Bra including compressed support zones

Abstract

An upper torso garment, such as a bra, includes a front portion made from three layers: an outer mesh layer, a molded foam middle layer, and an inner liner layer. The molded foam has contoured breast covering portions with vertically oriented channels and a series of apertures for breathability. Selected zones of the foam are compressed to increase density and provide targeted support, while other zones remain uncompressed for comfort and flexibility.

Description

BRA INCLUDING COMPRESSED SUPPORT ZONESFIELD OF THE INVENTION

[0001] Aspects herein relate to a bra comprising compressed portions configured to cradle the breasts of a wearer and a method of manufacturing lire bra comprising compressed portions.BACKGROUND OF THE INVENTION

[0002] Traditional bras, including sport bras, utilize different materials and constructions to provide a particular level of uniform compression to the chest of the wearer. Some bras providing higher compression and support are desired to uniformly restrict movement of the breasts of the wearer, however, these bras fail to prevent increased breast movement observed during an extended course of a particular activity, such as running.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Examples of aspects herein are described in detail below with reference to the attached drawings figures, wherein:

[0004] FIG. 1A illustrates an example bra comprising holes and channels in an as- worn configuration.

[0005] FIG. IB illustrates an example bra without holes and channels in an as- worn configuration

[0006] FIG. 2 illustrates an exploded view of the layered construction of tire front portion of the garment.

[0007] FIG. 3 illustrates a front view of an example bra comprising holes and channels.

[0008] FIGS. 4 A and 4B illustrate a comparison of a molded foam layer before and after mechanical compression, respectively.

[0009] FIGS. 5 A and 5B illustrate cross-sectional views of a molded pad portion of the bra before and after mechanical compression, respectively.

[0010] FIG. 6 illustrates a flow diagram of an example method of manufacturing a bra.DETAILED DESCRIPTION OF THE INVENTION

[0011] The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to tire ones described in this document, in conjunction with oilier present or future technologies. Moreover, although the terms “step” and / or “block” might be used herein to identify different elements of methodsemployed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

[0012] Bras designed for athletic activities, such as running or high-impact training, typically provide uniform compression to minimize breast movement. However, such uniform compression often prioritizes immobility over comfort, leading to wearer discomfort over extended periods. Conventional sports bras fail to address the biomechanical and dynamic support needs of the body during activity. Specifically, uniform compression can restrict breathing, cause pressure buildup, and still allow for undesired oscillation of breast tissue over time.

[0013] Moreover, traditional bras rely on thick, heavy materials to achieve compression, which adds weight and reduces breathability — both of which negatively impact athletic performance. These designs also fail to account for the directional forces acting on the body during movement, offering no targeted reinforcement in high-stress zones or functional structuring to accommodate anatomical contours. As such, wearers often experience discomfort, overheating, and progressive loss of support as physical activity continues.

[0014] In contrast, the present disclosure provides a multi-layer upper torso garment that includes injection-molded foam with localized compression zones, vertically oriented channels, and integrated apertures. These features are selectively designed to improve breathability, directional stretch, and anatomical support during atiiletic use. The garment includes compressed zones located in the foam layer along the lateral and inferior regions of each breast cup to increase support where it is needed most, while non-compressed zones in the center region improve flexibility and comfort. The vertically oriented channels permit greater lateral stretch while reducing vertical elongation, resulting in directional control of material deformation during motion. Apertures formed through die foam layer enhance airflow, reducing heat and moisture buildup against die skin during activity.

[0015] At a high level, aspects herein are directed to a bra having at least three layers. In aspects, the bra has an exterior, outer-facing layer that is visible from a viewpoint facing a wearer of the bra when the bra is in an as-worn configuration (e.g., when the bra is donned by the wearer). In aspects, the bra has an interior, inner-facing layer that may contact the skin of the wearer in die as-worn configuration. In aspects, positioned between the exterior layer and the interior layer is a middle layer of the bra. In aspects, the three layers comprise a skin-facing inner liner, an injection-molded foam middle layer, and an outer mesh layer. The middle layer is molded to form contoured breast covering portions, channels, and through-holes. The foam initially has a uniform composition and thickness, widi specific zones mechanically compressed after molding to increase density. These zones are selected to provide localized support without requiring uniform material stiffness throughout. It is contemplated that the foam material is a stretchable, open-cell polyurethane, contributing to lightweight and breathable performance.

[0016] In example aspects, the middle foam layer is contoured to conform to the anatomical shape of the breasts and includes areas of varying thickness and density. The foam includes a sling-like structure that supports the underside of each breast, integrated into tire mold during the initial injection molding step. The lateral sides and bottom edges of each breast covering portion are selectively compressed to increase foam density and create reinforced zones for structural support. The center region between the breast cups and upper zones remains uncompressed to maintain comfort and accommodate movement.

