Dimensional foam brassiere

Abstract

A brassiere garment having a pair of cup portions, each cup portion with an inner foam cup molded generally to the shape of the wearer's bust, and an outer fabric layer overlying the foam cup. Each foam cup has a first lower portion comprising a foam ply that is substantially inelastic in its lateral dimension, and a second upper portion that exhibits one or more of a lighter weight, lower density, greater elasticity and lesser thickness than the lower first portion. The lower first portion and upper second portion join with one another along a line generally traversing the foam cup from a lower and inward side of the foam cup and extending upward and laterally outward in direction. In certain embodiments, the line along which the lower first portion and upper second portion are joined with one another generally extends to or through the apex of the foam cup. Further, a pair of chest bands extends laterally outward from either cup portion, the chest bands having respective complementary mating hook-and-eye closures on either end thereof.

1 . A brassiere garment comprising:
 a pair of cup portions, each having an inner foam cup molded generally to the shape of the wearer's bust, and an outer fabric layer overlying the foam cup, the cup portions being connected with one another by a bridge portion generally at a vertical centerline of the brassiere;   each foam cup having a first lower portion comprising a foam ply that is substantially inelastic in its lateral dimension, and a second upper portion that exhibits one or more of a lighter weight, lower density, greater elasticity and lesser thickness than the lower first portion;   the lower first portion and the upper second portion being joined with one another along a line generally traversing the foam cup from a lower and inward side of the foam cup and extending upward and laterally outward in direction; and   a pair of chest bands extending laterally outward from either cup portion, the chest bands having respective complementary mating hook-and-eye closures on either end.   
   
   
       2 . A brassiere garment according to  claim 1 , wherein each foam cup further comprises an outer portion extending generally inward from an outer lateral extent of each cup, each outer portion joining the respective lower potion along a line generally traversing the cup upward and inward from a lower and outward side of the cup, and extending upward and inward in direction. 
   
   
       3 . A brassiere garment according to  claim 2 , wherein each outer portion joins the respective upper potion along a line generally traversing the cup upward and inward from a lower and outward side of the cup, and extending upward and inward in direction. 
   
   
       4 . A brassiere garment according to  claim 2 , wherein each outer portion joins the respective upper potion along a line generally traversing the cup upward and inward from a lower and inward side of the cup, and extending upward and outward in direction. 
   
   
       5 . A brassiere garment according to  claim 1 , wherein each lower first portion comprises an inelastic fabric layer bonded thereto. 
   
   
       6 . A brassiere garment according to  claim 5 , wherein the inelastic fabric layer comprises one or more of marisquette, taffeta, or nylon. 
   
   
       7 . A brassiere garment according to  claim 5 , wherein the inelastic fabric layer comprises a woven or non-stretch knit construction. 
   
   
       8 . A brassiere according to  claim 1 , wherein the upper second portion of each foam cup has an elongation of about 50%. 
   
   
       9 . A brassiere according to  claim 1 , wherein the foam cup comprises a polyurethane foam. 
   
   
       10 . A brassiere according to  claim 1 , wherein the lower first portion and upper second portion being joined with one another by sonic joining. 
   
   
       11 . A brassiere according to  claim 1 , wherein the outer fabric layer comprises a single unitary panel overlying each foam cup. 
   
   
       12 . A brassiere according to  claim 1 , wherein the outer fabric layer comprises multiple parts, joined to each other by a sonic finish. 
   
   
       13 . A brassiere according to  claim 12 , wherein the multiple parts correspond in size and shaper to their respective underlying lower first portion and upper second portion of each foam cup. 
   
   
       14 . A brassiere according to  claim 1 , wherein the outer fabric layer comprises a microfiber fabric layer. 
   
   
       16 . A brassiere according to  claim 1 , wherein the line along which the lower first portion and upper second portion are joined with one another generally extends to or through an apex of the foam cup. 
   
   
       17 . A brassiere garment comprising:
 a pair of cup portions, each having an inner foam cup molded generally to the shape of the wearer's bust, and an outer fabric layer overlying the foam cup;   each foam cup having a first lower portion comprising a foam ply having a generally inelastic fabric bonded thereto, and a second upper portion having an elastic fabric layer bonded thereto;   the lower first portion extending from a point at a lower and inward side of the foam cup and extending upward and laterally outward in direction; and   a pair of chest bands extending laterally outward from either cup portion, the chest bands having respective complementary mating hook-and-eye closures on either end.   
   
   
       18 . A brassiere garment according to  claim 17 , further comprising a pair of straps, one each connecting each of the respective chest bands to its adjacent cup portion. 
   
   
       19 . A brassiere garment according to  claim 18 , wherein each strap has a wider portion thereof located generally over the wearer's shoulder in ordinary use.