Front panel for a brassiere

Abstract

The present invention relates to a front panel for a brassiere, the front panel comprising an inner fabric layer with a first and second surface, and an outer fabric layer with a first and second surface, a first foam layer coupled to the first surface of the inner fabric layer and a second foam layer coupled to the first surface of the outer fabric layer, wherein the first foam layer and second foam layer are disposed between the first surface of the inner fabric layer and the first surface of the outer fabric layer, and the inner fabric layer and outer fabric layer each having an outer perimeter. The invention also relates to a method of manufacturing the front panel, and a garment comprising the front panel.

1 . A front panel for a brassiere, the front panel comprising an inner fabric layer with a first and second surface, and an outer fabric layer with a first and second surface,
 a first foam layer coupled to the first surface of the inner fabric layer and a second foam layer coupled to the first surface of the outer fabric layer, wherein the first foam layer and second foam layer are disposed between the first surface of the inner fabric layer and the first surface of the outer fabric layer,   the inner fabric layer and outer fabric layer each having an outer perimeter,   wherein the outer perimeter of the inner fabric layer and/or the outer fabric layer comprises a peripheral attaching element that folds over a peripheral edge of the first foam layer and a peripheral edge of the second foam layer, and wherein the peripheral attaching element is coupled to the outer perimeter of the other fabric layer,   
       optionally comprising a cavity between the first foam layer and the second foam layer. 
     
     
         2 . The front panel according to  claim 1 , wherein the peripheral attaching element extends along a neckline edge, an underarm edge and an under-breast edge of the inner fabric layer or outer fabric layer; and/or
 wherein the peripheral attaching element is coupled to the outer perimeter of the other fabric layer by stitching or bonding means,   optionally wherein the peripheral attaching element is coupled to the neckline edge, the underarm edge and the under-breast edge of the other fabric layer by stitching or bonding means,   further optionally wherein the peripheral attaching element is coupled to the outer perimeter of the other fabric layer by bonding means selected from an adhesive or ultrasonic bonding, for example, wherein the bonding means is an adhesive selected from an adhesive tape (e.g. double-sided adhesive tape), liquid glue, or hotmelt powder glue.   
     
     
         3 . The front panel according to  claim 1 , wherein the first foam layer is coupled to the first surface of the inner fabric layer by a bonding means; and/or
 wherein the second foam layer is coupled to the first surface of the outer fabric layer by a bonding means,   optionally wherein the bonding means is an adhesive or ultrasonic bonding, for example, the bonding means may be an adhesive selected from an adhesive tape (e.g. double-sided adhesive tape), film adhesive (e.g. a thermoplastic polyurethane (TPU) adhesive film), liquid glue, or hotmelt powder glue, optionally wherein the adhesive tape is a dot adhesive or a mesh adhesive.   
     
     
         4 . The front panel according to  claim 1 , wherein the first foam layer and second foam layer each have a three-dimensional shape that is configured to conform to a user's chest region,
 optionally wherein the three-dimensional shape of the first foam layer and second foam layer are formed by compression moulding of the first foam layer and second foam layer.   
     
     
         5 . The front panel according to  claim 1 , wherein the first foam layer and second foam layer are each formed from a foam material, optionally wherein the first foam layer and second foam layer are each formed from a polyurethane foam; and/or
 wherein the first foam layer and second foam layer each have a thickness of from about 2 mm to about 8 mm, for example from about 3 mm to 5 mm thick (e.g. about 4 mm thick).   
     
     
         6 . The front panel according to  claim 1 , wherein the front inner fabric layer and front outer fabric layer are each independently formed from one or more yarns selected from the group consisting of a polyurethane yarn (e.g. elastane), a polyester yarn, a polyamide yarn (e.g. nylon), cotton yarn, silk yarn, and a combination of two or more thereof, optionally wherein the fabric is a spacer fabric (e.g. a fabric comprising at least fabric layers connected by spacer yarn and/or pile yarns),
 optionally wherein the inner fabric layer and outer fabric layer are formed from:
 about 74 to about 94 wt % nylon; and about 6 to about 26 wt % elastane, for example, about 84 wt % nylon; and about 16 wt % elastane. 
   
     
     
         7 . The front panel according to  claim 1 , wherein the weight of the inner fabric layer and outer fabric layer are each independently from about 200 g/m 2  to about 240 g/m 2 , for example, about 220 g/m 2 . 
     
     
         8 . The front panel according to  claim 1 , wherein any one of the following applies:
 (i) further comprising an additional material disposed within the cavity, wherein the additional material is selected from the group consisting of a power mesh material and a under breast supporting element (e.g. a bra underwire),   optionally wherein the additional material is a power mesh material, for example a power mesh material formed from polyester and elastane, and optionally wherein the power mesh material is a 4-way stretch power mesh material;   (ii) wherein a back panel is coupled to the front panel by bonding means (e.g. an adhesive or ultrasonic bonding) or stitching;   (iii) wherein the first foam layer and a second foam layer are not directly attached to each other.   
     
     
         9 . The front panel according to claim  9 , wherein the additional material is coupled to one or both the first foam layer and second foam layer by bonding means,
 optionally wherein the bonding means is an adhesive or ultrasonic bonding, for example, the bonding means may be an adhesive selected from an adhesive tape (e.g. double-sided adhesive tape), film adhesive (e.g. a thermoplastic polyurethane (TPU) adhesive film), liquid glue, or hotmelt powder glue, optionally wherein the adhesive tape is a mesh adhesive tape.   
     