[0017] In example aspects, the vertically oriented channels in the foam allow for enhanced stretch across the chest (e.g., in the lateral direction) while limiting vertical stretch that could lead to breast displacement during running. Additionally, the orientation and placement of the apertures within the channels promote airflow and increase breathability during physical exertion. These features work together to deliver targeted performance benefits — namely, increased lateral and inferior support, reduced material weight, and improved comfort over long durations of wear.

[0018] A method of manufacturing the garment includes injection molding a foam layer using a mold that defines breast-shaped contours, vertically oriented channels, and apertures. A mesh outer layer and a liner inner layer are aligned with tire molded foam layer. An adhesive is applied to one or more of the layers. The layers are then bonded together under pressure to form a unified laminate. During this bonding step, selected regions of tire molded foam layer are mechanically compressed, increasing the density of those regions while maintaining the original thickness and density in adjacent, uncompressed areas.

[0019] As used herein, tire term “bra” encompasses any structure configured to be worn around a wearer’s torso and at least partially cover the wearer’s breasts. Although aspects herein are discussed with respect to a bra, it is understood that tire disclosed technology is not limited to a bra and may be applied to any upper-torso garment used to support breast tissue, such as camisoles, swimwear, tank tops, or other garments with built-in breast support.

[0020] As used herein, the term “foam” refers to an open-cell polyurethane material that is moldable and capable of being mechanically compressed. The foam may initially exhibit a substantially uniform composition and density prior to selective compression in one or more zones.

[0021] As used herein, the term “compressed” or “compression” with respect to a foam zone refers to mechanical compaction that reduces a thickness of the foam and increases its density relative to an adjacent, non-compressed region. Such compression may be localized and may result in differential performance characteristics (e.g., stiffness or support) between zones.

[0022] As used herein, the term “channel” refers to a groove or recessed feature formed in a surface of the molded foam layer during the injection molding process. Channels described herein are generally oriented vertically when the garment is worn and may vary in depth along their length. In some aspects,the channels exhibit a depth gradient that corresponds to variations in the thickness of the molded foam layer. Channels are distinct from apertures in that they do not extend through the entire thickness of the foam layer.

[0023] As used herein, the term “aperture" refers to an opening that extends entirely through the thickness of the foam layer and is distinct from a channel. Apertures may be circular, oval, or irregularly shaped and are provided for increased breathability and ventilation.

[0024] As used herein, the term “zone” refers to a localized region of tire foam layer that is structurally or materially distinct from another region. For example, a “first zone” may refer to a compressed area of increased density while a “second zone” may refer to an uncompressed or less compressed region. Zones may differ in thickness, density, flexibility, or other physical characteristics.

[0025] As used herein, the term “molded” refers to the shaping of foam using an injection mold prior to any compression step. A “molded” shape may include breast covering contours, channels, apertures, or variable thickness features defined by the mold cavity.

[0026] Positional terms used when describing the bra, such as front, sides, back, superior, inferior, top, bottom, upper, lower, lateral, medial, right, left, interior, exterior, inner-facing, and outer-facing and the like, are used with respect to the bra being worn as intended with the wearer standing upright such that tire lower portion of the bra extends around the wearer’s torso and the upper portion of the bra is positioned generally over the wear’ s chest. Additionally, the front portion of the bra is configured to at least partially cover the wearer’s breasts while tire back portion is configured to at least partially cover the wearer’s back. Shoulder straps are configured to extend over the wearer’s shoulders from the front portion to the back portion and at least partly define openings through which the wearer’s arms extend and an opening through which tire wearer’s head and neck extend. It should be understood, however, that use of positional terms do not depend on tire actual presence of a human being for interpretative purposes.

[0027] Additionally, there are various numerical measurements provided herein. Unless indicated otherwise, the term “about” or “substantially” with respect to a measurement means within ± 10% of the indicated value. Further, unless indicated otherwise, all measurements provided herein are with respect to the bra being in a resting state (i.e., a non-stretched) at standard ambient temperature and pressure (298.15 K and 100 kPa).

[0028] FIGS. 1A and IB illustrate two configurations of an example bra 100 in an as-worn configuration. The bra 100 includes a front portion 102 configured to cover at least a portion of the wearer’s chest, including the breasts, and a back portion 104 that extends around and covers at least a portion of the wearer’s back. The front portion 102 and back portion 104 are joined at a first side 106 and a second side 108, located on generally opposite lateral sides of the bra 100.

[0029] In aspects, a first shoulder strap 110 and a second shoulder strap 112 may extend from die front portion 102 to the back portion 104, generally over the shoulders of the wearer. The first and second shoulder straps 110, 112 help define a pair of arm openings on either side of tire bra and a head opening between them. The straps may attach at defined shoulder edges and may be fixed or adjustable in length. In various implementations, tire straps may be formed with seams, bonding regions, or as edgeless components for comfort.

