BRA pads

Abstract

The present invention relates to a pad for a breast supporting garment, the pad comprising a top fabric layer, a foam panel, and a fabric lining layer, wherein: at least one of the top fabric layer and fabric lining layer has a neckline edge, an under-breast edge, and an arm edge together corresponding to an outer perimeter of the pad, the foam panel has a graduated thickness that decreases in thickness to a peripheral edge of the foam panel, the top fabric layer having an inner surface coupled to a top surface of the foam panel, and the fabric lining layer having an inner surface coupled to the bottom surface of the foam panel and to the inner surface of the top fabric layer, thereby sealing the peripheral edge of the foam panel between the inner surface of the top fabric layer and the inner surface of the fabric lining layer. The invention also relates to a method of manufacturing the pad, and a breast supporting garment comprising the pad.

Description

[0001] BRA PADS

[0002] FIELD OF INVENTION

[0003] This application relates to pads for a garment, in particular bra pads, and methods of creating them.

[0004] BACKGROUND

[0005] In the intimates bra cup space, there are different levels of lining used to give the wearer different levels of support and coverages. Of these different levels, the unlined bra cups refer to cups that contain only fabric without any foam layers, like in bralettes. This type of cups provides the wearer with comfort, breathability and a light level of shaping, but do not provide adequate support or nipple concealment.

[0006] Lightly lined bra cups refer to cups made with foam layers to add a medium level of support, higher level of shaping, and modesty with nipple concealment. The cups can contain foams of different thickness to provide different levels of support. However, these lightly lined cups are heavier, denser and has less breathability than unlined bra cups. It is particularly uncomfortable to wear such cups in humid weather.

[0007] Therefore, there is a need for an improved bra cup, and a method of making it.

[0008] SUMMARY OF INVENTION

[0009] The invention seeks to provide a solution to the problem above, by providing a wearer with the lightweight comfort and breathability of an unlined bra and the support and nipple concealment of a lightly lined bra. The speciality of this invention is also that the edge of the shaved foam will not be felt or seen by the wearer or through any outer garments. This bra pad will provide superior support or nipple concealment as lightly lined bra cups with seamlessly graduated foam edges.

[0010] Foam panels with shaved edges thinning out to nothing, laminated on to nylon / spandex fabric liners on both sides. The shaved foam is placed in different configurations into a panel that is then molded into a cup. The foam is laminated to the liners with a spray glue lamination method and the portions of the cups without the foam section is greater than the shaved foam cookie. Essentially adding foam placement support to an unlined bra cup. The foam placements are designed to add different functions including but not limited to nipple concealment, side support, shaping and contouring the natural breast shape to an otherwise unlined fabric bra cup.

[0011] According to the placement of the shaved foam cookie, the function of the pad will be changed.

[0012] Further, the addition of either a TPE adhesive or PU dispersion print will enhance the support, nipple concealment and smoothness of the cup.

[0013] 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.

[0014] 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.

[0015] The term “pad” or ““bra pad” as used herein refers a component of a brassiere, bralette, or similar garments for supporting a breast. The pad as defined herein may comprise 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 or foam material. The pad can be either a single bra pad (to support a breast), or a one-piece bra pad (to support cover two breasts).

[0016] The term “fabric” refers to a flexible material formed by a network of natural or artificial fibres, such as a yarn or thread. This network of fibres may be created in any suitable manner, such as by weaving, knitting, spreading, crocheting, bonding, etc. Yarn is produced by spinning raw fibres of a natural or artificial fiber to produce long strands.

[0017] The term "coupled" as used herein refers to elements that are connected or attached by stitching, bonding, fastening, adhering etc. The term “attached” is to be considered as meaning “fixedly attached”, unless stated otherwise. Many methods for attaching elements together are known in the art, and include, for example, adhesive bonding (e.g. laminate bonding), pressure bonding, thermal bonding, ultrasonic bonding, mechanical fastening, and the like. The means by which the elements are attached is preferably heat stable up to at least 40 °C or 190 °C, which may enable the bra to be washed and / or dried multiple times.

[0018] When used herein, the term “laminate” is intended to refer to a layer that couples two material together, such as the attachment to two (or more) layers of material together by any suitable lamination method. Examples of suitable lamination methods include, but are not limited to spray lamination (e.g. spraying a glue onto one or both surfaces of the materials that are to be laminated together) or hot melt lamination. It will be appreciated, that lamination generally requires the presence of an adhesive of some form to create the attachment between the component materials. Any suitable adhesive may be used to create the attachment and is not particularly limited herein, except that it should form a bond. Suitable adhesives may be derived from polyurethane, polyamide, co-polyamide, polyester, co-polyester, acrylic adhesives and combinations thereof. Particular examples of adhesives that may be mentioned herein include heat activated adhesives that may be provided as layers, i.e. a heat activated layer adhesive (e.g. web adhesive).

