet in the mold to about 20°C (68°F) to about 60°C (140°F) over a second press for a period of about 60 seconds to about 120 seconds, and 3) cooling the bio-based open-cell foamed sheet at room temperature in the press for about 30 seconds to about 70 seconds, so that each partial pad portion (115a and 115b) is formed in a mold into a shape having a substantially concave inner surface and a substantially convex outer surface, the pad portion having a hardness value of about 20 to about 70 on the Shore 00 hardness scale, preferably about 35 to about 55 on the Shore 00 hardness scale. The process of FIG. 7 shows examples of partially formed pad portions 115a and 115b after the pad cup portion has been formed using the preferred molding method described above.

[0036] An example of a finished pad portion 108 formed according to the above process is shown in Figure 8. In addition to the preferred molding process described above, multiple molding process time and temperature variations can be employed to result in pad portions having various cup sizes and styles, such as the various methods for creating multiple styles in the table disclosed below. TIFF2025079330000006.tif65150

[0037] A number of such pad portion samples were subjected to ASTM test methods to evaluate a preferred range of hardness properties of the pad material. The samples were subjected to ASTM D2240 standard test method using a durometer having a Shore 00 scale to measure material hardness to determine the material hardness of each sample at various surface points in a cup size range of 32A to 44G (US standard size). After such hardness testing, a range of Shore 00 hardness values ​​of about 20 to about 70 was observed, with a preferred Shore 00 material hardness range of about 35 to about 55 found to provide both adequate cushioning and sufficient support for the breasts of a wearer of a sustainable bra garment or other garment incorporating such pad 108.

[0038] It was found that a bio-based carbon content of 77% was achievable in a sample of the finished pad section 108. The bio-based carbon content of the finished pad section sample was determined by standard ASTM D6866 (Method B) analysis, which indicates the percentage of carbon from "natural" (plant or animal by-product) sources versus "synthetic" (petrochemical) sources. For reference, 100% bio-based carbon indicates that the material was sourced entirely from plants or animal by-products, and 0% bio-based carbon indicates that the material contained no carbon from plants or animal by-products. Values ​​in between represent a mix of natural and fossil fuel sources as found in the finished pad section 108 described herein.

[0039] The front surface 110 of each pad 108 may also be laminated to aid in application of the outer elements 120 of the cup portions 102a, 102b. The rear surface 112 of each pad 108 may be free of lamination. Alternatively, each pad 108 may be completely free of lamination, i.e., on neither the front surface 110 nor the rear surface 112.

[0040] Connected to the outer edge of each cup portion 102a, 102b are side wing panels 104a, 104b, respectively. The side wing panels 104a, 104b can be made of one or more fabrics, such as nylon and recycled nylon. The side wing panels 104a, 104b can be made of the same or different recycled fabrics as those of the cup portions 102a, 102b. Recycled threads can also be used to sew the periphery of any portion or panel of the bra garment 100, such as the periphery 109 of the side wing panels 104a, 104b. The free ends of the side wing panels 104a, 104b include corresponding fastening elements 130 and 132, such as hook and eye elements, that fasten the free ends together in a conventional manner. The fastening elements 130 and 132 can be made of recycled materials, such as recycled metal for the hooks and fabric or thread for the holes.

[0041] The shoulder straps 106a, 106b can be formed of recycled materials, such as recycled elastic materials, such as recycled yarns, to provide flexibility and comfort to the wearer. Each shoulder strap 106a, 106b can be adjusted using an adjustable element, such as a corresponding ring and hook member 134, 136, which functions as known in the art. The ring and hook members 134, 136 can be formed of a sustainable material, such as sugar cane polymer. The sugar cane polymer of the ring and hook members 134, 136 is firmer and harder than the sugar cane polymer forming the pad 108. That is, the sugar cane polymer of the ring and hook members 134, 136 has a sufficient hardness value and stiffness to bond to and allow adjustment of the shoulder straps 106a, 106b.