[0030] The bra 100 may also include a band 114 that extends along a lower edge of the front portion 102 and back portion 104 and defines a bottom edge 116 of the bra. The band 114 is configured to sit below the bust and may include an elastic structure or structural reinforcement to secure the bra to the torso. In some aspects, the band 114 is integrally formed with the body of the bra, while in others it is separately formed and attached using sewing, bonding, or lamination techniques.

[0031] In some embodiments, the back portion 104 may include one or more closure mechanisms (not shown), such as hook-and-eye closures, zippers, or snaps, to enable the bra to be opened and secured. In other implementations, the bra may be pullover-style and lack discrete closures. The bra 100 may also include terminal boundaries such as a neckline edge 118, a first underarm edge 120, and a second underarm edge 122, which may be finished using hems, bonding, or seamless transitions depending on the construction.

[0032] FIG. 1A illustrates an exterior view of the bra 100 with channels and apertures visible on the front portion 102. These features may be visible through a mesh outer layer and are associated with a molded foam structure described in more detail in later figures. FIG. IB illustrates an alternative configuration in which the channels and apertures are either not present or not externally visible, such as when hidden beneath a thicker fabric or when the outer layer lacks transparency.

[0033] FIG. 2 illustrates an exploded view 200 of an example bra (e.g., bra 100 from FIGS 1 A and IB), showing the layered construction of tire front portion 102 of tire garment. As shown, the bra includes an outer layer 202, a middle layer 204, and an inner layer 206. These layers correspond respectively to an outer-facing mesh layer (e.g., outer layer 202), a molded foam layer (e.g., middle layer 204), and an inner-facing liner layer (e.g., inner layer 206) in the assembled bra. In the as-worn configuration, the layers 202, 204, 206 are joined to form a unified laminate that provides structural support, directional flexibility, and wearer comfort. The exploded configuration in FIG. 2 is presented for explanatory purposes only, and in the final product, the layers are bonded or laminated together as described herein.

[0034] In aspects, the outer layer 202 is a mesh or stretch textile material configured to form the exterior surface of the bra 100. The outer layer 202 may extend across a front portion of the garment and conform to the contoured surface of the underlying middle layer 204 when assembled. In some implementations, the outer layer 202 is bonded to an outward-facing surface 208 of the middle layer204 using adhesive applied across at least a portion of tire outward-facing surface 208 area. It is contemplated that the mesh construction of the outer layer 202 permits airflow through tire garment and allows apertures formed in tire middle layer 204 to remain exposed for ventilation.

[0035] In aspects, the middle layer 204 comprises a foam layer formed of a uniform open-cell polyurethane material using an injection molding process. Although foam is used in this context, and may or may not be injection molded, in other aspects the middle layer 204 may comprise a different compressible material, such as a gel-based polymer, thermoplastic elastomer (TPE), memory foam, natural latex, or a multilayer spacer fabric. As shown in FIG. 2, die middle layer 204 includes a contoured shape defining a first breast covering portion and a second breast covering portion, configured to align with die anatomy of the wearer.

[0036] The inner layer 206 may comprise a textile liner configured to contact the skin of the wearer in the as-worn configuration. In aspects, the inner layer 206 comprises a polyester or moisture-wicking material to enhance comfort and breathability. The inner layer 206 is joined to an inward-facing surface 210 of the middle layer 204 using adhesive applied across all or a portion of the inward-facing surface 210 area. When assembled, the inner layer 206 conforms to the inward-facing surface 210 of the molded cups, preserving the contoured shape while providing a smooth and comfortable contact surface.

[0037] In example aspects, die outer layer 202, the middle layer 204, and the inner layer 206 are bonded together under heat and / or pressure to form a unitary laminate. During diis step, the compression of a portion of the middle layer 204 may be performed simultaneously with the bonding operation, such that mechanical densification of die middle layer 204 (e.g., die molded foam layer) and lamination of the textile layers (e.g., outer layer 202 and inner layer 206) occur in a single step.

[0038] FIG. 3 illustrates a front view of an example bra 300 in an as-worn configuration, showing structural details of a molded foam layer 302 visible through or apart from die exterior layer 304. The bra 300 comprises a first side 309 and a second side 311, located on generally opposite lateral sides of the bra 300. A neckline edge 310 is positioned along an upper portion of die bra, while a bottom edge 312 defines die lower boundary of the front panel. The molded foam layer 302 includes a plurality of vertically oriented channels 306 and a plurality of apertures 308. In aspects, the channels 306 are recessed regions or grooves molded into an outward-facing surface of the foam layer 302.