[0019] The term “top fabric layer” as used herein encompasses the term “outer fabric layer” as used in the drawings disclosed herein. The term “fabric lining layer” as used herein encompasses the term “inner fabric layer” as used in the drawings disclosed herein.

[0020] The term “foam panel” as used herein encompasses the terms “foam” and “foam cookie” as used herein. The term “foam area” refers to a portion of a “foam panel” and the like.

[0021] The term “lined portion” refers to a portion of a bra pad that contains a foam. The term “unlined portion” refers to a portion of a bra pad that does not substantially contain a foam. The unlined portion can contain a portion of a foam as the foam area tapers from the lined portion to the unlined portion.

[0022] The term “thermoplastic material” refers to a polymer that can be softened through heating and processed using methods such as extrusion, injection, moulding, thermoforming, and blow moulding. The thermoplastic can be an elastomer that offer flexibility and softness, while avoiding deformation from washing and movement. Examples of thermoplastics include but are not limited to polyethylene, polypropylene, PVC, TPE, and polyurethane.

[0023] In a first aspect, the invention provides a pad for a breast supporting garment, the pad comprising a top fabric layer, a foam panel, and a fabric lining layer, wherein: at least one of the top fabric layer and fabric lining layer has a neckline edge, an under-breast edge, and an arm edge together corresponding to an outer perimeter of the pad, the foam panel has a graduated thickness that decreases in thickness to a peripheral edge of the foam panel, the top fabric layer having an inner surface coupled to a top surface of the foam panel, and the fabric lining layer having an inner surface coupled to the bottom surface of the foam panel and to the inner surface of the top fabric layer, thereby sealing the peripheral edge of the foam panel between the inner surface of the top fabric layer and the inner surface of the fabric lining layer.

[0024] Advantageously, the pad can provide a desired level of support at desired areas for a wearer, while providing breathability and comfort.

[0025] In an embodiment, the foam panel comprises a thermoplastic material.

[0026] Advantageously, thermoplastics are easily molded and make manufacturing cost-effective. The thermoplastic may be an elastomer, thus providing stretchability and flexibility to facilitate movement of the wearer. This will improve comfort for the wearer.

[0027] In an embodiment, the thermoplastic material is a polyurethane foam.

[0028] Advantageously, polyurethane does not irritate the skin, and is suitable for use in a garment worn directly on the skin.

[0029] In an embodiment, the graduated thickness of the foam panel decreases in thickness from a central portion of the foam panel to the peripheral edge of the foam panel, wherein the peripheral edge of the foam panel forms an outer perimeter of the foam panel.

[0030] Advantageously, the gradual transition between the edge of the foam panel reduces visibility of the bra pad and reduces visibility of the undergarment beneath clothing, thus providing modesty and comfort for the wearer.

[0031] In an embodiment, the central portion of the foam panel is positioned between the top fabric layer and the fabric lining layer such that, when the pad is in use as a component of a breast supporting garment, the central portion of the foam panel aligns with a nipple of a wearer of the breast supporting garment.

[0032] Advantageously, the central portion conceals the nipple and provides modesty.

[0033] In an embodiment, the peripheral edge of the foam panel, the top fabric layer, and the fabric lining layer together form a seamless transition region wherein the inner surface of the fabric lining layer transitions from being coupled to the bottom surface of the foam panel to being coupled to the inner surface of the top fabric layer.

[0034] Advantageously, the seamless transition region provides a smooth surface beneath clothing, less irritation on the skin, and more comfort for the wearer. In an embodiment, the graduated thickness of the foam panel decreases in thickness from a first peripheral edge of the foam panel to a second peripheral edge of the foam panel.

[0035] Advantageously, the graduated thickness provides a smooth contour for the bra pad beneath clothing, and provides support at desired areas.

[0036] In an embodiment, the foam panel is positioned between the top fabric layer and the fabric lining layer such that the first peripheral edge of the foam panel aligns with an under-breast region of a wearer of the breast supporting garment.

[0037] Advantageously, this placement of the peripheral edge of the foam provides support from the under-breast of a wearer to present sufficient lift and comfort.

[0038] In an embodiment, the second peripheral edge of the foam panel, the top fabric layer, and the fabric lining layer together form a seamless transition region wherein the inner surface of the fabric lining layer transitions from being coupled to the bottom surface of the foam panel to being coupled to the inner surface of the top fabric layer.