[0042] As shown in Figures 1 and 2, the bra garment 100 can include an underwire, or as shown in Figures 3 and 4, the bra garment 100' can be underwire-free. The bra garment 100 has underwire channels 140a, 140b at the bottom of the supports 102a, 102b, respectively. The underwire channels 140a, 140b can be formed from a recycled fabric, such as recycled yarn, and are sized to receive a conventional underwire. A bridge panel 138 extends between the underwire channels 140a, 140b to connect the cup portions 102a, 102b. The bridge panel 138 can be formed from a recycled material, such as recycled nylon.

[0043] The bra garment 100' as shown in Figures 3 and 4 is substantially the same as the bra garment 100 of Figures 1 and 2, except that the bra garment 100' does not have an underwire or underwire channel. The cup portions 102a', 102b' of the bra garment 100' are the same as the cup portions 102a, 102b, except that the cup portions 102a, 102b' are sewn together at a center line 150 and a bottom line 152 using recycled yarn, as best seen in Figure 4. An optional lace trim 154 may be provided on the top of the cup portions 102a', 102b'. The lace trim 154 may be formed from recycled materials, such as recycled yarn.

[0044] It will be apparent to those skilled in the art having the benefit of the teachings set forth in the foregoing description and the associated drawings that modifications, combinations, subcombinations and variations may be made without departing from the spirit or scope of the present disclosure. Similarly, the various examples described may be used alone or in combination with other examples. Those skilled in the art will recognize various combinations of embodiments that are not specifically described or shown herein but are nevertheless within the scope of the present disclosure. In this regard, it is to be understood that the present disclosure is not limited to the specific examples described, and that the embodiments of the present disclosure are intended to be illustrative and not limiting.

[0045] In this disclosure, the following definitions and terminology are used: EVA As used in this disclosure, "EVA" is an acronym known and used in the art to refer to "ethylene vinyl acetate," an elastomeric petroleum-based polymer that can be used to produce materials and products that have rubber-like softness and flexibility. Bio-based EVA As used in this disclosure, "bio-based EVA" is used to describe a carbon-negative material made substantially from sugarcane (sugarcane ethanol) and used as an alternative 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 typically in the form of pellets and are certified as EVA Evance SVT2145 and SVT2180, which are processed to obtain foam sheets for use in soles of footwear products or in toys and furniture. Polyethylene ("PE") As used in this disclosure, "polyethylene" or "PE" is used to refer to a synthetic resin formed from the polymerization of ethylene. Polyethylene is an important member of the family of polyolefin resins and is one of the most widely used plastics in the world, processed into products ranging from clear food wraps and shopping bags to detergent bottles and automobile fuel tanks. Polyethylene can also be slit or spun into synthetic fibers or modified to take on the elastic properties of rubber. Bio-PE As used in this disclosure, "bio-based PE" is used to describe a polyethylene synthetic resin that has a high percentage of renewable feedstocks, such as sugar cane, as its starting material. Open Cell FoamAs used in this disclosure, "open cell foam" is used to describe a foam material composed of a series of interconnected cells with an open structure that enhances the elastic properties of the cells. When compressed, the