Dual-layered seamless sports bra and camisole

[0001] This application claims priority to Provisional Application No. 60/224,307 filed Aug. 10, 2000, which is herein incorporated by reference in its entirety.

[0002] Not applicable.

[0003] The invention relates to women's active apparel and sports equipment. More specifically, a seamless sports bra is disclosed having a unique construction that provides ample support for moderate to strenuous physical activity while also providing nonabrasive comfort and style.

[0004] Support wear for women is known in the art. The bra and camisole have been standard items in the women's clothing industry for many years. As women's athletics has become increasingly popular, an industry has grown in an effort to meet the needs of female athletes. U.S. Pat. No. 5,996,120, the entirety of which is herein incorporated by reference, discloses a single layer seamless liner for a swimsuit and support system; however, this does not provide sufficient support for other activities. U.S. Pat. No. 6,068,538, the entirety of which is herein incorporated by reference, discloses a wraparound sports bra for supporting the breasts and back muscles, but is not dual-layered or seamless.

[0005] Generally, existing every-day wear, seamless bras are manufactured using a circular knitting technology. Garments produced in this manner typically fall into the categories of innerwear and lingerie. Garments manufactured with this technique lack a support structure to allow for comfortable exercise and movement. Current seamless bras made using circular knitting technology are designed and created with aesthetics as the primary goal and do not evidence the support necessary for active sports.

[0006] On the other hand, most sport bras are designed by using cut-and-sew sections of fabric to lift and shape the breasts. Cups are created with molded technology and are sewn into the paneled bra structure. Additional support may be provided by sewing underwire into the cups. While they provide support, sport bras of this common construction can be uncomfortable due to seams inherent in the cut-and-sew design as well as the underwire. Moreover, these bras provide uneven support that concentrates pressure on the chest area directly beneath the breasts and on the shoulders where the straps hold the bra up and in place.

[0007] It has been many years since manufacturers first designed the sport bra as a garment for women to use while they exercise. Initially, manufacturers thought that women would feel more comfortable exercising if they were able to reduce the vertical displacement of the breast and therefore eliminate the bounce factor. After many modifications to the to the garment, women still complain that they can't get enough support or the bra digs into their shoulders and is too tight around the ribs.

[0008] The breast is essentially a sophisticated sweat gland considered a solid structure with a gelatin-like consistency. It is composed of fatty lobules with sebaceous glands, ducts and connective tissue. The arreolar area contains dense nerve innervation and the vascular supply enters through the anterior shoulder, axilla and lower lateral breast area. The only muscle found in the breast is in the ductal system of the nipple and has an erectile function. The breasts sit on top of the bony thorax cage and over the pectoralis muscle group. Therefore, the breast tissue is exposed and when compressed, irritated or subject to contact, can become irritated, inflamed, bruised and chafed.

[0009] In analyzing garment construction, there are elements that directly oppose the natural physiology of the breast. The areas of greatest vascularization are also the areas where shoulder straps exert pressure or rib bands compress tissue. The sensitive nipple area is often compressed and subject to seams and fabric ridges. The lateral breast has the highest accumulation of fatty tissue and is exposed to compression and pinching from the lateral panels of the garment. A better match between physiology and garment construction may ease some breast problems.

[0010] Accordingly, a sports bra that is both fashionable and functional is desired by the women's fitness apparel industry. The present invention provides women's support wear that addresses the needs for an aesthetically pleasing, comfortable, non-irritating and supportive bra. The present invention is directed to two embodiments, a bra and a camisole, but the technology described in this application can be used in other garments. Thus, the description in terms of a bra or camisole is not limiting.

[0011] The present invention provides for a seamless women's support garment created by utilizing an innovative two-layer construction system. The dual layers are preferably, but not necessarily, knitted together using a Santoni knitting machine. In a preferred embodiment, the inner layer includes molded cups, lateral breast uplift panels and inner mesh ventilation panels. The camisole embodiment incorporates these features as well as an elastomeric bra liner that surrounds the wearer. Accordingly, an object of the present invention is to provide a seamless support garment that is aesthetically pleasing and sturdy enough to permit comfortable athletic movement. Another object of the invention is to provide a method of making a dual-layered seamless garment that will support a person's breasts comfortably during both light and strenuous exercise as well as other activity. A further object of the invention is to present a system of providing support during activity comprising a seamless garment having two material layers. In a preferred embodiment, the invention also provides a seamless support structure as defined above wherein the:

[0012] (i) maximum support stitch is used under the bust and on the sides of the bust;

[0013] (ii) medium support stitch is used above the bust, over the bust, and on the back of the garment; and

[0014] (iii) soft support stitch is used between the breasts.