[0039] As shown in FIG. 3, the channels 306 are generally aligned in a diagonal direction when the bra 300 is worn, extending from the neckline edge 310 toward the bottom edge 312. In other aspects, the channels 306 may be oriented vertically, extending from the neckline edge 310 toward the bottom edge 312. A vertical orientation may be selected to provide increased lateral (side-to-side) stretch and reduced vertical elongation across the front portion of the bra 300. The depth of each channel 306 may vary along its length in a gradient manner, corresponding to variations in the underlying foam thickness.

[0040] Apertures 308 are positioned within the channels 306 and are formed during die injection molding process. Each aperture 308 extends entirely through die thickness of die molded foam layer 302 from die outward-facing surface to the inward-facing surface (described in FIG. 2). In example aspects, each channel 306 may include a series of apertures arranged in a vertical column. In some aspects, the apertures in a first channel 314 are staggered in position relative to the apertures in an adjacent second channel 316. This staggered configuration may promote uniform pressure distribution, maintain structural integrity across die foam layer, and improve airflow during compression and recovery.

[0041] Apertures may also be present in a central region 318 (e.g., a center-bridge) between the two breast covering portions 320, 322 to provide continued airflow across the chest area. That is in some aspects the central region 318 may include apertures without including channels. Thus, the channels in the two breast covering portions 320, 322 are separated from one another by the central region 318.

[0042] The channels 306 may be oriented to extend in a rectilinear direction (e.g., straight), in some aspects. In odier aspects, the channels 306 may extend in a curved direction.

[0043] As seen in FIG. 3, the channels 306 may extend from a bottom edge to a tope edge of the middle layer. In other aspects, die channels 306 may terminate a position proximate to the bottom edge or the top edge.

[0044] Also as seen in FIG. 3, die channels 306 may extend generally in a vertical direction, which may the channels 306 tilted inward or outward. For example, die bottom of a channel in the illustrated aspect is medial to die top of the channel such dial die top is more lateral dian die bottom, when in an as-worn configuration.

[0045] FIGS. 4A and 4B illustrate a comparison of a molded foam layer (e.g., middle layer 204 described in FIG. 2) before (e.g., molded foam layer 400 in FIG. 4A) and after (e.g., molded foam layer 450 in FIG. 4B) mechanical compression, respectively. FIGS. 4A and 4B illustrate how the foam thickness is compressed to define distinct support zones within the molded structure of the bra. In each figure, a side cross-sectional view of the molded foam layer is shown through a representative breastcovering portion. The depicted section may correspond, for example, to a lateral or inferior region of a molded cup, where enhanced support is desired.

[0046] As shown in FIG. 4A, a molded foam layer 400 is depicted in an uncompressed state as it exists immediately following injection molding. The molded foam layer 400 includes multiple zones with varying molded thicknesses across the breast-covering portion of the garment. A central region 402, positioned at the center of the breast-covering area, has a first molded thickness, which may range from about 3 mm to 5 mm; in aspects, the thickness is approximately 4 mm. Surrounding the central region is a perimeter region 404 having a molded thickness, which may range from about 2 mm to 4mm; in aspects, the thickness is approximately 3 mm. The majority of the surrounding breast-covering area 406 has a thinner molded thickness, which may range from about 1 mm to 3 mm; in aspects, the thickness is approximately 2 mm.

[0047] A sling structure is formed above and below the central region 402 and includes an upper sling portion 408 molded to a thickness, which may range from about 4 mm to 6 mm; in aspects, the thickness is approximately 5 mm. Beneath die upper sling portion 408 is a lower sling support region 410a, molded to a thickness, which may range from about 4 mm to 6 mm; in aspects, the thickness is approximately 5 mm. A peripheral reinforcement region 412a extends around the lateral sides 413 and lower edge 415 of the bra and is molded to a thickness, which may range from about 6 mm to 8 mm; in aspects, the thickness is approximately 7 mm. The outermost edge regions 414 may have a molded thickness ranging from about 1 mm to 3 mm; in aspects, the thickness is approximately 2 mm. It is contemplated that the opposite side of the molded foam layer mirrors the structure described above to provide symmetrical shaping and support for both breast-covering regions.

[0048] FIG. 4B shows a molded foam layer 450 after mechanical compression has been selectively applied to specific regions. The originally molded region 410a is shown as compressed region 410b, having a reduced thickness, which may range from about 3 mm to 5 mm; in aspects, the thickness is approximately 4 mm. Likewise, the peripheral reinforcement region 412a becomes compressed region 412b, having a reduced thickness, which may range from about 4 mm to 6 mm; in aspects, die thickness is approximately 5 mm. These compressed regions exhibit increased material density, which enhances localized stiffness and support without increasing material bulk. Also likewise, the outermost edge regions 414 may be compressed and have a reduced thickness in FIG.4B, which may range from 0.5 mm to 1.5 mm; in aspects, the diickness is approximately 1 mm. Compressing die outermost edge regions 414 enhances the coupling between die outer layer 202, the foam layer 450, and the inner layer 206.