[0039] Advantageously, the seamless transition region provides a smooth surface beneath clothing, less irritation on the skin, and more comfort for the wearer.

[0040] In an embodiment, the pad comprises a cup structure having a concave inner surface and a convex outer surface, wherein the concave inner surface is configured to correspond to a chest region of a wearer of a breast supporting garment comprising the pad.

[0041] Advantageously, the concave inner surface can accommodate a chest region of a wearer well, so that the bra pad is comfortable to wear.

[0042] In an embodiment, the top fabric layer and the fabric lining layer are independently formed from 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 top fabric layer and fabric lining layer are each independently 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.

[0043] Advantageously, different fabrics can be used for different purposes. For example, satin may be used to provide a smooth silky texture. Cotton, silk, or other natural fibres may be used to minimise skin irritation and maximise sweat absorption. Synthetic fibres such as polyester or a cotton-polyester mix, may be used to improve sweat-wicking properties to keep the skin dry.

[0044] In an embodiment, the top fabric layer and the fabric lining layer are each formed from polyurethane yarns (e.g. elastane), polyamide yarns (e.g. nylon), or a combination of polyurethane yarns (e.g. elastane) and polyamide yarns (e.g. nylon). Advantageously, these fabric materials are stretchable, machine washable, and breathable, thus improving comfort.

[0045] In an embodiment, the top surface of the foam panel and the inner surface of the top fabric layer are coupled together by an adhesive, the bottom surface of the foam panel and the inner surface of the fabric lining layer is coupled together by an adhesive, and the inner surface of the top fabric layer and the inner surface of the fabric lining layer are coupled together by an adhesive.

[0046] Advantageously, the adhesive maintains secure attachment of the layers to prevent the layers rubbing against each other and moving out of position.

[0047] In an embodiment, the adhesive is a lamination adhesive, a thermoplastic elastomer (TPE) adhesive, or a combination thereof.

[0048] Advantageously, a lamination adhesive can be applied quickly to large areas of fabric, thus making manufacturing fast and cost-effective. A thermoplastic elastomer provides stretchability, while being machine washable. The adhesive may be applied by spraying or brushing.

[0049] In an embodiment, the adhesive that couples together the foam panel, top fabric layer and fabric lining layer is a lamination adhesive, for example a polyurethane reactive (PUR) adhesive.

[0050] Advantageously, a polyurethane reactive adhesive is easy to apply, is weatherproof, does not cause skin irritation in a fabric worn directly on the skin, and forms a strong durable bond on the fabric.

[0051] In an embodiment, the adhesive that couples together the foam panel, top fabric layer and fabric lining layer is a TPE adhesive.

[0052] Advantageously, a TPE adhesive adhesive is easy to apply, does not cause skin irritation in a fabric worn directly on the skin, is weatherproof, and forms a strong durable bond on the fabric.

[0053] In an embodiment, the adhesive that couples together the top surface of the foam panel and the inner surface of the top fabric layer is a lamination adhesive, and the adhesive that couples together the bottom surface of the foam panel and the inner surface of the fabric lining layer, and the inner surface of the top fabric layer and the inner surface of the fabric lining layer, is a TPE adhesive layer.

[0054] Advantageously, a TPE adhesive adhesive is easy to apply, does not cause skin irritation in a fabric worn directly on the skin, is weatherproof, and forms a strong durable bond on the fabric. In an embodiment, the pad comprises a polyurethane resin layer disposed on the top surface of the foam panel, and optionally disposed on the inner surface of the top fabric layer or the inner surface of the fabric lining layer, or both the inner surface of the top fabric layer and the inner surface of the fabric lining layer.

[0055] Advantageously, a polyurethane resin layer is a protective coating that enhances durability and resistance to water and chemical damage. The resulting pad will have high wash durability.

[0056] In an embodiment, the polyurethane resin layer has the form of a plurality of discrete deposits of polyurethane resin each disposed on the top surface of the foam panel, and optionally disposed on the inner surface of the top fabric layer.

[0057] Advantageously, the polyurethane resin layer provides nipple concealment and support while having superb durability.

[0058] In an embodiment, the foam panel spans less than or equal to about 65% of the total two- dimensional surface area of the pad, for example from about 15% to about 65%, or about 30% to about 40% of the total two-dimensional surface area of the pad.

[0059] Advantageously, the foam panel area can be adjusted to suit desired coverage levels.

