Cross Reference to Related Application(s)

The present disclosure claims the benefit of Singapore Patent Application No. 10202010482T filed on 22 October 2020, which is incorporated in its entirety by reference herein.

Technical Field

The present disclosure generally relates to a cradle structure for a garment cup such as a bra cup. More particularly, the present disclosure describes various embodiments of a cradle structure for forming a garment cup in a garment and a method of making the cradle structure.

Background

Bra cups are used in female garments such as such as innerwear (e.g. bra and lingerie), swimwear (e.g. swimsuit and tankini, swim top), and activewear (e.g. sports bra, active tankini). The cradle structure is the part that forms the bra cup which covers the breast while providing the required fit, support, and modesty to the breast. Current garments such as one-piece swimsuits, tankinis, swim top and sports bras, active tankini have integrated cradle structures having multiple components such as foam cup, under bust elastic, centre front gore with stabilizer, and cup supporter with power mesh or liner. Moreover, as shown in Figure 1 , when it comes to styling different garments 100 currently, different shapes of the bra cups 110 and style lines are used to get the desired aesthetics and functional requirements. Thus, separate versions of the multiple components of the cradle structures, such as different shapes and sizes of the bra cups 110, as well as different materials for making the cradle structures need to be procured. There are also additional operations, such as sewing and stitching, to attach the components together to make the cradle structures. All these affect the total production time and process complexity. Therefore, in order to address or alleviate at least one of the aforementioned problems and/or disadvantages, there is a need to provide an improved cradle structure for a bra cup.

Summary

1 . A cradle structure for forming a garment cup in a garment, the cradle structure comprising: a fabric layer comprising a cradle centre region and a cradle peripheral region surrounding the cradle centre region; a polymer peripheral layer formed on the cradle peripheral region for stiffening the cradle peripheral region to enhance support of a user’s breast wearing the garment cup; and a polymer band layer formed on the cradle peripheral region below the cradle centre region for elasticizing the cradle structure to fit the garment on the user, wherein the cradle structure is shaped to volumize the cradle centre region and accommodate different shapes of the garment cup.

2. The cradle structure according to clause 1 , wherein the polymer peripheral layer has varying stiffness that increases towards the cradle centre region to enhance support of the cradle centre region.

3. The cradle structure according to clause 1 or 2, wherein the polymer peripheral layer comprises a polymer outer region laterally outside of the cradle centre region for laterally supporting the cradle centre region.

4. The cradle structure according to clause 3, wherein the polymer peripheral layer comprises a polymer inner region laterally opposite the polymer outer region across the cradle centre region, the polymer inner region for laterally supporting a centre gore region between garment cups of the garment. 5. The cradle structure according to any one of clauses 1 to 4, wherein the polymer band layer comprises a ribbed structure.

6. The cradle structure according to any one of clauses 1 to 5, wherein the cradle structure is shaped by a moulding process.

7. The cradle structure according to any one of clauses 1 to 6, wherein the fabric layer comprises a spacer fabric material.

8. The cradle structure according to clause 7, wherein the spacer fabric material comprises one or more of cotton, polyester, spandex, and nylon.

9. The cradle structure according to any one of clauses 1 to 8, wherein the polymer peripheral layer and polymer band layer comprise silicone.

10. The cradle structure according to claim 9, wherein the silicone comprises colour pigments.

11. A method of making a cradle structure for forming a garment cup in a garment, the method comprising: forming a fabric layer comprising a cradle centre region and a cradle peripheral region surrounding the cradle centre region; forming a polymer peripheral layer on the cradle peripheral region for stiffening the cradle peripheral region to enhance support of a user’s breast wearing the garment cup; forming a polymer band layer on the cradle peripheral region below the cradle centre region for elasticizing the cradle structure to fit the garment on the user; and shaping the cradle structure to volumize the cradle centre region and accommodate different shapes of the garment cup.

12. The method according to clause 11 , further comprising trimming the cradle structure after shaping the cradle structure. 13. The method according to clause 11 or 12, wherein shaping the cradle structure comprises moulding the cradle structure.

14. The cradle structure according to any one of clauses 11 to 13, wherein the polymer peripheral layer has varying stiffness that increases towards the cradle centre region to enhance support of the cradle centre region.

15. The cradle structure according to any one of clauses 11 to 14, wherein the polymer peripheral layer comprises a polymer outer region laterally outside of the cradle centre region for laterally supporting the cradle centre region.

16. The cradle structure according to clause 15, wherein the polymer peripheral layer comprises a polymer inner region laterally opposite the polymer outer region across the cradle centre region, the polymer inner region for laterally supporting a centre gore region between garment cups of the garment.