cells collapse tightly against one another in all directions, and when compression is released, air flows in and the padding quickly returns to its original state. Open cells are less likely to break and perform better over time. Open cells are typically less dense than closed cell foams, but the composition of the padding can be altered to increase density in some applications. Closed Cell Foam : As used in this disclosure, "closed cell foam" is composed of a series of trapped hollow areas equivalent to small balloons or rubber balls compressed within a rubber membrane. When compressed, air escapes through the cell walls and the hollow areas collapse into small disks. When compressed, air re-enters through the cell walls at a slower rate than open cells. Because of this, closed cells tend to be rigid or stiff and have excellent moisture resistance, making them ideal for use in wet applications such as gasketing and insulation. The composition of closed cells can be modified to alter density, stiffness, compression resistance and other properties, similar to open cell pads. Hydrogen peroxide or bis(trifluoromethyl) peroxide As used in this disclosure, "hydrogen peroxide" or "bisperoxide" is used to refer to a chemical used as an initiator (or catalyst) for unsaturated ethylenic molecules in the production of stable polymeric materials, including bio-based EVA and PE as initiators, to result in crosslinked open-cell foams with enhanced mechanical properties. Examples of crosslinking peroxides suitable for open-cell foams are Perkadox® BC-FF (Nouryon) and Luperox® 802 (Arkema). Blowing Agent or Foaming AgentAs used in this disclosure, "Blowing Agent" or "Foaming Agent" is used to describe the chemical components used in state-of-the-art polymerization processes, typically azodicarbonamide, which can reduce the density of the base polymer and increase the stiffness ratio to generate cellular structures through the foaming process. It has also been found that more environmentally friendly compositions such as baking soda (Alve-One™ available from Solvay) can be used as an effective blowing agent for forming bio-based EVA and PE open-cell foams. Another suitable commercially available blowing agent is Hydrocerol (Avient). Zinc oxide As used in this disclosure, "zinc oxide" is used to describe what is known in the art as a "kicker," which is typically added to formulations to aid in heat flow distribution within the foam and reduce the temperature of blowing agents such as azodicarbonamide during the foaming process. Titanium dioxide or titanium dioxide IV (TiO2) As used in this disclosure, "titanium dioxide" or "titanium IV oxide" is used to describe a material typically used as a pigment for paints (also known as "titanium white") and polymers. Shore hardness / Asker hardness : "Shore hardness" and "Asker hardness" as used in this disclosure are terms used to describe the hardness scale of a given material (or how resistant it is to a permanent indentation) measured by the depth of indentation made on the material by a specified force. The measuring instrument typically used is known as a durometer, and different respective standards (such as Asker, Shore, Rockwell hardness scales) are known in the art for measuring hardness. Thus, different hardness standards are used to measure the robustness of different materials with various properties such as rubber products, polymers, and elastomers. The most commonly used standards for measuring the hardness of rubber materials are Asker C and Shore 00, or A scale for soft materials, and Shore D scale for hard materials. Generally, Asker C, Asker F, and Shore 00 scales are used to measure the hardness of highly flexible foam or rubber materials.