[0049] The foam layer 450 may further include a seam 416 positioned along its peripheral edge 415. This seam 416 may be formed using a trim piece applied in a two-step bonding process described further herein. The seam 416 construction described herein may improve edge durability, facilitate integration widi other garment components (e.g., shoulder straps or underbands), and contribute to a refined garment finish.

[0050] The differences in foam thickness and density illustrated between FIGS. 4A and 4B demonstrate how targeted compression of a uniform foam structure enables differentiated support zones. In the final garment, the foam layer may be bonded between an outer mesh and an inner liner as described herein.

[0051] FIGS. 5 A and 5B illustrate cross-sectional views of a molded pad portion of a bra (e.g., bra 100 described in FIGS 1 A and IB) before and after mechanical compression, respectively. These viewscorrespond to the molded foam layers 400 and 450 shown in FIGS. 4 A and 4B and demonstrate the change in thickness and material structure across selected support zones of tire foam layer.

[0052] As shown in FIG. 5A, the foam layer 400 is in an uncompressed state. The foam layer 400 includes a generally uniform thickness between an inward-facing surface 502 and an outward-facing surface 504. In this configuration, tine foam material across the foam layer 400 exhibits a consistent density as it has not been altered by mechanical compression. The contours of the molded pad correspond to an as-molded geometry formed via an injection molding process. In aspects, the foam has a substantially uniform material composition and porosity throughout the section shown. Channel recesses and apertures formed during molding may also be present, but the foam thickness across the entire pad remains approximately equal (e.g., about 6 mm).

[0053] FIG. 5B illustrates a cross-section of the same foam layer following application of mechanical compression to a localized region. As shown, the compressed foam layer 450 now includes a first zone 506 that has been compressed to a reduced thickness (e.g., about 2mm) and a second zone 508 that retains the original thickness of foam layer 400. The first zone 506 corresponds to a support region, such as the lateral or inferior side of a breast-covering portion described in FIGS. 4 A and 4B and has undergone mechanical compaction through the application of pressure. As a result, the first zone 506 has a higher material density than the adjacent uncompressed zone 508. The surfaces 502 and 504 of tire foam layer 450 are now closer together in first zone 506, indicating a change in material structure rather than a simple shape variation.

[0054] The compression of the foam in zone 506 may occur during a heat press step in the manufacturing process, following initial injection molding of tire foam. This compression may be applied with or without simultaneous bonding of the outer and inner textile layers. In either case, the compression results in a permanent or semi-permanent change to (lie foam thickness and density in zone 506. The second zone 508 remains uncompressed and preserves its original thickness and softness, offering flexibility and comfort in areas that do not require structural reinforcement. In aspects, apertures located within the compressed region may become deformed or distorted, such that their originally molded geometry becomes narrowed, elongated, or irregular. The specific deformation may depend on the direction and magnitude of the applied pressure. Although these apertures begin as uniform openings, compression may cause changes in their cross-sectional shape and perimeter while still permitting airflow through the molded foam layer.

[0055] In some aspects, the molded foam layer 450 may further include a third zone 510 positioned along a peripheral edge of the foam. This third zone 510 may be held in a compressed state and may exhibit a third density that is different from both the compressed first zone 506 and the uncompressed second zone 508. The third zone 510 may be provided to reinforce edge stability, improve shaping, or facilitate bonding to adjacent garment structures.

[0056] Now referring to FIG. 6, a flow diagram is provided depicting an example method 600 of manufacturing a bra (e.g., tire bra 100), including a middle layer (e.g., tire molded foam layer 204) positioned between an outer layer (e.g., the outer layer 202) and an inner layer (e.g., the inner layer 206).

[0057] At step 610, the middle layer is formed by injection molding a foam material (e.g., opencell polyurethane) into a mold defining a contoured shape for breast covering portions. The mold further includes recessed features and through-mold projections configured to form a plurality of vertically oriented channels (e.g., the channels 306) and a plurality of apertures (e.g., the apertures 308). The middle layer 204 is initially formed with a substantially uniform foam composition, a generally consistent thickness, and a uniform material density.

[0058] At step 620, an adhesive is applied to at least one of the outer layer or the inner layer. In aspects, the adhesive may be a pressure-sensitive adhesive or a heat-activated adhesive applied in a continuous or patterned manner across all or part of the surface. In some implementations, adhesive is applied to both the outer layer and the inner layer prior to alignment with the middle layer.