[0060] In a second aspect, the invention provides for a method of manufacturing the pad, the method comprising: (a) shaving or cutting a foam material to provide a foam panel having a graduated thickness; and (b) sealing a portion or the entirety of the foam panel between a top fabric layer and a fabric lining layer to provide an intermediate pad assembly; and (c) optionally, subjecting the intermediate pad assembly to compression moulding to form the pad, wherein the compression moulding imparts a three-dimensional shape and / or variable thickness to the pad.

[0061] Advantageously, the graduated thickness enables a gradual seamless transition from the lined portion to unlined portion, to present a smooth outer contour not visible beneath a garment.

[0062] In an embodiment, the intermediate pad assembly is cut to a desired shape and / or the pad is cut to a desired shape following compression moulding.

[0063] Advantageously, the intermediate pad will be easily handled after cutting.

[0064] In an embodiment, the compression moulding imparts a cup structure to the pad, the cup structure having a concave inner surface and a convex outer surface, wherein the concave inner surface is configured to correspond to a chest region of a wearer of a breast supporting garment comprising the pad.

[0065] Advantageously, the concave inner surface can accommodate a chest region of a wearer well, so that the bra pad is comfortable to wear. In an embodiment, step (b) comprises: i) coupling a top surface of the foam panel to an inner surface of the top fabric layer; ii) coupling a bottom surface of the foam panel to an inner surface of the fabric lining layer; and iii) coupling the inner surface of the top fabric layer to the inner surface of the fabric lining layer; wherein, steps i) and ii) can be performed sequentially in any order or performed simultaneously.

[0066] In an embodiment, steps i) to iii) comprise applying a lamination adhesive to one or more of the foam panel, the top fabric layer, and the fabric lining layer, and optionally applying a TPE adhesive to one or more of the foam panel, the top fabric layer, and the fabric lining layer.

[0067] Advantageously, the adhesive maintains secure attachment of the layers to prevent the layers rubbing against each other and moving out of position. The layers are also easier to handle when coupled together.

[0068] In an embodiment, step (b) comprises before step i): applying a polyurethane resin layer to the top surface of the foam panel, and optionally to the inner surface of the top fabric layer.

[0069] Advantageously, the polyurethane resin layer provides additional support and durability, and makes the foam panel easier to handle for further processing.

[0070] In an embodiment, the polyurethane resin layer is applied to the foam panel and optionally to the top fabric layer by polyurethane dispersion printing.

[0071] Advantageously, the polyurethane resin layer provides nipple concealment and support while having superb durability.

[0072] In a third aspect, the invention provides for a breast supporting garment comprising the pad.

[0073] Advantageously, the garment comprising the pad can provide a desired level of support at desired areas for a wearer, while providing breathability and comfort.

[0074] In an embodiment, the breast supporting garment is a bra or bralette.

[0075] Advantageously, the bra or bralette can provide a desired level of support at desired areas for a wearer, while providing breathability and comfort.

[0076] BRIEF DESCRIPTION OF DRAWINGS

[0077] Fig. 1 A is a front view of a bra pad with a round shaved foam cookie.

[0078] Fig. 1 B is a side view of the bra pad of Fig. 1A.

[0079] Fig. 2A is a front view of a bra pad with a top cup shaved foam partial cup.

[0080] Fig. 2B is a cross section of Fig. 2A. Fig. 2C is a front view of a bra pad with a side sling shaved foam cookie at side cup.

[0081] Fig. 2D is a front view of a bra pad with a side to bottom sling shaved foam cookie.

[0082] Fig. 3A is a front view of a bra pad with a shaved foam nipple disk with a layer of TPE adhesive throughout the pad.

[0083] Fig. 3B is a cross section of Fig. 3A.

[0084] Fig. 4A is a front view of a bra pad with a shaved foam nipple disk with a graduated dispersion print on nipple disk area.

[0085] Fig. 4B is a cross section of Fig. 4A.

[0086] Fig. 5A is a front view of a bra pad with a shaved foam nipple disk with dispersion printing throughout the cup.

[0087] Fig. 5B is a cross section of Fig. 5A.

[0088] Fig. 6A is a plan drawing of a one-piece bra pad.

[0089] Fig. 6B is a plan drawing of a bra pad with more foam padding.

[0090] DETAILED DESCRIPTION

[0091] The foam panel present in the pad of the invention provides a region of the pad that is thicker than the rest of the pad. This thicker region may be positioned between the top fabric layer and fabric lining layer such that the pad provides concealment for a nipple region of a user of the pad. Additionally, or alternatively, the thicker region of the pad provided by the foam panel may be positioned such that the pad provides additional support to a breast of the user of the pad. For example, the foam panel may be positioned such that the thicker potion of the foam panel aligns with an under-breast region of a wearer of the breast supporting garment.

