A BRA cup and a method of manufacturing thereof

Abstract

A BRA CUP AND A METHOD OF MANUFACTURING THEREOF A bra cup (1400) comprising a cup structure and an elongate supporting element (100, 200, 300, 401-404, 500, 600, 700, 800, 901-903, 1000, 1100, 1200, 1420), wherein the elongate supporting element is formed from a thermosetting polymer and is fused to the fabric body along an edge portion of a concave inner surface (1410), wherein the elongate supporting element comprises a central region (110, 210, 310, 411-414, 510, 610, 710, 810, 1010, 911-913, 1110, 1210) and a peripheral region (120, 130, 220, 230, 320, 330, 421-424, 431-434, 520, 530, 620, 630, 720, 730, 820, 830, 1020, 1030, 921-923, 931-933, 1120, 1130, 1220, 1230) adjacent to the central region, the peripheral region having a 3-dimensional structure and / or thickness that is different to a 3-dimensional structure and / or thickness of the central region such that the structural support provided to the edge portion by the peripheral region is different to the structural support provided to the edge portion by the central region. A garment comprising the bra cup, and a method of making the bra cup.

Description

[0001] A BRA CUP AND A METHOD OF MANUFACTURING THEREOF

[0002] Field of Invention

[0003] The present invention relates to a bra cup and a method of manufacturing it. The invention also relates to a brassiere (or “bra”) and a garment comprising the bra cup.

[0004] Background

[0005] Bra cups are contained in brassieres (or “bras”) and garments. They can contain under-bust wires that are typically made of metal, to provide support and shape to the breasts of a user. Common problems with metal bra wires are irritation and poking. The rigid nature of metal wires can cause discomfort, especially when they dig into the skin. Metal wires are non- customizable, so they cannot adapt to the unique shape of each individual user’s body. This causes additional discomfort from the poor fit. Inflexibility of the metal wires can lead to them digging into the user’s ribcage, causing pain and soreness, particularly when worn for prolonged periods and in humid weather.

[0006] There are currently several materials and bra cup designs used in the market to address these issues. For example, a plastic wire may be used instead of a metal wire. These materials offer more flexibility than metal but still fall short in providing the necessary support and comfort. A monofilament wire may be more flexible than a metal wire, but does not offer the same level of support as a metal wire. A stabilizer located in the bra cup (in addition to a wire) can help distribute the weight more evenly but does not eliminate the discomfort caused by the rigid wire. A compressed foam wire or sling can provide some level of comfort but lacks the support and customization needed for a perfect fit.

[0007] Therefore, there is a need for an improved bra cup.

[0008] Summary of the Invention

[0009] The present invention provides a bra cup that overcomes the abovementioned problems by enabling a more comfortable and personalized fit, addressing the discomfort associated with the original uniform thickness design. Unlike traditional metal wires, the invented wire can be customized to meet individual fit and comfort levels. It provides the necessary support while ensuring comfort, reducing the risk of irritation and poking. The bra cup of the present invention introduces variations in wire thickness, width and structure, to offer a customizable fit that is comfortable for various breast shapes, ensuring a better fit for a wider range of users that wear it for a prolonged duration. The bra cup of the present invention provides customised stretch and flexibility. Existing bra cups which rely on a metal wire do not have the customised stretch and flexibility provided by the present invention since the metal wire is unable to be customised.

[0010] In embodiments herein, the word “comprising” may be interpreted as requiring the features mentioned, but not limiting the presence of other features. Alternatively, the word “comprising” may also relate to the situation where only the components / features listed are intended to be present (e.g. the word “comprising” may be replaced by the phrases “consists of” or “consists essentially of”). It is explicitly contemplated that both the broader and narrower interpretations can be applied to all aspects and embodiments of the present invention. In other words, the word “comprising” and synonyms thereof may be replaced by the phrase “consisting of” or the phrase “consists essentially of” or synonyms thereof and vice versa.

[0011] As used herein, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. The term “about” as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, within 1 %, within 0.5%, within 0.1 %, within 0.05%, within 0.01 %, within 0.005%, or within 0.001% of a stated value or of a stated limit of a range, and includes the exact stated value or range.

[0012] The term “bra cup” refers a component of a brassiere, bralette, or similar garments for supporting a breast. The bra cup as defined herein comprises a cup structure, the cup structure typically configured to conform to and provide support to a breast of a wearer of a brassiere, bralette, or similar garment. A cup structure may be formed by a knit pattern and / or by moulding of a suitable fabric. In certain example, the cup structure may comprises regions having different thickness, densities and / or stiffnesses. In certain other examples, the cup structure may be a moulded polymer cup structure, for example a moulded polyurethane cup structure. For the avoidance of doubt, the terms “bra”, “brassiere” and “bralette” may be used interchangeably herein.

[0013] The term "fabric" when used herein includes woven fabrics, knit fabrics, nonwoven fabrics, multilayer fabrics, and the like.

[0014] Suitable methods for forming a cup structure are known in the art, for example as disclosed by WO2022 / 086439 and WO2022 / 086438, which are each incorporated herein by reference. Regions of a fabric forming a cup structure of the bra cup with different thickness, densities and / or stiffnesses from each other may be formed, for example, by varying thicknesses of the fabric layer and / or varying compression of the fabric during moulding. The thicknesses of the fabric may be varied, for example, by varying the density of tuck stitches, the thickness of the yarns (e.g. spacer yarns), and / or the knit structure of the fabric. Examples of how regions of a fabric having different thickness, densities and / or stiffnesses may be formed are provided, for example, by WO 2022 / 086441 , which is disclosed herein by reference.

[0015] The term “elongate supporting element” as used herein refers to a structural component or member of the bra cup of the invention that is elongated in shape and is configured to provide structural support, stability, or reinforcement to an an edge portion of the concave inner surface of the cup structure of the bra cup.