[0015] Other and further objects of the invention, together with additional features of novelty pertinent thereto, will appear in view of the drawings and in the course of the following description.

[0016] The disclosed aspects of the present invention may be best understood by reference to the accompanying drawings of a preferred embodiment that form a part of the specification and are to be read in conjunction therewith; and in which like reference numerals and reference letters are used to indicate like parts in the various views:

[0017] FIG. 1 is a front view of the inside layer of the sport bra of a preferred embodiment present invention.

[0018] FIG. 2 is a rear view of the inside layer of the sport bra of a preferred embodiment present invention.

[0019] FIG. 3 is a front view of the outside layer of the sport bra of a preferred embodiment present invention;

[0020] FIG. 4 is a rear view of the outside layer of the sport bra of a preferred embodiment present invention;

[0021] FIG. 5 is a front view of the inside layer of the sport camisole of a preferred embodiment present invention;

[0022] FIG. 6 is a rear view of the inside layer of the sport camisole of a preferred embodiment present invention;

[0023] FIG. 7 is a front view of the outside layer of the sport camisole of a preferred embodiment present invention;

[0024] FIG. 8 is a rear view of the outside layer of the sport camisole of a preferred embodiment present invention;

[0025] FIG. 9 is a detailed expanded view of FIG. 1 showing aspects of a preferred embodiment preferred embodiments of the sport bra embodiment; and

[0026] FIG. 10 is a detailed expanded view of FIG. 5 showing aspects of a preferred embodiment preferred embodiments of the sport camisole embodiment.

[0027] As used herein, the term breast is preferably defined as either of two protuberant glandular organs situated on the front of the chest or thorax in a human. In a most preferred embodiment, the human is a female and the breast (or breasts in the plurality) are glandular milk-producing organs and normally function producing milk only during the period of lactation following pregnancy. Furthermore, a breast may or may not be surgically altered.

[0028] As used herein, the term bust is preferably defined as the portion of a garment covering the upper area of a human torso, but especially the breasts.

[0029] In the past, sports bras have featured technology that depends on using cut and sew panels. These panels utilize sections of fabric cut to a specific form to surround the breast, lift, and shape it. Heat-molded cups (i.e., molded technology) are sewn into the panel to provide support for the breast during vigorous activity. Past embodiments of the sports bra have generally used Lycra or nylon fabric for a compression effect to provide additional support to the breasts. In some cases, underwire support can be sewn into the cups of a cut and sew paneled bra where even greater support is required. Finally, sports bras of the past have also featured only one layer of a thick Lycra, cotton, nylon fabric or some blend of these fabrics.

[0030] Sports bras featured in the prior art have generally been designed with functionality in mind. Attempts to make a fashionable sports bra have relied on varying color schemes or changing some minor aspect of the exterior design. Another problem of past sports bras is chafing of the delicate skin in the aorta and underarm areas of the breasts. Moreover, when thicker fabrics are use to provide additional support, they can prevent sweat from being properly drawn away from the skin, resulting in uncomfortable rashes on users with more sensitive skin. Finally, underwire designs and sports bras that are constructed with a thick elastic band to provide greater breast support constrict the area of the chest directly beneath the breasts. This can cause painful rashes, scratching, and pinching in this area. Moreover, in underwire designs, the wire may bend out of shape with regular wear shortening the useful life of the attire, and may penetrate the fabric and scratch or poke the user.

[0031] Seamless bras have become available recently in the innerwear/lingerie industry. These products feature circular knitting technology that eliminates the need for an obvious seam. These products have enjoyed widespread popularity with female users because of the level of comfort and style they provide. Their popularity is also due in part to their aesthetic appeal. However, these seamless bras do not provide the necessary support for vigorous athletic activity. Indeed, it is not clear if the prior art bras could even hold up to such activity.