17. The cradle structure according to any one of clauses 11 to 16, wherein the polymer band layer comprises a ribbed structure.

18. A garment component for forming garment cups of a garment, the garment component comprising a pair of cradle structures according to any one of claims 1 to 10, wherein the cradle structures are joined together.

19. The garment component according to clause 18, wherein the cradle structures are joined together by a dividing region at a centre gore region that enables the cradle structures to separate from each other.

20. A garment comprising a pair of garment cups, each garment cup comprising a cradle structure according to any one of clauses 1 to 10. A cradle structure for a garment cup according to the present disclosure is thus disclosed herein. Various features, aspects, and advantages of the present disclosure will become more apparent from the following detailed description of the embodiments of the present disclosure, by way of non-limiting examples only, along with the accompanying drawings.

Brief Description of the Drawings

Figure 1 is an illustration of current garments with different shapes of bra cups.

Figures 2A and 2B are illustrations of a cradle structure for a bra cup, in accordance with embodiments of the present disclosure.

Figures 3A and 3B are illustrations of garments comprising the cradle structures that form bra cups in the garments.

Detailed Description

Descriptions of embodiments of the present disclosure are directed to a cradle structure for a garment cup, in accordance with the drawings. While aspects of the present disclosure will be described in conjunction with the embodiments provided herein, it will be understood that they are not intended to limit the present disclosure to these embodiments. On the contrary, the present disclosure is intended to cover alternatives, modifications and equivalents to the embodiments described herein, which are included within the scope of the present disclosure as defined by the appended claims. Furthermore, in the following detailed description, specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be recognized by an individual having ordinary skill in the art, i.e. a skilled person, that the present disclosure may be practiced without specific details, and/or with multiple details arising from combinations of aspects of particular embodiments. In a number of instances, known systems, methods, procedures, and components have not been described in detail so as to not unnecessarily obscure aspects of the embodiments of the present disclosure. In embodiments of the present disclosure, depiction of a given element or consideration or use of a particular element number in a particular figure or a reference thereto in corresponding descriptive material can encompass the same, an equivalent, or an analogous element or element number identified in another figure or descriptive material associated therewith. References to “an embodiment I example”, “another embodiment I example”, “some embodiments I examples”, “some other embodiments I examples”, and so on, indicate that the embodiment(s) I example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment I example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase “in an embodiment I example” or “in another embodiment I example” does not necessarily refer to the same embodiment I example.

The terms “comprising”, “including”, “having”, and the like do not exclude the presence of other features I elements I steps than those listed in an embodiment. Recitation of certain features I elements I steps in mutually different embodiments does not indicate that a combination of these features I elements I steps cannot be used in an embodiment. The terms “a” and “an” are defined as one or more than one. The use of in a figure or associated text is understood to mean “and/or” unless otherwise indicated. The recitation of a particular numerical value or value range herein is understood to include or be a recitation of an approximate numerical value or value range.

Representative or exemplary embodiments of the present disclosure describe a cradle structure 200 for forming a garment cup in a garment, such as a bra cup as shown in Figures 2A and 2B. Embodiments of the present disclosure also describe a method of making the cradle structure 200 for forming the garment cup. Embodiments of the present disclosure describe the cradle structure 200 for forming a bra cup in female garments, but it will be appreciated that the cradle structure 200 can be used to form other type of garment cups. The method includes a step of forming a fabric layer 210 and a step of forming a polymer peripheral layer 220 on the fabric layer 210. The fabric layer 210 comprises or is made of a fabric material that is preferably spacer fabric material. The polymer peripheral layer 220 comprises or is made of a polymer material that is preferably silicone.

As shown in Figure 2A, the fabric layer 210 includes a cradle centre region 212 and a cradle peripheral region 214 surrounding the cradle centre region 212. As shown in Figure 2B, the polymer peripheral layer 220 is formed on the cradle peripheral region 214 for stiffening the cradle peripheral region 214 to enhance support of a user’s breast wearing the bra cup. The polymer peripheral layer 220 is designed to complement the fabric layer 210 provide the proper support, fit, and modulus levels to the breast.

The cradle structure 200 further includes a polymer band layer 230 formed on the cradle peripheral region 214 below the cradle centre region 212 for elasticizing the cradle structure 200 to fit the garment on the user. The method of making the cradle structure 200 further includes a step of forming the polymer band 230 on the cradle peripheral region 214 below the cradle centre region 212. In one embodiment, the polymer band layer 230 is formed together with the polymer peripheral layer 220 on the cradle peripheral region 214, for example by a printing process. In another embodiment, the polymer band layer 230 is separately formed and attached to the cradle peripheral region 214.