[0059] At step 630, the outer layer is positioned on an outward-facing surface of tire molded foam layer, and the inner layer is positioned on an inward-facing surface of tire molded foam layer. In aspects, the three layers are aligned to correspond with the contours of the molded foam and the intended edge geometry of the front portion of the bra (e.g., from a neckline edge to a bottom edge and from a first underarm edge to a second underarm edge).

[0060] At step 640, the three layers are bonded together using heat and / or pressure. In aspects, the bonding step also includes compressing a first zone (e.g., tire first zone 146) of the molded foam layer to reduce its thickness and increase its material density relative to an adjacent second zone (e.g., tire second zone 148). The first zone may correspond to a lateral side and / or bottom edge of tire breast covering portions of the molded foam layer. In aspects, the second zone remains uncompressed to preserve flexibility and comfort in other regions of the bra.

[0061] At step 650, tire resulting multi-layer str ucture is finished, trimmed, and joined to additional garment elements (e.g., the first shoulder strap 110, second shoulder strap 112, or the band 114).

[0062] At step 660, a him piece is applied to form a finished seam around one or more peripheral edges of the molded foam layer. A first edge of the trim piece is aligned with the edge of the foam layer and bonded in place. The ends of tire trim piece may also be bonded to one another to form a continuous loop or closed edge segment. The trim piece is then wrapped around the edge of the foam layer such that it covers both the outward-facing and inward-facing surfaces along the edge, and the opposing edge of the trim is bonded to the opposite surface. This seam is configured to enclose the edge of the bra and form a secure, durable seam. In aspects, the seam region may comprise a thickness that ranges from about 0.5 mm to 2 mm; in aspects, the thickness is approximately 1 mm or as thin as necessary to allowstitching or clean joining. This finishing step may be performed before or after final garment assembly and contributes to improved edge strength, comfort, and attachment of other structural components.

[0063] The following clauses represent example aspects of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are illustrative in nature and are not limiting.

[0064] Clause 1. An upper torso garment comprising: a front portion comprised of an inner layer, a middle layer, and an outer layer; the middle layer comprised of a foam material having a contoured shape, the middle layer having a first zone having a first material property, the middle layer also having a second zone having a second material property, the first material property being different than the second material property; and the middle layer having an inward facing surface and an outward facing surface, the inner layer joined to the inward facing surface of the middle layer and the outer layer joined to the outward facing surface of the middle layer such that the first zone is in a compressed state.

[0065] Clause 2. The upper torso garment of clause 1, wherein the upper torso garment comprises a bra.

[0066] Clause 3. The upper torso garment of any of clauses 1-2, wherein the middle layer includes a first breast covering portion and a second breast covering portion, wherein tire first zone comprises a support region that extends from a top edge of the front portion along a first lateral side of the first breast covering portion to a bottom side of tire first breast covering portion, tire support region continuing laterally across the middle layer along the bottom side of tire first breast covering portion and tire second breast covering portion to a second lateral side of tire second breast covering portion, lire support region extending from tire bottom side of the second breast covering portion to the lop edge of the front portion, wherein the second zone comprises a central region medially inward from the support region.

[0067] Clause 4. The upper torso garment of any of clauses 1 -3 further comprising the middle layer having a third zone having a third material property, wherein in the third zone comprises a perimeter of the middle layer.

[0068] Clause 5. The upper torso garment of any of clauses 1 -4, wherein the first material property, the second material property, and the third material property each respectively comprise a first density, a second density, and a third density.

[0069] Clause 6. The upper torso garment of any of clauses 1 -5, wherein the first density comprises a density of the foam material in a compressed state, the second density comprises a density of the foam material in an uncompressed state, and the third density comprises a density of the foam material in a second compressed state.

[0070] Clause 7. The upper torso garment of any of clauses 1-6, wherein the first material property, the second material property, and the third material property each respectively comprise a first thickness, a second thickness, and a third thickness.

[0071] Clause 8. The upper torso garment of any of clauses 1-7, wherein the first thickness is 5 millimeters, the second thickness is 2 millimeters, and the third thickness is 1 millimeter.

[0072] Clause 9. The upper torso garment of any of clauses 1-8 further comprising each of the first breast covering portion and the second breast covering portion having a modesty region with a fourth thickness, wherein the fourth thickness is 5 millimeters.

[0073] Clause 10. An upper torso garment comprising: a front portion comprised of an inner layer, a middle layer, and an outer layer; the middle layer having a bottom edge, a left side edge extending from a left end of the bottom edge, a right side edge extending from a right end of the bottom edge, and a top edge extending from the left side edge to the right side edge; the middle layer including a first breast covering portion and a second breast covering portion, each of the first breast covering portion and the second breast covering portion including a plurality of channels formed in an outer surface of the middle layer, wherein the plurality of channels extend in a direction that intersects with the bottom edge and the top edge; and each channel of the plurality of channels having at least one aperture extending through an entire thickness of the middle layer.