[0016] The term “monolithic structure” as used herein refers to the three-dimensional structure of the elongate supporting element portion that is formed from a continuous or uninterrupted deposit of the thermosetting polymer rather than being formed from multiple discrete parts or comprising void spaces or otherwise being an interrupted deposit of the thermosetting polymer.

[0017] The term “perforated structure” as used herein refers to a three-dimensional structure of a region of the elongate supporting element that is formed from the thermosetting polymer and comprising void spaces, holes, apertures or similar interruptions in the elongate supporting element structure formed by the thermosetting polymer. The perforations may be of any suitable size as required to alter the flexibility and / or stretchability of the specific region of the elongate supporting element.

[0018] The term “curved shaped” may refer herein to a U-shaped or substantially U-shaped structure.

[0019] In a first aspect, the invention provides a bra cup comprising a cup structure and an elongate supporting element, wherein the cup structure has a concave inner surface and a convex outer surface, the elongate supporting element is formed from a thermosetting polymer and is fused to the fabric body along an edge portion of the concave inner surface, thereby providing structural support to the edge portion, wherein the elongate supporting element comprises a central region and a peripheral region adjacent to the central region, the peripheral region having a 3-dimensional structure and / or thickness that is different to a 3- dimensional structure and / or thickness of the central region such that the structural support provided to the edge portion by the peripheral region is different to the structural support provided to the edge portion by the central region.

[0020] Advantageously, the bra cup comprises an elongate supporting element that can be custom- made for different dimensions, curvature, thickness, and stretchability. This customized supporting element offers an improved fit while providing the required comfort and support. The supporting element can be customized to have the flexibility to adjust to different fit or comfort levels. This customized supporting element can also support different breast shapes.

[0021] In an embodiment, the central region has a 3-dimensional structure that is a monolithic structure or a perforated structure.

[0022] A monolithic structure offers better structural support and easy assembly into a garment. A perforated structure offers a lighter weight, greater flexibility, and improved comfort.

[0023] In an embodiment, the central region is substantially linear shaped, substantially curved shaped, or substantially zigzag shaped.

[0024] A linear shape provides the least stretchability; a zigzag shape provides the most stretchability; and the curve shape provides an intermediate level of stretchability. Thus, the shape can be chosen to match the desired stretchability of the region, and address the breast shape and specific needs of the user. For example, in larger sizes, it may be desirable to provide more support from the central region and provide more flexible stretch in the side of the cup. In smaller sizes, the bottom of the cup may be empty and so it may be desirable to provide stretch and flexibility in the central region. The present invention allows the stretch and flexibility to be controlled depending on the requirements of the user.

[0025] In an embodiment, the peripheral region has a 3-dimensional structure that is a monolithic structure or a perforated structure.

[0026] A monolithic structure offers better structural support and easy assembly into a garment. A perforated structure offers a lighter weight, greater flexibility, and improved comfort.

[0027] In an embodiment, the peripheral region is substantially linear shaped, substantially curved shaped, or substantially zigzag shaped. A linear shape provides the least stretchability; a zigzag shape provides the most stretchability; and the curve shape provides an intermediate level of stretchability. Thus, the shape can be chosen to match the desired stretch ability of the peripheral region, and address the breast shape and specific needs of the user. As mentioned above, different sizes may require stretchability in different regions for optimal comfort.

[0028] In an embodiment, the central region has a thickness that is greater than a thickness of the peripheral region.

[0029] The central region can be adjusted to provide more support and less stretchability compared to the peripheral region by adjusting the 3-dimensional structure of the central region. The central region thickness can be increased for more support and less stretchability compared to the peripheral region. This may be used for sportswear when more support is needed.

[0030] In an embodiment, the central region or the peripheral region comprise two or more sub regions each having a monolithic structure or a perforated structure, for example, two, three or four sub regions each having a monolithic structure.

[0031] The sub regions having a monolithic structure offer more areas for customization, such that different regions within the supporting element have different levels of support and stretchability, while keeping the manufacturing method easy.

[0032] In an embodiment, each sub region has a monolithic structure that is substantially linear shaped, substantially curved shaped, or substantially zig-zag shaped.

[0033] A linear shape provides the least stretchability; a zigzag shape provides the most stretchability; and the curve shape provides an intermediate level of stretchability. Thus, the shape can be chosen to match the desired stretchability of the sub region, and address the breast shape and specific needs of the user.

[0034] In an embodiment, the central region and / or the peripheral region comprises a plurality of sub regions each formed from a deposit of the thermosetting polymer to form a dotted, zigzag, or dashed pattern.

[0035] A dotted pattern provides the highest stretchability; a dashed pattern provides the lowest stretability; and a zigzag pattern provides an intermediate level of stretchability. Therefore, the pattern can be chosen to match the desired stretch ability of the region, and address the specific needs of the user.

[0036] In an embodiment, the elongate supporting element comprises a central region, a first peripheral region adjacent to the central region and a second peripheral region adjacent to the central region, wherein the first peripheral region is distal to the second peripheral region.

[0037] This supporting element comprises different regions for customization, to cater for different breast shapes and support levels. This will also improve fit and comfort levels.

[0038] In an embodiment, the first peripheral region and second peripheral region each have a 3- dimensional structure and / or thickness different to the 3-dimensional structure and / or thickness of the central region such that the structural support provided to the edge portion by the first and second peripheral regions is different to the structural support provided to the edge portion by the central region.

[0039] The central region would bear more pressure compared to the peripheral regions. Thus, it would be advantageous for the central region to have a different thickness compared to the peripheral regions to provide adequate support and comfort to the user.

[0040] In an embodiment, the first peripheral region and second peripheral region have substantially the same 3-dimensional structure and / or thickness as each other.