The method further includes a step of shaping the cradle structure 200 to volumize the cradle centre region 212 and accommodate different shapes 240 of the bra cup. Preferably, the cradle structure 200 is shaped by a moulding process. This creates a standard block pattern in the cradle structure 200 and gives it the required capacity and fit for various bra cup shapes and styles 240. The fabric material, preferably spacer fabric material, provides the desired properties of nipple concealment, modesty, and proper support to the breast. The stretch levels of the spacer fabric material are able to accommodate the required coverage of the breast along while maintaining the appropriate fit to user’s body. This block pattern standardizes the cradle structure 200 and enables it to be used for various garments including innerwear, swimwear, and activewear. The cradle structure 200 is shaped, such as by moulding, to give adequate volume and capacity to accommodate the breast with minimal fitting and comfortability issues. Specifically, the moulding shape, diameter, and depth are analysed based on existing bra cup shapes and sizes 240 to give the required volume and capacity to the breast in order to obtain proper fit and comfortability levels. Alternatively, the cradle structure 200 may be shaped using other methods instead of moulding, such as dart, pleat, or gathering constructions of the fabric material.

The standardized cradle structure 200 has defined designs for the fabric layer 210 and polymer peripheral layer 220 and the cradle structure 200 can be flexibly used for various shapes 240 of bra cups and for various garments. The method of making the cradle structure 200 may further include a step of trimming the cradle structure 200 after shaping the cradle structure 200. This trimming step is done based on the styling requirement of the cradle structure 200 and the garment on which the cradle structure 200 is used to form the bra cups. For example, the cradle structure 200 can be trimmed to provide a shaped neckline to the bra cups of the garment, such as V-shaped or II- shaped. The trimming step may be done by various means including overlocker cutting, single needle cutting, laser cutting, die cutting, or a manual or machine cutting operation such as Gerber or Lectra cutting. Accordingly, the trimming step enables the cradle structure 200, which has a standardized block pattern for various styles, to be tailored to a specific bra cup and garment style.

The cradle structure 200 is formed as a single panel or garment component 300 that is ready to be attached, such as by sewing, stitching, or suitable bonding I adhesive means, to the garment and form the bra cups of the garment. The ready-to-attach garment component 300 reduces complexity of making the garment and achieves a cleaner appearance for the garment. In some embodiments, the garment component 300 includes a single cradle structure 200 for forming one bra cup. In some embodiments as shown in Figure 2B, the garment component 300 includes a pair of cradle structures 200 that are joined together via a centre front or gore region 250 made of the same fabric material as the cradle structures 200. Optionally, the pair of cradle structures 200 are joined together by a dividing region 252 at the centre gore region 250 that enables the cradle structures 200 to separate from each other. For example, the dividing region 252 includes a demarcation or line that is cut during the trimming step. This separates the cradle structures 200 so that they can be separately attached to the same or different garment.

In some embodiments, the polymer peripheral layer 220 has varying stiffness that increases towards the cradle centre region 212 to enhance support of the cradle centre region 212. The polymer peripheral layer 220 gradually changes from low build polymer material to high build polymer material at the boundary with the cradle centre region 212. Low build polymer material gives lower modulus levels and higher stretchability while high build polymer material gives higher modulus levels and lower stretchability. The build level of the polymer material should be optimized according to specific user requirements, such as based on the user’s comfortability factor, stretch levels of the fabric material, required fit, lift, and support levels. For example, the stiffness variations of the polymer peripheral layer 220 underneath the cradle centre region 212, i.e. the under bust area, would give the proper under bust support in order to get the proper breast lift.

The polymer peripheral layer 220 may include a polymer outer region 222 and/or a polymer inner region 224. The polymer outer region 222 is on the outer side of the cradle structure 200 and laterally outside of the cradle centre region 212. The polymer inner region 224 is on the inner side of the cradle structure 200, i.e. at the centre gore region 250, laterally opposite the polymer outer region 222 across the cradle centre region 212.

The polymer outer region 222 is arranged for laterally supporting the cradle centre region 212. This provides lateral support to the breast and reduces lateral left-right movement of the breast, especially for larger breast sizes. The polymer material of the polymer outer region 222 can also give a smoothing effect to the side of the breast, especially if it is bulging out, thus achieving better breast projection and shaping.