[0074] Clause 11. The upper torso garment of any of clauses 1-10, wherein the top edge comprises a left arm opening edge, a left strap edge, a neckline edge, a right strap edge, and a right arm opening edge.

[0075] Clause 12. The upper torso garment of any of clauses 1-11 further comprising an underband coupled to bottom edge.

[0076] Clause 13. The upper torso garment of any of clauses 1-12 further comprising a centerbridge portion positioned between the first breast covering portion and the second breast covering portion, the center-bridge does not include the plurality of channels.

[0077] Clause 14. The upper torso garment of any of clauses 1-13, wherein the center-bridge further comprises at least one aperture extending through the middle layer.

[0078] Clause 15. The upper torso garment of any of clauses 1-14, wherein the plurality of channels extend rectilinearly across the first breast covering portion and the second breast covering portion.

[0079] Clause 16. The upper torso garment of any of clauses 1-15, wherein the at least one aperture of each of the plurality of channels is rectilinearly aligned with a respective aperture in adjacent channels across the first breast covering portion.

[0080] Clause 17. An upper torso garment comprising: a front portion comprised of an inner layer, a middle layer, and an outer layer; the middle layer having a bottom edge, a left side edge extendingfrom a left end of the bottom edge, a right side edge extending from a right end of tire bottom edge, and a top edge extending from the left side edge to tire right side edge; the middle layer including a first breast covering portion and a second breast covering portion; the middle layer comprised of a foam material having a contoured shape with a variable thickness across a plurality of zones of the middle layer; the plurality of zones including at least a first zone, a second zone, and a third zone; the first zone comprises a support region that extends from the top edge to the bottom edge along a lateral side of the first breast covering portion, continuing along a bottom side of the first breast covering portion and the second breast covering portion to a second lateral side of the second breast covering portion, further continuing from the bottom edge to the top edge along the second lateral side; the second zone comprises a central region medially inward from the support region; the third zone comprises a perimeter region adjacent a perimeter edge of the middle layer; the middle layer having an inward facing surface and an outward facing surface, the inner layer joined to the inward facing surface of the middle layer and the outer layer joined to the outward facing surface of the middle layer; each of the first breast covering portion and the second breast covering portion including a plurality of channels formed in an outward facing surface of the middle layer, wherein the plurality of channels extend in a direction that intersects with the bottom edge and the top edge; each channel of the plurality of channels having at least one aperture extending through an entire thickness of the middle layer; and a center-bridge portion positioned between the first breast covering portion and tire second breast covering portion, tire centerbridge does not include the plurality of channels, the center-bridge including at least one aperture extending through the middle layer.

[0081] Clause 18. The upper torso garment of any of clauses 1-17, wherein the first zone has a first thickness and a first density, tire second zone has a second thickness and a second density, and tire third zone has a third thickness and a third density, wherein the first thickness is greater than tire second thickness, and the second thickness is greater than the third thickness, wherein the third density is greater than tire first density, and the first density is greater than the second density.

[0082] Clause 19. The upper torso garment of any of clauses 1-18 further comprising the plurality of zones including a fourth zone, tire fourth zone comprises a modesty region positioned at least one of the first breast covering portion and the second breast covering portion, the fourth zone has first thickness and the second density.

[0083] Clause 20. The upper torso garment of any of clauses 1-19, wherein the inner layer comprises polyester, die middle layer comprises polyurethane, and the outer layer comprises a composition of nylon and elastane.

[0084] Aspects of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative aspects will become apparent to those skilled in the art that do not departfrom its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure.

[0085] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.

Claims

CLAIMSWhat is claimed is:

1. An upper torso garment comprising: a front portion comprised of an inner layer, a middle layer, and an outer layer; the middle layer comprised of a foam material having a contoured shape, the middle layer having a first zone having a first material property, the middle layer also having a second zone having a second material property, the first material property being different than the second material property; and the middle layer having an inward facing surface and an outward facing surface, the inner layer joined to the inward facing surface of the middle layer and the outer layer joined to the outward facing surface of the middle layer such that the first zone is in a compressed state.

2. The upper torso garment of claim 1 , wherein the upper torso garment comprises a bra.

3. Hie upper torso garment of claim 1, wherein die middle layer includes a first breast covering portion and a second breast covering portion, wherein tire first zone comprises a support region that extends from a top edge of the front portion along a first lateral side of the first breast covering portion to a bottom side of the first breast covering portion, the support region continuing laterally across the middle layer along the bottom side of tire first breast covering portion and the second breast covering portion to a second lateral side of the second breast covering portion, the support region extending from the bottom side of the second breast covering portion to the top edge of the front portion, wherein the second zone comprises a central region medially inward from the support region.