[0092] The design of the pad, in particular the foam panel, allows for the introduction of functionality to a pad such as concealment and / or support functionality whilst still providing a lightweight pad for use in a breast supporting garment. In certain examples, the pad may further comprise a thermoplastic elastomer (TPE) adhesive layer disposed between inner surface of the top fabric layer and the inner surface of the fabric lining layer, and / or the pad may further comprise a polyurethane (PU) resin layer disposed on the top surface of the foam panel, and optionally disposed on the inner surface of the top fabric layer. The TPE layer and / or PU resin layer can be included to provide additional concealment and / or support functionality to the pad. For example, the TPE adhesive layer and / or PU resin layer may be disposed on the surface of the top and / or bottom surfaces of the foam panel to enhance its concealment and / or support functionality. Additionally, or alternatively, the TPE adhesive layer and / or PU resin layer may be disposed on the surface of the top and fabric lining layer to enhance or improve the seamless transition region where the inner surface of the fabric lining layer transitions from being coupled to the bottom surface of the foam panel to being coupled to the inner surface of the top fabric layer. For example, the TPE adhesive layer and / or PU resin layer may be applied such that in the assembled pad there is no visible deviation in the top fabric layer or fabric lining layer formed where the inner surface of the fabric lining layer transitions from being coupled to the bottom surface of the foam panel to being coupled to the inner surface of the top fabric layer. The TPE adhesive layer and / or polyurethane resin layer may be disposed on the foam panel, top fabric layer, or the fabric lining layer as a plurality of discrete deposits or as a continuous layer.

[0093] These benefits are illustrated by the data in the below Examples.

[0094] EXAMPLES

[0095] Bra Pad and Variations

[0096] It will be appreciated that the bra pads shown in the drawings are examples, and the invention is not limited to these examples. The various features relating to the contour and shape of the foam cookie, placement of the lined and unlined portions, presence and placement of nipple disk, are interchangeable and can be combined to form different bra pads. An undergarment or garment can contain a combination of any of these bra pads according to a wearer’s needs.

[0097] Figs. 1A and 1 B show a bra pad 1 containing a nipple concealment shaved foam cookie 100 in a substantially center position that aligns with a wearer’s nipple when worn, with unlined fabric pad construction. The foam cookie is shaped to provide nipple concealment and modesty. The bra pad comprises a lightly lined portion 10 between two unlined portions 15. The lightly lined portion 10 comprises a foam area 1 1 adjacent to at least one segment of shaved graduating foam 12 that provides a seamless transition 13 from foam to fabric. The foam 12 may have a graduated thickness. Preferably, foam 1 is thickest around an area positioned to conceal a nipple, and decreases in thickness towards at least one peripheral edge. If there are multiple peripheral edges, the edges are referred to as first peripheral edge, second peripheral edge, etc. The foam area 11 is coated with adhesive lamination 14, 16. An outer suface of the foam area 1 1 adheres to an outer fabric layer 17 (also called “top fabric layer”), and an inner surface of the lightly lined foam area 1 1 adheres to an inner fabric layer 18 (also called “fabric lining layer”). The inner fabric layer 18 faces towards the body of a user when a garment containing the bra pad is worn. The outer fabric layer 17 faces outwards. Adhesive 14, 16 may be applied onto the foam and / or fabric, by spraying, brushing, depositing, or other suitable ways. At least one peripheral edge of the foam 12 may be sealed by the fabric layer.

[0098] Fig. 2A to 2D show bra pads containing shaved foam cookies that provide partial coverage, with unlined fabric pad construction. Fig. 2A and 2B show a bra pad 2 containing a top cup shaved foam cup 200, to provide bottom cup support with nipple concealment. The bra pad comprises a lightly lined portion 20 adjacent to an unlined portion 25. The lightly lined portion 20 comprises a foam area 21 adjacent to at least one segment shaved graduating foam 22 that provides a seamless transition 23 from foam to fabric. An outer face and an inner face of the foam area 21 is applied with adhesive lamination 24, 26 to adhere to an outer fabric layer 27 and an inner fabric layer 28 respectively. Fig. 2C shows a bra pad containing a side sling shaved foam cookie 201 at side cup, to provide side cup support. Fig. 2D shows a bra pad containing side to bottom sling shaved foam cookie 202, to provide side cup support with bottom cup lift.

