Cushioned casing for an underwire and method of manufacturing the cushioned casing

Abstract

There is provided a cushioned casing for an underwire of a brassiere. The cushioned casing comprises a cushioning material and a structure for enclosing an underwire and the cushioning material. The structure comprises a body having a channel for receiving an underwire and a wing member integral with and extending from the body. The cushioning material is positioned on the outside of the body, and the wing member is folded around the cushioning member to capture the cushioning material between the body and the wing member. There is also provided a cushioned casing for an underwire of a brassiere comprising a cushioning material and a structure for enclosing an underwire and the cushioning material. The structure comprises an inner sleeve and an outer fabric layer. The inner sleeve comprises a longitudinal body having a channel for receiving an underwire.

What is claimed is: 
     
         1 . A cushioned casing for an underwire of a brassiere comprising:
 a cushioning material;   a structure for enclosing an underwire and the cushioning material, the structure comprising an inner sleeve and an outer layer;   wherein the inner sleeve comprises a longitudinal body having a channel for receiving an underwire and a protrusion extending from an outer surface of the longitudinal body, the protrusion extending longitudinally;   wherein the cushioning material is positioned on the outer surface of the body adjacent the protrusion; and   wherein the outer layer surrounds the cushioning material and at least a portion of the inner sleeve, such that the cushioning material is captured between the inner sleeve and the outer layer.   
     
     
         2 . The cushioned casing of  claim 1 , wherein the protrusion extends substantially along the full length of the longitudinal body. 
     
     
         3 . The cushioned casing of  claim 2 , wherein the inner sleeve comprises a second protrusion extending from the outer surface of the longitudinal body, the second protrusion extending longitudinally;
 wherein the first and second protrusions are spaced apart; and   wherein the cushioning material is positioned on the outside surface of the body between the first and second protrusions.   
     
     
         4 . The cushioned casing of  claim 3 , wherein one or both of the protrusions and the outer surface of the body is shaped to accommodate the shape of the cushioning material. 
     
     
         5 . The cushioned casing of  claim 1 , further comprising a film layer positioned between the outer layer and the cushioning material. 
     
     
         6 . The cushioned casing of  claim 1 , wherein the outer layer wraps substantially all the way around the outer surface of the combined inner sleeve and cushioning material to enclose the cushioning material and substantially enclose the inner sleeve. 
     
     
         7 . A method for manufacturing a cushioned casing for an underwire of a brassiere, the method comprising:
 providing an inner sleeve comprising a longitudinal body having a channel for receiving an underwire and a protrusion extending from an outer surface of the longitudinal body, the protrusion extending longitudinally;   placing a cushioning material on the outer surface of the body adjacent the protrusion; and   wrapping an outer layer around the cushioning material and at least a portion of the inner sleeve, such that the cushioning material is captured between the inner sleeve and the outer layer.   
     
     
         8 . The method of  claim 7 , wherein the inner sleeve comprises a second protrusion extending from the outer surface of the longitudinal body, the second protrusion extending longitudinally, and the method comprises positioning the cushioning material on the outside surface of the body between the first and second protrusions.