[0041] In such an embodiment, the support and stretchability within the elongate supporting element would be symmetrical, and would be easy to manufacture. In other embodiments, the first peripheral region and the second peripheral region may have different 3-dimensional structures and / or thickness as each other. A non-symmetric configuration may be preferred depending on breast weight distribution and where stretching is required.

[0042] In an embodiment, the central region, first peripheral region, and second peripheral region each have a monolithic structure, and wherein the central region has a thickness that is greater than a thickness of the first and / or second peripheral regions.

[0043] The central region would bear more pressure compared to the peripheral regions. Thus, it would be advantageous for the central region to be thicker compared to the peripheral regions to provide adequate support and comfort to the user. In an embodiment, the central region has a width that is greater than the width of the first and / or second peripheral regions.

[0044] The central region would bear more pressure compared to the peripheral regions. Thus, it would be advantageous for the central region to be wider compared to the peripheral regions to provide adequate support and comfort to the user.

[0045] In an embodiment, the central region has a monolithic structure that is substantially linear shaped or substantially curved shaped, and the first peripheral region and second peripheral region each comprise two or more sub regions each having a monolithic structure that is substantially linear shaped, substantially curved shaped, or substantially zig-zag shaped.

[0046] In an embodiment, the central region has a monolithic structure that is substantially linear shaped or substantially curved shaped, and the first peripheral region and second peripheral region each have a monolithic structure that is substantially linear shaped or substantially curved shaped.

[0047] In an embodiment, the central region comprises two or more sub regions having a monolithic structure that is substantially linear shaped, substantially curved shaped, or substantially zigzag shaped, and the first peripheral region and second peripheral region each having a monolithic structure that is substantially linear shaped or substantially curved shaped.

[0048] A linear shape provides the least stretchability; a zigzag shape provides the most stretchability; and the curve shape provides an intermediate level of stretchability. Thus, the shape can be chosen to match the desired stretchability of the peripheral regions, and address the breast shape and specific needs of the user.

[0049] In an embodiment, the bra cup comprises two or more (e.g. two, three or four) elongate supporting elements each fused to the fabric body and arranged parallel with respect to each other along the edge portion of the bra cup.

[0050] This arrangement allows the elongate supporting elements to distribute pressure across their entire lengths, while reducing the likelihood of entanglement, to ensure smooth and comfortable fit for the user.

[0051] In an embodiment, the elongate supporting element requires a force of about 7.5 Ibf to stretch by about 4.3% to about 92.6% of its original length. In an embodiment, any of the following applies: i. the elongate supporting element requires a force of about 1 .8 Ibf to about 2.3 Ibf to stretch the elongate supporting element by about 20% of its original length; ii. the elongate supporting element requires a force of about 3.2 Ibf to about 4.4 Ibf to stretch the elongate supporting element by about 30% of its original length; iii. the elongate supporting element requires a force of about 5.3 Ibf to about 7.8 Ibf to stretch the elongate supporting element by about 40% of its original length; or iv. the elongate supporting element requires a force of about 9.1 Ibf to about 12.4 Ibf to stretch the elongate supporting element by about 50% of its original length.

[0052] The elongate supporting element can be customized according to the desired stretchability, comfort level, and purpose.

[0053] In an embodiment, in the elongate supporting element has a width of from about 1 mm to about 15 mm, optionally wherein the width of the elongate supporting element varies along its length from about 1 mm to about 15 mm, for example, wherein the central region has width that is greater than the width of the first and second peripheral elements.

[0054] This width allows multiple elongate supporting elements to fit inside the edge of a bra cup without creating bulkiness.

[0055] In an embodiment, the elongate supporting element has a thickness of from about 0.5 mm to about 3 mm, optionally wherein the thickness of the elongate supporting element varies along its length from about 0.5 mm to about 3 mm, for example, wherein the central region has a greater thickness than the thickness of the first and second peripheral regions.

[0056] This thickness allows multiple elongate supporting elements to fit inside the edge of a bra cup without creating bulkiness and interfering with the aesthetic appeal of the bra cup.

[0057] In an embodiment, the thermosetting polymer is selected from a group consisting of a polyurethane reactive (PUR) adhesive, a polyester urethane (TPU), a polyether urethane (PEU), a elastomeric polyurethane (EPU), a polyolefin elastomers (POE), a silicone rubber, and a combination of two or more thereof, for example, thermosetting polymer may be a polyurethane reactive (PUR) adhesive. Thermosets are not damaged by heat, so they can maintain their shape over prolonged use. This increases the durability of the bra cup and garments comprising such bra cups. These thermosets are also cost-effective and easy to produce, thus reducing customization costs.

[0058] In an embodiment, the cup structure is formed from a polyurethane foam, for example, a moulded polyurethane foam.

[0059] Polyurethane (PU) is a comfortable and moldable foam material that is machine washable, and thus suitable for use in bra cups and garments. It does not get distorted through machine wash, thus making it easy to clean.

[0060] In an embodiment, the cup structure is formed from a fabric comprising one or more yarns selected from the group consisting of a polyurethane yarn (e.g. elastane), a polyester yarn, a polyamide yarn (e.g. nylon), cotton yarn, silk yarn, and a combination of two or more thereof, optionally wherein the fabric is a lace fabric, a spacer fabric (e.g. a fabric comprising at least fabric layers connected by spacer yarn and / or pile yarns), or a satin.

[0061] Fabrics wick sweat away from the body and are machine washable, and are thus comfortable and durable for prolonged use.

[0062] In an embodiment, the cup structure is formed by a knit pattern and / or by moulding of the fabric.

[0063] A cup structure made using this method conlains minimal seams, thus improving comfort and reducing chafing for the user. This also preserves the stretchability of the elongate supporting element within the cup structure.