4. The upper torso garment of claim 3 further comprising die middle layer having a third zone having a third material property, wherein in tire third zone comprises a perimeter of the middle layer.

5. The upper torso garment of claim 4, wherein the first material property, the second material property, and the tirird material property each respectively comprise a first density, a second density, and a tirird density.

6. The upper torso garment of claim 5, wherein the first density comprises a density of the foam material in a compressed state, the second density comprises a density of the foam material in an uncompressed state, and the tirird density comprises a density of the foam material in a second compressed state.

7. The upper torso garment of claim 4, wherein the first material property, the second material property, and the third material property each respectively comprise a first thickness, a second thickness, and a third thickness.

8. The upper torso garment of claim 7, wherein the first thickness is 5 millimeters, the second thickness is 2 millimeters, and tire third thickness is 1 millimeter.

9. The upper torso garment of claim 8 further comprising each of the first breast covering portion and the second breast covering portion having a modesty region with a fourth thickness, wherein the fourth thickness is 5 millimeters.

10. An upper torso garment comprising: a front portion comprised of an inner layer, a middle layer, and an outer layer; the middle layer having a bottom edge, a left side edge extending from a left end of the bottom edge, a right side edge extending from a right end of the bottom edge, and a top edge extending from the left side edge to the right side edge; the middle layer including a first breast covering portion and a second breast covering portion, each of the first breast covering portion and the second breast covering portion including a plurality of channels formed in an outer surface of the middle layer, wherein tire plurality of channels extend in a direction that intersects with the bottom edge and the top edge; and each channel of the plurality of channels having at least one aperture extending through an entire thickness of tire middle layer.

11. The upper torso garment of claim 10, wherein the top edge comprises a left arm opening edge, a left strap edge, a neckline edge, a right strap edge, and a right arm opening edge.

12. The upper torso garment of claim 10 further comprising an underband coupled to bottom edge.

13. The upper torso garment of claim 10 further comprising a center-bridge portion positioned between the first breast covering portion and tire second breast covering portion, the centerbridge does not include the plurality of channels.

14. The upper torso garment of claim 13, wherein the center-bridge further comprises at least one aperture extending through the middle layer.

15. The upper torso garment of claim 10, wherein tire plurality of channels extend rectilinearly across the first breast covering portion and the second breast covering portion.

16. The upper torso garment of claim 10, wherein the at least one aperture of each of the plurality of channels is rectilinearly aligned with a respective aperture in adjacent channels across the first breast covering portion.

17. An upper torso garment comprising: a front portion comprised of an inner layer, a middle layer, and an outer layer; tire middle layer having a bottom edge, a left side edge extending from a left end of the bottom edge, a right side edge extending from a right end of the bottom edge, and a top edge extending from the left side edge to the right side edge; the middle layer including a first breast covering portion and a second breast covering portion; the middle layer comprised of a foam material having a contoured shape with a variable thickness across a plurality of zones of the middle layer; the plurality of zones including at least a first zone, a second zone, and a dtird zone; the first zone comprises a support region that extends from the top edge to the bottom edge along a lateral side of the first breast covering portion, continuing along a bottom side of the first breast covering portion and the second breast covering portion to a second lateral side of the second breast covering portion, further continuing from the bottom edge to the top edge along the second lateral side; the second zone comprises a central region medially inward from the support region; the third zone comprises a perimeter region adjacent a perimeter edge of the middle layer; the middle layer having an inward facing surface and an outward facing surface, the inner layer joined to the inward facing surface of the middle layer and the outer layer joined to the outward facing surface of the middle layer; each of the first breast covering portion and the second breast covering portion including a plurality of channels formed in an outward facing surface of the middle layer, wherein the plurality of charnels extend in a direction that intersects with the bottom edge and die top edge; each channel of the plurality of channels having at least one aperture extending through an entire thickness of the middle layer; and a center-bridge portion positioned between die first breast covering portion and die second breast covering portion, die centerbridge docs not include the plurality of channels, the center-bridge including at least one aperture extending through the middle layer.

18. The upper torso garment of claim 17 , wherein the first zone has a first thickness and a first density, the second zone has a second thickness and a second density, and the third zone has a third thickness and a third density, wherein the first thickness is greater than the second thickness, and the second thickness is greater dian the third thickness, wherein the third density is greater than the first density, and the first density is greater than the second density.

19. The upper torso garment of claim 18 further comprising the plurality of zones including a fourth zone, the fourth zone comprises a modesty region positioned at least one of the first breast covering portion and the second breast covering portion, the fourth zone has first thickness and the second density.

20. The upper torso garment of claim 17, wherein the inner layer comprises polyester, the middle layer comprises polyurethane, and the outer layer comprises a composition of nylon and elastane.

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