[0032] To date, there has not been a seamless sport bra introduced on the market for active use. The technology used to produce the seamless bras and liners of the innerwear industry has been limited to a single layer design because past sewing techniques have been unable to incorporate a second layer into the seamless design. The inventors recognized that a second layer is necessary to provide the appropriate amount of breast support during exercise. The inventors discovered that a double layer also permits some movement between the layers. This ability permits the double layer material to be more adaptable to shape and movement than single layer that was of similar support. Moreover, it was discovered that the double layer permitted unexpectedly better wicking of moisture such as perspiration. This better ability to keep the breasts dry explains some of the surprising comfort that is associated with the bras of this invention.

[0033] Two embodiments of a dual-layered seamless support garment are disclosed. They include novel aspects, which are improvements over the current states of sports bras and seamless innerwear. The disclosed embodiments are exemplary only and those of ordinary skill in the art will readily ascertain alternative implementations of the current invention.

[0034] One embodiment of the invention may be in the form of a sports bra. The design shown in FIGS. 1-4 and 9 demonstrates an innovative 2-layer construction system applied to a sport bra embodiment of the present invention. FIGS. 3 and 4 show the front and back views, respectively, of the outer layer 200 of the present invention. This layer is a smooth layer composed of a single or combination of materials that are known in the art. In a preferred embodiment, this layer is composed of at least one material selected from the group consisting of spandex, cotton, nylon, and comparable materials. In a more preferred embodiment, this layer is composed of a duality of materials selected from the group consisting of spandex, cotton, nylon, and comparable materials. The ratio of these materials may be any combination known in the art, but will preferably be a ratio of about 50%-50%, more preferably will be of about 80%-20%, even more preferably will be of about 90%-10%, and most preferably will be of about 93%-7% of non-stretching material compared to stretching.

[0035] In a preferred embodiment, the duality of materials will be selected from the group consisting of nylon and spandex (Tactel Nylon and Lycra are disclosed in the Example). A ratio for these materials of about 50%-50% is preferred, a ratio for these materials of about 80%-20% is more preferred, a ratio for these materials of about 90%-10% is even more preferred, and a ratio for these materials of about 93%-7% is most preferred.

[0036] In a preferred embodiment of the present invention, the back 210 and front shoulders of the outer layer 200 of material, shown in FIG. 4, comprises an outer mesh ventilation panel 212. The mesh ventilation panel 212 is a section of woven or knit fabric that has an open texture and evenly spaced holes. In this embodiment, the mesh ventilation panel allows an inner layer of material 100 to have direct access to the outside environment, facilitating heat transfer away from the user and allowing sweat absorbed by the inner layer to evaporate more quickly. This helps to keep the wearer of the garment cool and dry. The mesh ventilation panel 212 may be created using a singular, duality, or plurality of materials, selected from the group and in the combination(s) and ratios described above.

[0037] FIGS. 1, 2, and 9 show the inner layer 100 of the present invention. FIGS. 1 and 2 demonstrate the front and back views, respectively, while FIG. 9 portrays a more detailed view of FIG. 1. In a preferred embodiment, this layer is composed of at least one material selected from the group consisting of spandex, cotton, nylon, or comparable materials. In a more preferred embodiment, this layer is composed of a duality of materials selected from the group consisting of spandex, cotton, nylon, or comparable materials. The ratio of these materials may be any combination known in the art.

[0038] In a preferred embodiment, the duality of materials will be selected from the group consisting of nylon and spandex (Tactel Nylon and Lycra are disclosed in the example). A ratio for these materials of about 50%-50% is preferred, a ratio for these materials of about 80%-20% is more preferred, a ratio for these materials of about 90%-10% is even more preferred, and a ratio for these materials of about 93%-7% is most preferred.

[0039] In a preferred embodiment of the present invention, both the inner and outer layers, and all subparts thereof, will be comprised of the same material or combination of materials to provide a consistent texture and touch to the user.

[0040] In a preferred embodiment, the inner layer comprises inner mesh ventilation panels and an engineered bra, with molded cups and lateral breast uplift panels. The inner mesh ventilation panel 130 functions as described for the outer mesh ventilation panel. In the preferred embodiment, the mesh ventilation panel may be created using a singular, duality, or plurality of materials, selected from the group and in the combination(s) and ratios described above.

[0041] Items 104, 106, and 110 of FIG. 9 portray the engineered bra of a preferred embodiment of the present invention. Item 104 portrays the molded cups of the present invention. The molded cups are sections of material knitted to be close fitting to the breast(s) of the user of the present invention and provide a medium level of support over the bust. The shape of the cup 104 follows the shape of the breast and provides an amount of flexibility sufficient to allow the breast to maintain a comfortable position during periods of activity or exercise.