[0064] In an embodiment, the elongate supporting element has a thickness and / or width that varies along the length of the elongate supporting element, for example, the central region may have a thickness and / or width that is greater than that of the first and / or second peripheral regions.

[0065] The central region would bear more pressure compared to the peripheral regions. Thus, it would be advantageous for the central region to be thicker or wider compared to the peripheral regions to provide adequate support and comfort to the user. In an embodiment, the elongate supporting element is substantially U-shaped.

[0066] This fits well with the typical breast shape.

[0067] In an embodiment, the elongate supporting element and edge portion of the cup structure are together configured to provide support to a breast of a human user.

[0068] In a second aspect, the invention provides a method of manufacturing a bra cup, the method comprising: (a) providing a substrate; (b) providing a specification of an elongate supporting element to a printer; and (c) printing the elongate supporting element onto the substrate to provide the bra cup, wherein step (c) comprises dispensing a thermosetting polymer formulation onto the substrate using drop-on-demand printing, extrusion, spraying, injection moulding, or depositing.

[0069] Advantageously, this manufacturing method results in a bra cup that is custom-made to desired dimensions, curvature, stretchability, and strength. Drop-on-demand (DOD) printing provides an efficient and cost-effective way of making customized bra cups.

[0070] In an embodiment, step (c) comprises dispensing the thermosetting polymer formulation at a barrel temperature of about 120 °C to about 170 °C, a nozzle temperature of about 180 °C to about 230 °C, a processing speed of about 1000 dots / min to about 10000 dots per minute, and a valve on time of about 2 ms to about 10 ms. The barrel temperature may be about 140 °C to about 170 °C.

[0071] The dispensing step has been tested to work in these range of conditions to produce a desirable custom-made bra cup with an elongate supporting element.

[0072] In an embodiment, step (c) comprises dispensing the thermosetting polymer formulation at a barrel temperature of about 130 °C, a nozzle temperature of about 190 °C, a processing speed of about 5000 dots per minute, and a valve on time of about 2.6 ms.

[0073] The dispensing step preferably works under this set of conditions to provide a desirable custom-made bra pad with an elongate supporting element.

[0074] In an embodiment, the substrate is a polyurethane foam, a mesh, a membrane, or a fabric. These materials are easy to procure, easy to wash (can be machine washed), and easy to print a polymer on the material.

[0075] In an embodiment, the method comprises a step of subjecting the substrate following step (c) to a moulding process to form a cup structure having concave inner surface and a convex outer surface.

[0076] The polymer can be shaped along with the substrate to form a cup structure, thus saving time during the manufacturing process.

[0077] In an embodiment, the substrate provided in step (a) is a polyurethane foam and comprises a cup structure, wherein the cup structure is formed by moulding of the polyurethane foam.

[0078] This method quickly forms a cup structure in step (a) before dispensing the polymer so the manufacturing process can be faster. An elongate supporting element that is stiff or thick can be made using this process.

[0079] In an embodiment, the substrate provided in step (a) is a fabric and comprises a cup structure, wherein the cup structure is formed by a knit pattern and / or by moulding of the fabric.

[0080] A cup structure made using this method contains minimal seams, thus improving comfort and reducing chafing for tire user. This also preserves the siretchability of the elongate supporting element within the cup structure.

[0081] In an embodiment, the substrate is a fabric comprising one or more yarns selected from the group consisting of a polyurethane yarn (e.g. elastane), a polyester yarn, a polyamide yarn (e.g. nylon), cotton yam, silk yarn, and a combination of two or more thereof, optionally wherein the fabric is a lace fabric, a spacer fabric (e.g. a fabric comprising at least fabric layers connected by spacer yarn and / or pile yarns), or a satin.

[0082] These fabrics wick sweat away from the body and are machine washable, and are thus comfortable and durable for prolonged use. The substrate can be applied on a lightweight metal wire and customized to create the desired support via this method.

[0083] In an embodiment, the elongate supporting element has a thickness and / or width that varies along the length of the elongate supporting element. Coating thickness can be customised to meet the desired comfort and support. Areas that need higher support can be coated with a thicker layer, and areas that need minimal support can be coated with minimal to no coating. The coating may be applied to a metal wire, such as a lightweight metal wire, and the application of the coating can be controlled to customize the support provided by the coated metal wire.

[0084] In an embodiment, the thermosetting polymer formulation comprises a polyurethane reactive (PUR) adhesive.

[0085] PUR contain low to no Volatile Organic Compounds (VOCs), and does not pollute the environment nor cause harm to the user.

[0086] In an embodiment, further comprising a step (d) of curing the thermosetting polymer formulation after it has been printed onto the substrate.

[0087] This method allows a relatively flexible polymer to be printed on the substrate, before being cured to the desired stiffness. This allows the printing process to progress smoothly without causing issues to the machinery.

[0088] In an embodiment, the elongate supporting element is as defined above.

[0089] The elongate supporting element offers an improved fit while providing the required comfort and support. This supporting element can be customized to have the flexibility to adjust to different fit or comfort levels.

[0090] In a third aspect, the invention provides a bra cup obtained by any abovementioned method.

[0091] A bra cup made using the abovementioned method provides a custom-made solution to fit the user’s breast shape, desired support and stretchability, and comfort level.

[0092] In a fourth aspect, the invention provides a garment comprising any abovementioned bra cup.

[0093] Garments made using the abovementioned bra cup would be customized to fit the user’s breast shape, desired support and stretchability, and comfort levels. In an embodiment, the garment is a bra, bralette, cut panel, sportwear, swimwear, or finished garment.

[0094] The customisability of the bra cup allows it to be used in a wide variety of garments for the user.

[0095] Brief Description of the Drawings

[0096] FIG. 1 is a schematic drawing of one embodiment of the present invention, comprising a zigzag structure with variable thickness & solid middle area.