[0046] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly indicates otherwise. Similarly, the adjective "another," when used to introduce an element, is intended to mean one or more than one element. The terms "comprising," "including," "having," and similar terms are intended to be inclusive such that there may be additional elements other than the listed elements.

[0047] Additionally, where the methods described above do not explicitly require an order to follow its steps, or where no order is necessary based on the language of the specification or claims, no particular order is intended to be inferred. Similarly, if a step recited in the above description is not explicitly recited in a method claim below, that step should not be considered required for that claim.

[0048] In addition, geometric terms or related terms may be used in the specification and claims. These terms are not intended to limit the present disclosure, but are generally used for convenience to facilitate explanation based on examples shown in the drawings. In addition, the geometric terms or related terms may not be precise. For example, walls may be considered to be perpendicular or parallel, even though they may not be precisely perpendicular or parallel to each other due to surface roughness, tolerances allowed during manufacturing, etc. [Explanation of symbols]

[0049] 100, 100' Bra Clothing 102a', 102b' Cup part 104a, 104b Side wing panels 106a, 106b Shoulder strap 108 Pad 110 Front 112 Rear 120 outer element 122 Inner Elements 124 Pad Storage Area 130 Fastening elements 150 center line 152 Bottom Line 154 Lace Decoration

Claims

1. A bio-based cushioning support pad for use in a bra or other garment, comprising: a padding portion formed of one or more bio-based foam materials including at least about 40-85% bio-based EVA and bio-based PE formed substantially from sugarcane-based ethylene; The bio-based EVA and PE are at least A peroxide initiator, and Foaming agent, and the mixture of bio-based EVA, bio-based PE, peroxide-based initiator and blowing agent is applying heat to a temperature of about 105° C. to about 130° C. to form a molten mixture; extruding the molten mixture to form the mixture into a shape; maintaining said shape at a temperature of at least about 60° C. to about 90° C. during extrusion; compressing the shape to form a substantially flat sheet; formed into a substantially flat sheet by a process comprising: heating the sheet to about 135° C. to about 150° C. for about 30 minutes to about 45 minutes to obtain a substantially crosslinked foam material having limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 minutes to about 150 minutes to obtain a substantial volume expansion; expanding the volume of the substantially flat sheet by a heating method comprising: This is where the bio-based foam block is formed. crushing the bio-based foam block between compression rollers at least about four times to release a sufficient amount of air from within the bio-based foam block; crushing the bio-based foam block through a multiple compression roller process including: This is where the open-cell foam block is formed. cutting the open cell foam block into sheets; The bio-based open-cell foamed sheet is molded into a pad portion, the pad portion is formed in a mold into a shape having a substantially concave inner surface and a substantially convex outer surface. A bio-based cushioning support pad.

2. The bio-based EVA and PE are also combined with an olefin-based block copolymer; The bio-based cushioning support pad according to claim 1.

3. The bio-based foam material is comprised of at least about 40-85% bio-based EVA formed substantially from sugarcane-based ethylene; The bio-based cushioning support pad according to claim 1.

4. The bio-based EVA is combined with an olefin-based block copolymer; The bio-based cushioning support pad according to claim 3.

5. heating the foam block to about 165° C. to about 175° C. for about 40 minutes to about 50 minutes after the compression roller process to substantially restore the thickness of the foam block; The bio-based cushioning support pad according to claim 1.

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

7. The pad portion is comprised of about 40% to about 90% bio-based carbon content. The bio-based cushioning support pad according to claim 1.

8. The sheet formed by the cutting method has a hardness of about 0.020 to about 0.045 g / cm 3 The foam is made of an open-cell foam having a density of The bio-based cushioning support pad according to claim 1.

9. The pad portion is heating the bio-based open-cell foamed sheet in a mold to about 70°C to about 120°C for a first press period of about 80 seconds to about 140 seconds; reheating the bio-based foam sheet in the mold to about 20°C to about 60°C for a second press period of about 60 seconds to about 120 seconds; cooling the bio-based foam sheet in the mold to about room temperature over a period of about 30 seconds to about 70 seconds; The molding method includes the steps of: the partial pad portion is formed in the mold into a shape having a substantially concave inner surface and a substantially convex outer surface. The bio-based cushioning support pad according to claim 1.

10. The bio-based open-cell foamed sheet has at least one surface laminated, and the laminate layer is A natural or synthetic fabric; an adhesive for adhering the fabric to the foam sheet; Curing and drying each laminated foam sheet for about 24 hours; The bio-based cushioning support pad of claim 1 .

11. The fabric for laminating the foam sheet is made of a 72D ultra-fine raised fabric on both sides; The bio-based cushioning support pad according to claim 10.

12. The fabric for laminating the foam sheet is made of 100% polyester. The bio-based cushioning support pad according to claim 10.

13. The adhesive is comprised of NEL-1018 hot melt polyurethane adhesive having a preferred viscosity of about 8,000 to about 12,000 cps / 100°C; The bio-based cushioning support pad according to claim 10.

14. The adhesive is applied in an amount of about 25 grams per square meter of the foam sheet. The bio-based cushioning support pad according to claim 10.

15. Each of the foam sheets is laminated with a fabric lamination roller maintained at a temperature of about 95°C. The bio-based cushioning support pad according to claim 10.

16. Each of the cushioned support pads does not have a lamination layer or an adhesive layer at least on its rear surface. The bio-based cushioning support pad according to claim 1.