[0099] Fig. 3A and 3B show a bra pad 5 containing a nipple concealment shaved foam cookie 500 with all over TPE adhesive lamination. The bra pad comprises a lightly lined portion 50 between two unlined portions 55. The lightly lined portion 50 comprises a lightly lined foam area 51 adjacent to at least one segment of shaved graduating foam 52 that provides a seamless transition 53 from foam to fabric. One face of the lightly lined foam area 51 is coated with a TPE adhesive layer 56. The other face of the lightly lined foam area 51 may be coated with a spray adhesive lamination 54 or a TPE adhesive layer 56. The lightly lined foam area 51 is adhered to an outer fabric layer 57 and an inner fabric layer 58.

[0100] Fig. 4A and 4B show a bra pad 6 containing a nipple concealment shaved foam cookie with dispersion printed nipple disk 600. The bra pad comprises a lightly lined portion 60 between two unlined portions 65. The lightly lined portion 60 comprises a lightly lined foam area 61 adjacent to at least one segment of shaved graduating foam 62 that provides a seamless transition 63 from foam to fabric. One face of the lightly lined foam area 61 is coated with a spray adhesive 66. The other face (e.g. outer face) of the lightly lined foam area 61 is adjacent to the dispersion nipple disk 600. The outer face may be adhered to the dispersion nipple disk 600, which is in turn adhered using an adhesive 64 to an outer fabric layer 67. An inner face of the lightly lined foam area 61 is adhered to an inner fabric layer 68.

[0101] Fig. 5A and 5B show a bra pad 7 containing a nipple concealment shaved foam cookie with dispersion printed nipple disk 700 and outer liner 701. The bra pad comprises a lightly lined portion 10 between two unlined portions 75. The lightly lined portion 70 comprises a lightly lined foam area 71 adjacent to at least one segment of shaved graduating foam 72 that provides a seamless transition 73 from foam to fabric. An outer face and an inner face of the lightly lined foam area 71 may be coated with a spray adhesive lamination 74, 76. The lightly lined foam area 71 is adhered to an outer fabric layer 77 and an inner fabric layer 78.

[0102] Fig. 6A shows a one-piece bra pad 8 comprising a lightly lined portion 800 adjacent an unlined portion 801. The unlined portion 801 forms the neckline edge, an under-breast edge, and an arm edge. The lightly lined portion 800 may support two breasts as a single piece. This version accommodates more foam padding, thus providing more support while having a smooth exterior surface beneath clothing. The unlined portion 801 may be a continuous piece of fabric, or a segmented piece, depending on the design requirements. The lined portion 800 may have a raw cut edge for more comfort.

[0103] Fig. 6B shows a bra pad 802 in which the lined portion comprises a substantial portion of the bra pad to provide more support to a breast.

[0104] Method of Making the Bra Pads of Fig 1A-3B

[0105] 1) The process of creating the above innovated cups begin by cutting out the foam cookies to the relevant shape.

[0106] 2) The cookie is then shaved from either one side or up to all sides using a specifically designed shaving plate to match the final cookie shape. The shaved foam cookies are kept aside until the lining fabrics are laid out.

[0107] 3) The Nylon / Spandex outer liner is taken and laid face side up on the assembly table. A transfer board is placed on top of the fabric and it is then flipped over and placed with the reverse side of the fabric facing upwards.

[0108] 4) A placement pattern piece is created marking the final cup block and the placement of the shaved foam cookie. This pattern is then laid on the outer liner fabric prepared in step 3.

[0109] 5) The foam cookie prepared in step 2 is laid on a transfer board and taken to the spray glue machine. A solvent based, heat active liquid adhesive is sprayed on to the flat surface of the cookie.

[0110] 6) The cookie is then transferred glue side down on to the Nylon / Spandex outer liner prepared in step 4 according to the predetermined placement.

[0111] 7) The placement pattern board is then taken out of the layered fabric / foam panel (Panel A).

[0112] 8) The layered fabric and foam cookie placement panel is taken to the spray glue machine and placed with the cookie being exposed to the top side. A solvent based, heat active liquid adhesive is sprayed on to the full panel. This panel is then moved to the assembly table.

[0113] 9) A second nylon / spandex fabric panel is then taken as the inner liner and placed on a transfer board with the reverse side of the fabric facing upwards.

[0114] 10) The fabric prepared in step 9 is transferred and layered on to panel A on the assembly table, the face side of the fabric facing upwards creating a 3 layer panel (Panel B).

[0115] 11 ) Panel B is then taken to the molding machine and molded as per required shape, depth and temperature to output a completed unlined pad with shaved foam support.

[0116] Method of Making the Bra Pads of Figs. 4A-5B

[0117] There are a few additional steps in these two pad options shown as underlined:

[0118] 1) The process of creating the above innovated cups begin by cutting out the foam cookies to the relevant shape.