[0097] FIG. 2 is a schematic drawing of another embodiment of the present invention, comprising a zigzag structure with solid edges.

[0098] FIG. 3 is a schematic drawing of a further embodiment of the present invention, comprising a line structure with variable thickness & solid middle area.

[0099] FIG. 4 is a schematic drawings of another embodiment of the present invention, comprising a line structure with variable thickness.

[0100] FIG. 5 is a schematic drawing of yet another embodiment of the present invention, comprising a line structure with solid edges.

[0101] FIG. 6 is a schematic drawing of another embodiment of the present invention, comprising cut outs at required positions.

[0102] FIG. 7 is a schematic drawing of an embodiment of the present invention, showing a solid structure with a uniform thickness across entire length.

[0103] FIG. 8 is a perspective drawing of an embodiment of FIG. 7, comprising a solid structure with a uniform thickness across the entire length.

[0104] FIG. 9 is a schematic drawing of an embodiment of the present invention, comprising a structure with varying width along the wire length (highest at the middle).

[0105] FIG. 10 is a perspective drawing of an embodiment of FIG. 9, comprising a solid structure with varying thicknesses along the wire length. FIG. 1 1 is a schematic drawing of another embodiment of the present invention, comprising a zigzag line structure with variable thickness.

[0106] FIG. 12 is a schematic drawing of an embodiment of the present invention, comprising a discontinuous zigzag structure at a required area.

[0107] FIG. 13 is a schematic drawing of another embodiment of the present invention, comprising a discontinuous dashed structure at a required area.

[0108] FIG. 14 is a perspective drawing of a bra cup of the present invention.

[0109] Detailed Description of the Drawings

[0110] Figs. 1 to 14 show various designs of the elongate supporting element of the bra cup of the present invention, wherein the elongate supporting element comprises a central region and a peripheral region adjacent to the central region, and specifically wherein the elongate supporting element comprises a central region, a first peripheral region adjacent to the central region and a second peripheral region adjacent to the central region, wherein the first peripheral region is distal to the second peripheral region.

[0111] Fig. 1 shows an elongate supporting element 100 comprising a central region 1 10 which has monolithic structure that is substantially curved shaped, a first peripheral region 120 adjacent to the central region 110 and a second peripheral region 130 adjacent to the central region 110, wherein the first peripheral region 120 is distal to the second peripheral region 130. The first and second peripheral regions 120, 130 each comprise three sub regions 120a-c, 130a-c each having a monolithic structure that is substantially zig-zag shaped.

[0112] Fig. 2 shows an elongate supporting element 200 comprising a central region 210 which comprises three sub regions 210a, 210b, 210c each having a monolithic structure that is substantially zig-zag shaped, a first peripheral region 220 adjacent to the central region 210 and a second peripheral region 230 adjacent to the central region 210, wherein the first peripheral region 220 is distal to the second peripheral region 230. The first and second peripheral regions 220, 230 each have a monolithic structure that is substantially curved shaped.

[0113] Fig. 3 shows an elongate supporting element 300 comprising a central region 310 which has monolithic structure that is substantially curved shaped, a first peripheral region 320 adjacent to the central region 310 and a second peripheral region 330 adjacent to the central region 310, wherein the first peripheral region 320 is distal to the second peripheral region 330. The first and second peripheral regions 320, 330 each comprise four sub regions 320a-d, 330a-d each having a monolithic structure that is substantially curved shaped.

[0114] Fig. 4 shows elongate supporting elements 401-404 each comprising a central region 41 1 - 414 which has monolithic structure that is substantially curved shaped, a first peripheral region 421 -424 adjacent to the central region 41 1-414 and a second peripheral region adjacent 431 -434 to the central region, wherein the first peripheral region 421 -424 is distal to the second peripheral region 431 -434. The first and second peripheral regions 421 -424, 431 - 434 each having monolithic structure that is substantially curved shaped.

[0115] Fig. 5 shows an elongate supporting element 500 comprising a central region 510 which comprises four sub regions 510a-d each having a monolithic structure that is substantially curved shaped, a first peripheral region 520 adjacent to the central region 510 and a second peripheral region 530 adjacent to the central region 510, wherein the first peripheral region 520 is distal to the second peripheral region 530. The first and second peripheral regions 520, 530 each have a monolithic structure that is substantially curved shaped.

[0116] Fig. 6 shows an elongate supporting element 600 comprising a central region 610 which has monolithic structure that is substantially curved shaped, a first peripheral region 620 adjacent to the central region 610 and a second peripheral region 630 adjacent to the central region 610, wherein the first peripheral region 620 is distal to the second peripheral region 630. The first and second peripheral regions 620, 630 each have a perforated structure that is substantially curved shaped.

[0117] Fig. 7 shows an elongate supporting element 700 comprising a central region 710 which has monolithic structure that is substantially curved shaped, a first peripheral region 720 adjacent to the central region 710 and a second peripheral region 730 adjacent to the central region 710, wherein the first peripheral region 720 is distal to the second peripheral region 730. The first and second peripheral regions 720, 730 each have a monolithic structure that is substantially curved shaped. The central region 710 and first and second peripheral regions each of the same thicknesses and widths as each other. Thus, elongate supporting element 700 has a uniform thickness and width along its length. Fig 8 shows the elongate supporting element 700 in a different orientation to show that central region 710, first peripheral region 720, and second peripheral region 730, have the same thickness and width.

[0118] Fig. 9 shows an elongate supporting element 800 comprising a central region 810 which has monolithic structure that is substantially curved shaped, a first peripheral region 820 adjacent to the central region 810 and a second peripheral region 830 adjacent to the central region 810, wherein the first peripheral region 820 is distal to the second peripheral region 830. The central region 810 has a width that is greater than the width of the first and second peripheral regions 820, 830.