17. 1. A method for making a bio-based cushioning support pad for use in a bra or other garment, comprising: The bio-based cushioned support pad includes at least one pad portion formed of one or more bio-based foam materials including at least about 40-85% bio-based EVA and bio-based PE formed substantially from sugarcane-based ethylene; The bio-based EVA and PE are at least A peroxide initiator, and Foaming agent, and the mixture of bio-based EVA, bio-based PE, peroxide-based initiator and blowing agent is applying heat to a temperature of about 105° C. to about 130° C. to form a molten mixture; extruding the molten mixture to form the mixture into a shape; maintaining said shape at a temperature of at least about 60° C. to about 90° C. during extrusion; compressing the shape to form a substantially flat sheet; formed into a substantially flat sheet by a process comprising: heating the sheet to about 135° C. to about 150° C. for about 30 minutes to about 45 minutes to obtain a substantially crosslinked foam material having limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 minutes to about 150 minutes to obtain a substantial volume expansion; expanding the volume of the substantially flat sheet by a heating method comprising: This is where the bio-based foam block is formed. crushing the bio-based foam block between compression rollers at least about four times to release a sufficient amount of air from within the bio-based foam block; crushing the bio-based foam block through a multiple compression roller process including: This is where the open-cell foam block is formed. cutting the open cell foam block into sheets; The bio-based open-cell foamed sheet is molded into a pad portion, the pad portion is formed in a mold into a shape having a substantially concave inner surface and a substantially convex outer surface. A method comprising:

18. The bio-based EVA and PE are also combined with an olefin-based block copolymer.

20. The method of claim 17.

19. The bio-based foam material is comprised of at least about 40% to 85% bio-based EVA formed substantially from sugarcane-based ethylene; 20. The method of claim 17.

20. The bio-based EVA is combined with an olefin-based block copolymer; 20. The method of claim 19.

21. heating the foam block to about 165° C. to about 175° C. for about 40 minutes to about 50 minutes after the compression roller process to substantially restore the thickness of the foam block; 20. The method of claim 17.

22. the pad portion having a Shore 00 hardness value of at least about 25 to about 65; 20. The method of claim 17.

23. The pad portion is comprised of about 50% to about 90% bio-based carbon content.

20. The method of claim 17.

24. The pad portion is heating the bio-based open-cell foamed sheet in a mold to about 70°C to about 120°C for a first press period of about 80 seconds to about 140 seconds; reheating the bio-based foam sheet in the mold to about 20°C to about 60°C for a second press period of about 60 seconds to about 120 seconds; cooling the bio-based foam sheet in the mold to about room temperature over a period of about 30 seconds to about 70 seconds; The molding method includes the steps of: the partial pad portion is formed in the mold into a shape having a substantially concave inner surface and a substantially convex outer surface.

20. The method of claim 17.

25. A bra garment, first and second cup portions formed from one or more flexible recycled materials; first and second side wing panels extending from the first and second cup portions, respectively, the side wing panels being formed from one or more flexible recycled materials; first and second cushioned support pads configured to couple to the first and second cup portions, 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 formed from a bio-based open cell foam material having hardness and density values ​​that provide both cushioning and support to the breasts of a wearer of said bra garment; The bio-based open cell foam material comprises a mixture of at least about 60-85% bio-based EVA and bio-based PE formed substantially from sugarcane-based ethylene; The mixture of bio-based EVA and PE comprises at least A peroxide initiator, and Foaming agent, and the mixture of bio-based EVA, bio-based PE, peroxide-based initiator and blowing agent is applying heat to a temperature of about 105° C. to about 130° C. to form a molten mixture; extruding the molten mixture to form the mixture into a shape; maintaining said shape at a temperature of at least about 60° C. to about 90° C. during extrusion; compressing the shape to form a substantially flat sheet; formed into a substantially flat sheet by a process comprising: heating the sheet to about 135° C. to about 150° C. for about 30 minutes to about 45 minutes to obtain a substantially crosslinked foam material having limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 minutes to about 150 minutes to obtain a substantial volume expansion; expanding the volume of the substantially flat sheet by a heating method comprising: This is where the bio-based foam block is formed. crushing the bio-based foam block between compression rollers at least about four times to release a sufficient amount of air from within the bio-based foam block; crushing the bio-based foam block through a multiple compression roller process including: This is where the open-cell foam block is formed. cutting the open cell foam block into sheets; The bio-based open-cell foamed sheet is molded into a pad portion, the pad portion is formed in a mold into a shape having a substantially concave inner surface and a substantially convex outer surface. A bra garment characterized by:

26. The bio-based EVA and PE are also combined with an olefin-based block copolymer; 26. The bra garment of claim 25.

27. The bio-based foam material is comprised of at least about 40% to 85% bio-based EVA formed substantially from sugarcane-based ethylene; 26. The bra garment of claim 25.

