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. A method of manufacturing the cushioned casing is also provided.

What is claimed is: 
     
         1 . 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 comprising a body having a channel for receiving an underwire and a wing member integral with and extending from the body;   wherein the cushioning material is positioned on the outside of the body, and the wing member is folded around the cushioning material to capture the cushioning material between the body and the wing member.   
     
     
         2 . The cushioned casing of  claim 1 , wherein the structure comprises an integral three leaf structure, where two of the leaves are brought together to form the body having the channel and the third leaf is the wing member. 
     
     
         3 . The cushioned casing of  claim 1 , further comprising a film attached to the wing member on a side that contacts the cushioning material, such that the film is positioned between the wing member and the cushioning material. 
     
     
         4 . The cushioned casing of  claim 1 , wherein the structure further comprises a protrusion extending from the body, wherein the cushioning material is positioned adjacent the protrusion, such that the cushioning material is enclosed between the wing member, the protrusion, and the body. 
     
     
         5 . The cushioned casing of  claim 4 , wherein the protrusion is integral with the body. 
     
     
         6 . The cushioned casing of  claim 1  wherein the wing member is attached to the body. 
     
     
         7 . The cushioned casing of  claim 4 , wherein the wing member is attached to the protrusion. 
     
     
         8 . The cushioned casing of  claim 1 , further comprising an underwire extending through the channel of the body. 
     
     
         9 . A method for manufacturing a cushioned casing for an underwire of a brassiere, the method comprising:
 providing a structure comprising a body having a channel for receiving an underwire of a brassiere and a wing member integral with and extending from the body;   positioning a cushioning material on the outside of the body having the channel; and   folding the wing member around the cushioning material to capture the cushioning member between the body and the wing member.   
     
     
         10 . The method of  claim 9 , wherein the step of positioning the cushioning material on the outside of the body further comprises attaching the cushioning material to the body. 
     
     
         11 . The method of claim,  9  further comprising attaching a film to the wing member prior to folding the wing member around the cushioning material. 
     
     
         12 . The method of  claim 9 , wherein the structure comprises a protrusion extending from the body, and the step of positioning a cushioning material on the outside of the body comprises positioning the cushioning material adjacent the protrusion. 
     
     
         13 . The method of  claim 12 , wherein the wing member has two ends, one integral with the body and the other a free end, and the method further comprises attaching the free end of the wing member to the protrusion. 
     
     
         14 . The method of  claim 9 , wherein the wing member has two ends, one integral with the body and the other a free end, the method further comprising attaching the free end of the wing member to the body. 
     
     
         15 . A method for manufacturing a cushioned casing for an underwire of a brassiere, the method comprising:
 providing an integrated structure having three leaves, each leaf having an end joined to the other leaves and a free end;   positioning a cushioning material on a first leaf of the three leaves;   bringing the free ends of the three leaves together such that the first leaf and a second leaf of the three leaves form a body having a channel for receiving an underwire, with the cushioning material positioned on the outside of the body, and the third leaf of the three leaves is folded around the cushioning material to capture the cushioning material between the body and the third leaf.   
     
     
         16 . The method of  claim 15 , wherein the cushioning material is positioned on the first leaf after the first and second leaves have been brought together to form the body, and before the third leaf is folded around the cushioning material. 
     
     
         17 . The method of  claim 15 , wherein the three leaf structure has a T-shaped cross-section prior to the step of bringing the free ends of the leaves together. 
     
     
         18 . The method of  claim 15 , wherein the step of positioning the cushioning material on the outside of the body further comprises attaching the cushioning material to the body. 
     
     
         19 . The method of  claim 15 , further comprising attaching a film to the third leaf prior to bringing the free ends of the leaves together. 
     
     
         20 . The method of  claim 15 , wherein the three free ends of the leaves are attached together.