The polymer inner region 224 is arranged for laterally support the centre gore region 250 between the bra cups of the garment. The polymer material of the polymer inner region 224 stabilizes the centre gore region 250 and maintains the positions of the breasts as well as the proper distance between the breasts. Maintaining proper distance between the pair of cradle structures 200 also facilities the volumizing or capacity additions of the cradle centre regions 212 through the shaping or moulding operation.

The polymer band layer 230 is arranged for elasticizing the cradle structure 200, particularly the under bust area, to fit the garment on the user. Like the polymer peripheral layer 220, the polymer band layer 230 comprises or is made of a polymer material that is preferably silicone. Preferably, the polymer band layer 230 has a ribbed structure in the form of a series of vertical bands. For example, the ribbed structure of the polymer band layer 230 may alternate between a high build polymer material and a low build polymer material across the vertical bands. The polymer band layer 230 is formed on cradle peripheral region 214 at the lowest area of the cradle structure 200 to provide higher stretch levels to support the required recovery levels and maintain a smooth bottom edge on the cradle structure 200. The polymer band layer 230 functions as the under bust elastic while giving the proper elasticity to support and hold the cradle structure 200 in place on the user’s body. Particularly, the elastic polymer band layer 230 is arranged to compress the garment against the rib cage of the user.

In some embodiments, the cradle structure 200 is attached to the inside of the garment. The polymer peripheral layer 220 would be formed on the interior side of the fabric layer 210, i.e. on the side that faces or is touching the user’s skin. This may provide additional grip and support due to inherent frictional properties of the polymer material such as silicone.

In some embodiments, the cradle structure 200 is attached to the outside of the garment. The polymer peripheral layer 220 would be formed on the exterior side of the fabric layer 210, i.e. on the side that faces outwards. The polymer peripheral layer 220 can be designed with aesthetic factors to improve the appearance of the garment. For example, the polymer material may include colour pigments.

To form the polymer peripheral layer 220, the polymer material is preferably disposed on the fabric layer 210 using a printing process. The fabric material is preferably one that can be moulded and allows the polymer material to be printed on. The printing process may be configured with designs or artworks for the polymer material to form, thereby creating aesthetic features on the polymer peripheral layer 220. Additionally, the polymer band layer 230 may be formed together with the polymer peripheral layer 220 in the same printing process, such as part of the same designs of artworks. Alternatively, the polymer band layer 230 may be formed on the fabric layer 210 in a separate printing process. Yet alternatively, the polymer band layer 230 may be separately formed and attached to the fabric layer 210.

Although a printing process is described, it will be appreciated that the polymer material may be disposed on the fabric layer 210 using other suitable processes such as bonding, heat pressing, or lamination.

The fabric material of the fabric layer 210 is preferably a spacer fabric material such as cotton, polyester, spandex, nylon, or any combination thereof. The fabric material may be of other suitable materials such as foam, knit I woven fabrics, bonded I laminated fabric materials, or any combination thereof. The polymer material of the polymer peripheral layer 220 and polymer band layer 230 is preferably silicone which is a polymer made up of siloxane. The polymer material may be of other suitable materials such as thermoplastic polyurethane (TPU) or polyurethane (Pll).

As described above, the cradle structure 200 or garment component 300 having one or more cradle structures 200 can be attached to a garment to form the bra cups. The garment may be an innerwear (e.g. bra and lingerie), swimwear (e.g. swimsuit and tankini), or activewear (e.g. sports bra). Figures 3A and 3B show some examples of the garment 310 worn on a mannequin 320. The garment 310 includes a pair of bra cups 312, each bra cup 312 comprising the cradle structure 200.

Fit trials of the garments 310 using the cradle structures 200 have been conducted to evaluate the functionality of the cradle structures 200, particularly the effects of the polymer peripheral layers 220 and polymer band layers 230. It was found that such garments 310 provided good breast support, sufficient volume or capacity for accommodating the breast, appropriate nipple concealment, and were comfortable for the users.

In the foregoing detailed description, embodiments of the present disclosure in relation to a cradle structure for a bra cup are described with reference to the provided figures.

The description of the various embodiments herein is not intended to call out or be limited only to specific or particular representations of the present disclosure, but merely to illustrate non-limiting examples of the present disclosure. The present disclosure serves to address at least one of the mentioned problems and issues associated with the prior art. Although only some embodiments of the present disclosure are disclosed herein, it will be apparent to a person having ordinary skill in the art in view of this disclosure that a variety of changes and/or modifications can be made to the disclosed embodiments without departing from the scope of the present disclosure. Therefore, the scope of the disclosure as well as the scope of the following claims is not limited to embodiments described herein.