[0119] Fig 10 shows an elongate supporting element 1000 comprising a central region 1010 which has monolithic structure that is substantially curved shaped, a first peripheral region 1020 adjacent to the central region 1010 and a second peripheral region 1030 adjacent to the central region 1010, wherein the first peripheral region 1020 is distal to the second peripheral region 1030. The central region 1010 has a thickness that is greater than the thickness of the first and second peripheral regions 1010, 1020.

[0120] Fig. 1 1 shows elongate supporting elements 901 -903 each comprising a central region 91 1-913 which has monolithic structure that is substantially zig-zag shaped, a first peripheral region 921 -923 adjacent to the central region 91 1-913 and a second peripheral region 931-933 adjacent to the central region 91 1 -913, wherein the first peripheral region 921 -923 is distal to the second peripheral region 931 -933. The first and second peripheral regions 921-923, 931 -933 each having monolithic structure that is substantially zig-zag shaped, and wherein the central region 91 1 -913 has a width that is greater than the width of the first and second peripheral regions 921 -923, 931 -933.

[0121] Fig. 12 shows an elongate supporting element 1 100 comprising a central region 1 110 which has monolithic structure that is substantially curved shaped, a first peripheral region 1120 adjacent to the central region 1 1 10 and a second peripheral region 1 130 adjacent to the central region 11 10, wherein the first peripheral region 1 120 is distal to the second peripheral region 1 130. The first and second peripheral regions 1 120, 1 130 each comprise three sub regions 1120a-c, 1 130a-c each having a monolithic structure that is substantially zig-zag shaped. Optionally, elongate supporting element also comprising end portions 1 140 and 1 150 each having a monolithic structure. Fig. 13 shows an elongate supporting element 1200 comprising a central region 1210 which has monolithic structure that is substantially curved shaped, a first peripheral region 1220 adjacent to the central region 1210 and a second peripheral region 1230 adjacent to the central region 1210, wherein the first peripheral region 1220 is distal to the second peripheral region 1230. The first and second peripheral regions 1 120, 1130 each a plurality of sub regions each formed from a deposit of the thermosetting polymer to form a dotted or a dashed pattern. Optionally, the elongate supporting element also comprising end portions 1240 and 1250 each having a monolithic structure.

[0122] Fig. 14 shows a perspective drawing of a bra cup 1400 having an elongate supporting element 1420 is fused to the fabric body along an edge portion of the concave inner surface 1410.

[0123] The present inventors have found that different elongate supporting element designs (Figs. 12 and 13) display differences in their stretchability and therefore offer different levels of support to bra cup and ultimately to the breast of a wearer. It will be appreciated that, although the figures depict elongate supporting elements having peripheral regions which are the same, it is possible for the peripheral regions to be different from one another. For example, one peripheral region may comprise a zig-zag shaped structure and another peripheral region may have a dotted or dashed structure. All such combinations are considered herein. Having different structures in the peripheral regions may allow for additional control of the properties of the elongate supporting elements.

[0124] Table 1 below shows the force required to stretch the elongate supporting element from its original length such that the length of the elongate supporting element increases by 20%, 30%, 40% or 50%.

[0125] Table 1 Force required to stretch the elongate supporting element from its original length to various lengths

[0126] Therefore, the solution of the present invention provides a bra cup that is flexible, has improved fit, is customizable to the required comfort and support. The wire can also be customized to have the desired flexibility to adjust to desired fit or comfort levels and support different breast shapes.

[0127] Method of Manufacturing a Bra Cup

[0128] Various methods may be used to manufacture the claimed bra cup. In one embodiment, the elongate supporting element can be dispensed on the substrate using drop-on-demand printing.

[0129] The manufacturing process begins with the precision cutting of panels to specific dimensions and shapes. The cut panels are loaded onto a drop-on-demand (DOD) machine following proper placement and alignment which are crucial to ensure accurate printing. The customized wire artwork is printed onto the panels using DOD technology, which allows for precise and controlled printing. Alternatively, the artwork can be printed onto the panels using extrusion, spraying, injection moulding, or any method of depositing.

[0130] This technology can be used to coat a lightweight metal wire (or any other kind of bra wire) to give the needed support by varying the thickness of the deposition. For example, areas that need the higher support can be coated with a thick layer with the DOD technology and the areas which require minimal support can be coated with minimal to no coating. Therefore, the wire can be customized using this technology to meet the desired comfort and support.

[0131] When a DOD printer is set to dispense PUR glue on PU foam, the dispensing occurs at a barrel temperature of 130 °C, a nozzle temperature of 190 °C, a processing speed of 5000 dots / min, and a valve on time of 2.6 ms. The actual parameters may differ depending on the substrate, material of the elongate supporting element, and desired properties. For example, the PUR glue may be specific name: VP 9492 / 803(701.9.47), and the PU foam may be a material in Stretch Category (INOAC EL 83C), Firm Category (INOAC EWL 34H), Memory Category (INOAC EGR 45SP), and / or Marshmallow Category (INOAC EWL 40S). Other materials may be polyesters (Hayleys Textile IPE 152, Hayleys Textile ZIPE 153, Pacific Textile SI1040, Pacific Textile SI181 1 ), poly-spandex (Pacific Textiles RC1945S, Pacific Textiles TJ9398), spacers (Gemma Knit IBC 220AA / 12, Derun D-P64140SR / F2, Gemma Knit IAC-131 BA / 12), or nylon-spandex (Derun D36).