28. The bio-based EVA is combined with an olefin-based block copolymer; 28. The bra garment of claim 27.

29. heating the foam block to about 165° C. to about 175° C. for about 40 minutes to about 50 minutes after the compression roller process to substantially restore the thickness of the foam block; 26. The bra garment of claim 25.

30. the first and second cushioned support pads having a Shore 00 hardness value of at least about 20 to about 70; 26. The bra garment of claim 25.

31. the first and second cushioned support pads are comprised of about 40% to about 90% bio-based carbon content; 26. The bra garment of claim 25.

32. The sheet formed by the cutting method has a hardness of about 0.020 to about 0.045 g / cm 3 The foam is made of an open-cell foam having a density of 26. The bra garment of claim 25.

33. The bio-based open-cell foamed sheet is A natural or synthetic fabric; an adhesive for adhering the fabric to the foam sheet; Curing and drying each laminated foam sheet for about 24 hours; At least one surface of the sheet is laminated.

26. The bra garment of claim 25.

34. The fabric for laminating the foam sheet is made of a 72D ultra-fine raised fabric on both sides; 34. The bra garment of claim 33.

35. The fabric for laminating the foam sheet is made of 100% polyester.

34. The bra garment of claim 33.

36. The adhesive is comprised of NEL-1018 hot melt polyurethane adhesive having a preferred viscosity of about 8,000 to about 12,000 cps / 100°C; 34. The bra garment of claim 33.

37. The adhesive is applied in an amount of about 25 grams per square meter of the foam sheet.

34. The bra garment of claim 33.

38. Each of the foam sheets is laminated with a fabric lamination roller maintained at a temperature of about 95°C.

34. The bra garment of claim 33.

39. Each of the cushioned support pads does not have a lamination layer or an adhesive layer at least on its rear surface.

26. The bra garment of claim 25.

40. 1. A method for producing a bio-based open cell foam block for use in producing a cushioned support pad for a bra or other garment, comprising: The bio-based open cell foam block comprises one or more bio-based foam materials including at least about 40-85% bio-based EVA and bio-based PE formed substantially from sugarcane-based ethylene; The bio-based EVA and PE are at least A peroxide initiator, and Foaming agent, and the mixture of bio-based EVA, bio-based PE, peroxide-based initiator and blowing agent is applying heat to a temperature of about 105° C. to about 130° C. to form a molten mixture; extruding the molten mixture to form the mixture into a shape; maintaining said shape at a temperature of at least about 60° C. to about 90° C. during extrusion; compressing the shape to form a substantially flat sheet; formed into a substantially flat sheet by a process comprising: heating the sheet to about 135° C. to about 150° C. for about 30 minutes to about 45 minutes to obtain a substantially crosslinked foam material having limited volume expansion; heating the sheet to about 160° C. to about 185° C. for about 90 minutes to about 150 minutes to obtain a substantial volume expansion; expanding the volume of the substantially flat sheet by a heating method comprising: This is where the bio-based foam block is formed. crushing the bio-based foam block between compression rollers at least about four times to release a sufficient amount of air from within the bio-based foam block; crushing the bio-based foam block through a multiple compression roller process including: This is where the open-cell foam block is formed. A method comprising:

41. heating the foam block to about 165° C. to about 175° C. for about 40 minutes to about 50 minutes after the compression roller process to substantially restore the thickness of the foam block; 41. The method of claim 40.

42. The bio-based EVA and PE are also combined with an olefin-based block copolymer.

41. The method of claim 40.

43. The bio-based foam material is comprised of at least about 40% to 85% bio-based EVA formed substantially from sugarcane-based ethylene; 41. The method of claim 40.

44. The bio-based EVA is also combined with an olefin-based block copolymer.

44. The method of claim 43.

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