[0119] 2) Cut panels are meticulously placed and aligned on the printing machine to ensure accurate application of the polyurethane (PU) dispersion printing.

[0120] 3) PU dispersion is printed onto the fabric and foam using precise machine settings and suitable formulations. The PU can be applied to provide the stretch control at required areas of the pad.

[0121] 4) Panels are carefully unloaded from the printing machine. They are then subjected to a curing process to set the PU dispersion to bond firmly to the printed surface.

[0122] 5) Printed foam panels are used to create thin foam cookies using special shaving techniques and advanced machinery.

[0123] 6) The shaved foam cookies are kept aside until the lining fabrics are laid out.

[0124] 7) The nylon / spandex outer liner is taken and laid face side up on the assembly table. A transfer board is placed on top of the fabric and it is then flipped over and placed with the reverse side of the fabric facing upwards.

[0125] 8) A placement pattern piece is created marking the final cup block and the placement of the shaved foam cookie. This pattern is then laid on the outer liner fabric prepared in step 7.

[0126] 9) The foam cookie prepared in step 6 is laid on a transfer board and taken to the spray glue machine. A solvent based, heat active liquid adhesive is sprayed on to the flat surface of the cookie. 10) The cookie is then transferred glue side down on to the Nylon / Spandex outer liner prepared in step according to the predetermined placement.

[0127] 11 ) The placement pattern board is then taken out of the layered fabric / foam panel (Panel A). 12) The layered fabric and foam cookie placement panel is taken to the spray glue machine and placed with the cookie being exposed to the top side. A solvent based, heat active liquid adhesive is sprayed on to the full panel. This panel is then moved to the assembly table.

[0128] 13) A second Nylon / Spandex fabric panel is then taken as the inner liner and placed on a transfer board with the reverse side of the fabric facing upwards.

[0129] 14) The fabric prepared in step 9 is transferred and layered on to panel A on the assembly table, the face side of the fabric facing upwards creating a 3 layer panel (Panel B).

[0130] 15) Panel B is then taken to the molding machine and molded as per required shape, depth and temperature to output a completed unlined pad with shaved foam support.

Claims

CLAIMS1 . A pad for a breast supporting garment, the pad comprising a top fabric layer, a foam panel, and a fabric lining layer, wherein: at least one of the top fabric layer and fabric lining layer has a neckline edge, an under-breast edge, and an arm edge together corresponding to an outer perimeter of the pad, the foam panel has a graduated thickness that decreases in thickness to a peripheral edge of the foam panel, the top fabric layer having an inner surface coupled to a top surface of the foam panel, and the fabric lining layer having an inner surface coupled to the bottom surface of the foam panel and to the inner surface of the top fabric layer, thereby sealing the peripheral edge of the foam panel between the inner surface of the top fabric layer and the inner surface of the fabric lining layer.

2. The pad of claim 1 , wherein the foam panel comprises a thermoplastic material.

3. The pad of claim 1 or 2, wherein the thermoplastic material is a polyurethane foam.

4. The pad of any one of claims 1 to 3, wherein the graduated thickness of the foam panel decreases in thickness from a central portion of the foam panel to the peripheral edge of the foam panel, wherein the peripheral edge of the foam panel forms an outer perimeter of the foam panel.

5. The pad of claim 4, wherein the central portion of the foam panel is positioned between the top fabric layer and the fabric lining layer such that, when the pad is in use as a component of a breast supporting garment, the central portion of the foam panel aligns with a nipple of a wearer of the breast supporting garment.

6. The pad of claim 4 or 5, wherein the peripheral edge of the foam panel, the top fabric layer, and the fabric lining layer together form a seamless transition region wherein the inner surface of the fabric lining layer transitions from being coupled to the bottom surface of the foam panel to being coupled to the inner surface of the top fabric layer.

7. The pad of any one of claims 1 to 3, wherein the graduated thickness of the foam panel decreases in thickness from a first peripheral edge of the foam panel to a second peripheral edge of the foam panel.

8. The pad of claim 7, wherein the foam panel is positioned between the top fabric layer and the fabric lining layer such that the first peripheral edge of the foam panel aligns with an under-breast region of a wearer of the breast supporting garment.

9. The pad of claim 8, wherein the second peripheral edge of the foam panel, the top fabric layer, and the fabric lining layer together form a seamless transition region wherein the inner surface of the fabric lining layer transitions from being coupled to the bottom surface of the foam panel to being coupled to the inner surface of the top fabric layer.