[0132] Printing the customized wire artwork onto the panels using DOD technology allows for a precise and controlled printing. Once printed, the panels undergo a curing process to set the thermosetting polymer formulation into a solid state, ensuring it adheres securely to the substrate. The substrate can be polyurethane foam, mesh, membrane or a fabric comprising one or more yarns selected from polyurethane yarn (e.g., elastane), polyester yarn, and polyamide yarn (e.g., nylon). The thermosetting polymer formulation comprises a polyurethane reactive (PUR) adhesive, with alternatives including Polyester Urethane (TPU), Polyether Urethane (PEU), Elastomeric Polyurethane (EPU), Polyolefin Elastomers (POE), and Silicone Rubber.

[0133] Different components of the product are assembled, which may involve attaching various components to the printed panels. The assembled panels then undergo a final molding process to shape and bond them together. After molding, the panels are carefully removed from the molds are kept for cooling process. Trimming the molded panels by removing excess material using machinery to ensure the pads have the desired shape and size. A thorough inspection is performed to check for defects, quality issues, or any deviations from specifications. Finally, the finished products are packaged for distribution.

[0134] The finished product may be used in no-wire bra pad solutions, one-piece bra, lightly-lined bra, swimwear, sportswear, and other garments.

[0135] It would be appreciated that the invention is not limited to the embodiments shown in the figures, and that the invention can contain any combination of the features mentioned in this specification.

[0136] In summary, the present invention provides a bra cup comprising an elongate supporting element which provides different structural support between a central region and at least one edge region. The different structural support may be provided by having different three- dimensional structures, such as zigzag structures, dotted or dashed line structures, monolithic structures or perforated structures. Such different structures may be provided by, for example, drop-on-demand printing techniques. By having different structural support, it is possible to fine tune and customise the levels of support to provide a bra cup which is more comfortable for the user.

Claims

Claims1 . A bra cup comprising a cup structure and an elongate supporting element, wherein the cup structure has a concave inner surface and a convex outer surface, the elongate supporting element is formed from a thermosetting polymer and is fused to the fabric body along an edge portion of the concave inner surface, thereby providing structural support to the edge portion, wherein the elongate supporting element comprises a central region and a peripheral region adjacent to the central region, the peripheral region having a 3-dimensional structure and / or thickness that is different to a 3-dimensional structure and / or thickness of the central region such that the structural support provided to the edge portion by the peripheral region is different to the structural support provided to the edge portion by the central region.

2. The bra cup of claim 1 , wherein the central region has a 3-dimensional structure that is a monolithic structure or a perforated structure.

3. The bra cup of claim 2, wherein the central region is substantially linear shaped, substantially curved shaped, or substantially zig-zag shaped.

4. The bra cup of any preceding claim, wherein the peripheral region has a 3- dimensional structure that is a monolithic structure or a perforated structure.

5. The bra cup of claim 4, wherein the peripheral region is substantially linear shaped, substantially curved shaped, or substantially zig-zag shaped.

6. The bra cup of any preceding claim, wherein the central region has a thickness that is greater than a thickness of the peripheral region.

7. The bra cup of any preceding claim, wherein the central region or the peripheral region comprise two or more sub regions each having a monolithic structure or a perforated structure, for example, two, three or four sub regions each having a monolithic structure.

8. The bra cup of claim 7, wherein each sub region has a monolithic structure that is substantially linear shaped, substantially curved shaped, or substantially zig-zag shaped.

9. The bra cup of any one of claims 1 to 6, wherein the central region and / or the peripheral region comprises a plurality of sub regions each formed from a deposit of the thermosetting polymer to form a dotted, zigzag, or dashed pattern.

10. The bra cup of any preceding claim, wherein the elongate supporting element comprises a central region, a first peripheral region adjacent to the central region and a second peripheral region adjacent to the central region, wherein the first peripheral region is distal to the second peripheral region.

11. The bra cup of claim 10, wherein the first peripheral region and second peripheral region each have a 3-dimensional structure and / or thickness different to the 3-dimensional structure and / or thickness of the central region such that the structural support provided to the edge portion by the first and second peripheral regions is different to the structural support provided to the edge portion by the central region.

12. The bra cup of claim 10 or 1 1 , wherein the first peripheral region and second peripheral region have substantially the same 3-dimensional structure and / or thickness as each other.

13. The bra cup of any one of claims 10 to 12, wherein the central region, first peripheral region, and second peripheral region each have a monolithic structure, and wherein the central region has a thickness that is greater than a thickness of the first and / or second peripheral regions.

14. The bra cup of any one of claims 13, wherein the central region has a width that is greater than the width of the first and / or second peripheral regions.

15. The bra cup of any one of claims 10 to 14, wherein the central region has a monolithic structure that is substantially linear shaped or substantially curved shaped, and the first peripheral region and second peripheral region each comprise two or more sub regions each having a monolithic structure that is substantially linear shaped, substantially curved shaped, or substantially zig-zag shaped.

16. The bra cup of any one of claims 10 to 14, wherein the central region has a monolithic structure that is substantially linear shaped or substantially curved shaped, and the first peripheral region and second peripheral region each have a monolithic structure that is substantially linear shaped or substantially curved shaped.

17. The bra cup of any one of claims 10 to 14, wherein the central region comprises two or more sub regions having a monolithic structure that is substantially linear shaped, substantially curved shaped, or substantially zig-zag shaped, and the first peripheral region and second peripheral region each having a monolithic structure that is substantially linear shaped or substantially curved shaped.

18. The bra cup of any preceding claim, wherein the bra cup comprises two or more (e.g. two, three or four) elongate supporting elements each fused to the fabric body and arranged parallel with respect to each other along the edge portion of the bra cup.

19. The bra cup of any preceding claim, wherein the elongate supporting element requires a force of about 7.5 Ibf to stretch by about 4.3% to about 92.6% of its original length.