     
         10 . A method of manufacturing the front panel of  claim 1 , the method comprising:
 (a) providing an inner fabric layer and an outer fabric layer,   (b) coupling a first foam layer to the first surface of the inner fabric layer and a second foam layer to the first surface of the outer fabric layer;   (c) arranging the inner fabric layer coupled to the first foam layer and the outer fabric layer coupled to the second foam layer such that the first foam layer is disposed opposite the second foam layer; and   (d) coupling the inner fabric layer and outer fabric layer to each other along the respective outer perimeters,   optionally wherein the front panel comprises a cavity between the first foam layer and the second foam layer.   
     
     
         11 . The method according to  claim 10 , wherein at least one of the following applies:
 (i) following step (b) and before step (c), the method comprises a step of subjecting the inner fabric layer coupled to the first foam layer and the outer fabric layer coupled to the second foam layer to compression moulding to form a three-dimensional shape that is configured to conform to a user's chest region;
 (ii) wherein step (d) comprises: 
   (di) folding a peripheral attaching element of the inner fabric layer over a peripheral edge of the first foam layer and a peripheral edge of the second foam layer; and   (dii) coupling the peripheral attaching element to the outer perimeter of the outer fabric layer;   (iii) wherein step (d) comprises:   (di) folding a peripheral attaching element of the outer fabric layer over a peripheral edge of the first foam layer and a peripheral edge of the second foam layer; and   (dii) coupling the peripheral attaching element to the outer perimeter of the inner fabric layer;   (iv) wherein the peripheral attaching element is coupled to the outer perimeter of the other fabric layer by stitching or bonding means, optionally wherein the peripheral attaching element is coupled to a neckline edge, an underarm edge and an under-breast edge of the other fabric layer by stitching or bonding means, optionally wherein the peripheral attaching element is coupled to the outer perimeter of the other fabric layer by bonding means selected from an adhesive or ultrasonic bonding, for example, wherein the bonding means is an adhesive selected from an adhesive tape (e.g. double-sided adhesive tape), liquid glue, or hotmelt powder glue;   (v) wherein step (b) comprises:   (bi) bonding the first foam layer and to the first surface of the inner fabric layer; (vi) wherein step (b) comprises:
 (bii) bonding the second foam layer and to the first surface of the outer fabric layer, optionally wherein the bonding means is an adhesive or ultrasonic bonding, for example, the bonding means may be an adhesive selected from an adhesive tape (e.g. double-sided adhesive tape), film adhesive (e.g. a thermoplastic polyurethane (TPU) adhesive film), liquid glue, or hotmelt powder glue, optionally wherein the adhesive tape is a dot adhesive or a mesh adhesive. 
   
     
     
         12 . The method according to  claim 10 , wherein any one of the following applies:
 (i) the first foam layer and second foam layer are each formed from a foam material, optionally wherein the first foam layer and second foam layer are each formed from a polyurethane foam;   (ii) wherein the first foam layer and second foam layer each have a thickness of from about 2 mm to about 8 mm, for example from about 3 mm to about 5 mm thick (e.g. about 4 mm thick);   (iii) wherein the front inner fabric layer and front outer fabric layer are each independently formed one or more yarns selected from the group consisting of a polyurethane yarn (e.g. elastane), a polyester yarn, a polyamide yarn (e.g. nylon), cotton yarn, silk yarn, and a combination of two or more thereof, optionally wherein the fabric is a spacer fabric (e.g. a fabric comprising at least fabric layers connected by spacer yarn and/or pile yarns),   optionally wherein the inner fabric layer and outer fabric layer are formed from:
 about 74 wt % to about 94 wt % nylon; and about 6 wt % to about 26 wt % elastane, for example, 
 about 84 wt % nylon; and about 16 wt % elastane. 
   
     
     
         13 . The method according to  claim 10 , wherein the weight of the inner fabric layer and outer fabric layer are each independently from about 200 g/m 2  to about 240 g/m 2 , for example, about 220 g/m 2 . 
     
     
         14 . The method according to  claim 10 , wherein step (c) further comprises:
 (ci) arranging an additional material between the first foam layer and the second foam layer, the additional material is one selected from the group consisting of a power mesh material and a under breast supporting element (e.g. a bra underwire),   optionally wherein the additional material is power mesh material, for example, a power mesh material formed from polyester and elastane, and optionally wherein the power mesh material is a 4-way stretch power mesh material.   
     
     
         15 . The method according to  claim 14 , wherein the additional material is coupled to one or both the first foam layer and second foam layer by bonding means,
 optionally wherein the bonding means is an adhesive or ultrasonic bonding, for example, the bonding means may be an adhesive selected from an adhesive tape (e.g. double-sided adhesive tape), film adhesive (e.g. a thermoplastic polyurethane (TPU) adhesive film), liquid glue, or hotmelt powder glue, optionally wherein the adhesive tape is a mesh adhesive.   
     
     
         16 . A garment comprising a front panel according to  claim 1 . 
     
     
         17 . The garment according to  claim 16 , wherein the garment is a brassiere or bralette. 
     
     
         18 . The method according to  claim 10 , the method comprising:
 (i) manufacturing a front panel according to  claim 10 ;   (ii) providing a back panel;   (iii) coupling the back panel to the front panel,
 incorporating the front panel into a garment, optionally wherein the garment is a brassiere or bralette. 
   
     
     
         19 . The method according to  claim 18 , wherein step (iii) comprises bonding (e.g. an adhesive or ultrasonic bonding) or stitching the back panel to the front panel.