10. The pad of any one of the preceding claims, wherein the pad comprises a cup structure having a concave inner surface and a convex outer surface, wherein the concave inner surface is configured to correspond to a chest region of a wearer of a breast supporting garment comprising the pad.11 . The pad of any one of the preceding claims, wherein the top fabric layer and the fabric lining layer are independently formed from 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 top fabric layer and fabric lining layer are each independently 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.

12. The pad of claim 11 , wherein the top fabric layer and the fabric lining layer are each formed from polyurethane yarns (e.g. elastane), polyamide yarns (e.g. nylon), or a combination of polyurethane yarns (e.g. elastane) and polyamide yarns (e.g. nylon).

13. The pad of any one of the preceding claims, wherein the top surface of the foam panel and the inner surface of the top fabric layer are coupled together by an adhesive, the bottom surface of the foam panel and the inner surface of the fabric lining layer are coupled together by an adhesive, and the inner surface of the top fabric layer and the inner surface of the fabric lining layer are coupled together by an adhesive.

14. The pad of claim 13, wherein the adhesive is a lamination adhesive, a thermoplastic elastomer (TPE) adhesive, or a combination thereof.

15. The pad of claim 13, wherein the adhesive that couples together the foam panel, top fabric layer and fabric lining layer is a lamination adhesive, for example a polyurethane reactive (PUR) adhesive.

16. The pad of claim 13, wherein the adhesive that couples together the foam panel, top fabric layer and fabric lining layer is a TPE adhesive.

17. The pad of claim 13, wherein the adhesive that couples together the top surface of the foam panel and the inner surface of the top fabric layer is a lamination spray adhesive, and the adhesive that couples together the bottom surface of the foam panel and the inner surface of the fabric lining layer, and the inner surface of the top fabric layer and the inner surface of the fabric lining layer, is a TPE adhesive layer.

18. The pad of any one of the preceding claims, wherein the pad comprises a polyurethane resin layer disposed on the top surface of the foam panel, and optionally disposed on the inner surface of the top fabric layer or the inner surface of the fabric lining layer, or both the inner surface of the top fabric layer and the inner surface of the fabric lining layer.

19. The pad of claim 18, wherein the polyurethane resin layer has the form of a plurality of discrete deposits of polyurethane resin each disposed on the top surface of the foam panel, and optionally disposed on the inner surface of the top fabric layer.

20. The pad of any one of the preceding claims, wherein the foam panel spans less than or equal to about 80% of the total two-dimensional surface area of the pad, such as from about 15% to about 80%, from about 15% to about 65%, about 30% to about 40% of the total two-dimensional surface area of the pad.21 . A method of manufacturing the pad of any one of claims 1 to 20, the method comprising: (a) shaving or cutting a foam material to provide a foam panel having a graduated thickness; and(b) sealing a portion or the entirety of the foam panel between a top fabric layer and a fabric lining layer to provide an intermediate pad assembly; and(c) optionally, subjecting the intermediate pad assembly to compression moulding to form the pad, wherein the compression moulding imparts a three-dimensional shape and / or variable thickness to the pad.

22. The method of claim 21 , wherein the intermediate pad assembly is cut to a desired shape and / or the pad is cut to a desired shape following compression moulding.

23. The method of claim 21 or 22, wherein the compression moulding imparts a cup structure to the pad, the cup structure having a concave inner surface and a convex outer surface, wherein the concave inner surface is configured to correspond to a chest region of a wearer of a breast supporting garment comprising the pad.

24. The method of any one of claims 21 to 23, wherein step (b) comprises: i) coupling a top surface of the foam panel to an inner surface of the top fabric layer; ii) coupling a bottom surface of the foam panel to an inner surface of the fabric lining layer; and iii) coupling the inner surface of the top fabric layer to the inner surface of the fabric lining layer; wherein, steps i) and ii) can be performed sequentially in any order or performed simultaneously.

25. The method of claim 24, wherein steps i) to iii) comprise applying a lamination spray adhesive to one or more of the foam panel, the top fabric layer, and the fabric lining layer, and optionally applying a TPE adhesive to one or more of the foam panel, the top fabric layer, and the fabric lining layer.

26. The method of any one of claims 21 to 25, wherein step (b) comprises before step i): applying a polyurethane resin layer to the top surface of the foam panel, and optionally to the inner surface of the top fabric layer.

27. The method of claim 26, wherein the polyurethane resin layer is applied to the foam panel and optionally to the top fabric layer by polyurethane dispersion printing.

28. A breast supporting garment comprising the pad of any one of claims 1 to 20.

29. The breast supporting garment of claim 28, wherein the breast supporting garment is a bra or bralette.

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