20. The bra cup of any preceding claim, wherein any of the following applies: v. the elongate supporting element requires a force of about 1 .8 Ibf to about 2.3 Ibf to stretch the elongate supporting element by about 20% of its original length; vi. the elongate supporting element requires a force of about 3.2 Ibf to about 4.4 Ibf to stretch the elongate supporting element by about 30% of its original length; vii. the elongate supporting element requires a force of about 5.3 Ibf to about 7.8 Ibf to stretch the elongate supporting element by about 40% of its original length; or viii. the elongate supporting element requires a force of about 9.1 Ibf to about 12.4 Ibf to stretch the elongate supporting element by about 50% of its original length.21 . The bra cup of any preceding claim, wherein the elongate supporting element has a width of from about 1 mm to about 15 mm, optionally wherein the width of the elongate supporting element varies along its length from about 1 mm to about 15 mm, for examples, wherein the central region has width that is greater than the width of the first and second peripheral elements.

22. The bra cup of any preceding claim, wherein the elongate supporting element has a thickness of from about 0.5 mm to about 3 mm, optionally wherein the thickness of the elongate supporting element varies along its length from about 0.5 mm to about 3 mm, for example, wherein the central region has a greater thickness than the thickness of the first and second peripheral regions.

23. The bra cup of any preceding claim, wherein the thermosetting polymer is selected from a group consisting of a polyurethane reactive (PUR) adhesive, a polyester urethane (TPU), a polyether urethane (PEU), a elastomeric polyurethane (EPU), a polyolefin elastomers (POE), a silicone rubber, and a combination of two or more thereof, for example, thermosetting polymer may be a polyurethane reactive (PUR) adhesive.

24. The bra cup of any preceding claim, wherein the cup structure is formed from a polyurethane foam, for example, a moulded polyurethane foam.

25. The bra cup of any one of the claims 1 to 23, wherein the cup structure is farmed from a fabric comprising one or more yarns selected from the group consisting of a polyurethane yarn (e.g. elastane), a polyester yarn, a polyamide yarn (e.g. nylon), cotton yarn, silk yarn, and a combination of two or more thereof, optionally wherein the fabric is a lace fabric, a spacer fabric (e.g. a fabric comprising at least fabric layers connected by spacer yarn and / or pile yarns), or a satin.

26. The bra cup of claim 25, wherein the cup structure is formed by a knit pattern and / or by moulding of the fabric.

27. The bra cup of any preceding claim, wherein the elongate supporting element has a thickness and / or width that varies along the length of the elongate supporting element, for example, the central region may have a thickness and / or width that is greater than that of the first and / or second peripheral regions.

28. The bra cup of any preceding claim, wherein the elongate supporting element is substantially U-shaped.

29. The bra cup of any preceding claim, wherein the elongate supporting element and edge portion of the cup structure are together configured to provide support to a breast of a human user.

30. A method of manufacturing a bra cup, the method comprising:(a) providing a substrate;(b) providing a specification of an elongate supporting element to a printer; and(c) printing the elongate supporting element onto the substrate to provide the bra cup,wherein step (c) comprises dispensing a thermosetting polymer formulation onto the substrate using drop-on-demand printing, extrusion, spraying, injection moulding, or depositing.

31. The method according to claim 30, wherein step (c) comprises dispensing the thermosetting polymer formulation at a barrel temperature of about 120 °C to about 170 °C, a nozzle temperature of about 180 °C to about 230 °C, a processing speed of about 1000 dots / min to about 10000 dots per minute, and a valve on time of about 2 ms to about 10 ms.

32. The method according to claim 30 or 31 , wherein step (c) comprises dispensing the thermosetting polymer formulation at a barrel temperature of about 130 °C, a nozzle temperature of about 190 °C, a processing speed of about 5000 dots per minute, and a valve on time of about 2.6 ms.

33. The method according to any one of claims 30 to 32, wherein the substrate is a polyurethane foam, a mesh, a membrane, or a fabric.

34. The method according to claim 33, wherein the method comprises a step of subjecting the substrate following step (c) to a moulding process to form a cup structure having concave inner surface and a convex outer surface.

35. The method according to any one of claims 30 to 32, wherein the substrate provided in step (a) is a polyurethane foam and comprises a cup structure, wherein the cup structure is formed by moulding of the polyurethane foam.

36. The method according to any one of claims 30 to 32, wherein the substrate provided in step (a) is a fabric and comprises a cup structure, wherein the cup structure is formed by a knit pattern and / or by moulding of the fabric.

37. The method according to any one of claims 30 to 34 and 36, wherein the substrate is a fabric comprising one or more yarns selected from the group consisting of a polyurethane yarn (e.g. elastane), a polyester yarn, a polyamide yarn (e.g. nylon), cotton yarn, silk yarn, and a combination of two or more thereof, optionally wherein the fabric is a lace fabric, a spacer fabric (e.g. a fabric comprising at least fabric layers connected by spacer yarn and / or pile yarns), or a satin.

38. The method according to any one of claims 30 to 37, wherein the elongate supporting element has a thickness and / or width that varies along the length of the elongate supporting element.

39. The method according to any one of claims 30 to 38, wherein the thermosetting polymer formulation comprises a polyurethane reactive (PUR) adhesive.

40. The method according to any one of claims 30 to 39, further comprising a step (d) of curing the thermosetting polymer formulation after it has been printed onto the substrate.

41. The method according to any one of claims 30 to 40, wherein the elongate supporting element is as defined in any one of claims 1 to 29.

42. The method according to any one of claims 30 to 41 , wherein the bra cup is according to any one of claims 1 to 29.

43. A bra cup obtained by the method according to any one of claims 30 to 42.

44. A garment comprising the bra cup of any one of claims 1 to 29 or 43.

45. The garment of claim 44, wherein the garment is a bra, bralette, cut panel, sportswear, swimwear, or finished garment.

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