[0042] Item 106 portrays the lateral breast uplift panels of a preferred embodiment of the present invention. A lateral breast uplift panel is a section of material which provides maximum support for a breast and is positioned along the lower outside edge of each of the molded cups, i.e., on the side of the bust as depicted in FIG. 9. The lateral breast uplift panels of the present invention function to support and hold a breast in a comfortable position during activity or exercise.

[0043] Item 110 portrays a flexible section of material used in a preferred embodiment of the present invention as part of the engineered bra. This section of material is located between the breasts, i.e., in the center of the bust, and attaches to each of the molded cups. This section is sufficiently flexible to allow for breasts of varying sizes and shapes to occupy the engineered bra and to adjust the position of the bra and/or breast(s) such that the wearer of the garment is comfortable during activity or exercise. Furthermore, the flexibility of item 110 allows for changes in the size of the breast(s) due to weight gain, weight loss, water retention, or pregnancy/lactation.

[0044] Item 102 portrays a preferred embodiment of the present invention wherein a section of material provides medium support above the bust and in the back of the garment. In an alternative embodiment, a medium support area may be provided over the shoulders of the wearer as well. The area depicted by item 102 is a means of additional support in the garment.

[0045] The combination of the two layers provides the necessary support of the bust for moderate to strenuous activity. Furthermore, the dual layered design of the present invention adds a level of modesty not found in the single layer seamless construction used for innerwear and lingerie. During exercise, sweat, skin irritation, and changes in skin temperature can cause the nipple area of the breasts to become erect. Single layer seamless designs and even the traditional cut and sew panels that utilize only one layer of material do not provide adequate coverage to minimize the visual effects of these changes. However, the dual layer design of the present invention provides for more modest coverage of these areas.

[0046] In addition, the inclusion of a dual-layered design negates the necessity to use thicker materials to support and constrict the breasts. This allows for sweat to be drawn away from the skin faster than in traditional sports bra models that use a thick, single layer of material. Sweat is drawn through the first layer of material and into the second, where it is exposed to the surrounding air and quickly evaporates causing less skin irritation in the wearer. Moreover, the lack of seams precludes those seams from absorbing moisture and salt from perspiration. This adds to the low level of irritation from the bra.

[0047] A preferred embodiment of the present invention also features a maximum support, wide ribbed band for added comfort. FIGS. 1, 2 and 9 show the wide ribbed band of the present invention, but its functionality and construction is best portrayed by item 108 of FIG. 9. The wide ribbed band is a section of material positioned beneath the breasts, or in a preferred embodiment positioned below the engineered bra, and is composed of the same materials used to construct the inner layer of the present invention. Its function is to provide maximum support under the bust and to give structure to the garment. Unlike simple elastic bands wrapped around the upper torso found in some sports bras, this rib support system provides diffuse pressure over a wider area of skin. It supplies more support for the breasts without constricting movement or irritating the skin.

[0048] The two layers of material used in the present invention are adhered together at the hems, shown in FIGS. 1-4 and 9. In one embodiment of the present invention, there is a wide hem 120 located directly beneath the ribbed support system. Unlike the elastic bands found in traditional sports bras, the hem 120 is seamless and offers more flexibility, comfort and freedom of movement than is found in the prior art. In one embodiment, this hem is used along all edges of the garment; in an alternative embodiment, soft elastic edging may be used to adhere the two material layers, eliminating the need for either seams or an elastic band. Sports bras that have seams can have the effect of cutting into the skin around the shoulders and underarm. The seamless construction of the bra eliminates chafing, pinching, and constricting of the delicate skin that surrounds the breasts.

[0049] Moreover, the lack of seams allows the bra to provide continuous, even and uninterrupted support throughout the upper torso and especially in the breast area. Because this pressure is diffused throughout the bra rather than concentrated in areas where seams or elastic would normally be found, the invention can provide support that is consistent throughout the garment.

[0050] The design of the seamless sports bra itself generates more support than designs found in the prior art. The molded cups and ribbed support system in the bra provide excellent all-around support that results in less movement or bounce of the breasts during exercise. The elasticity of the design provides more than ample pressure on the breasts to restrict vertical movement while maintaining sufficient flexibility to enhance comfort.

[0051] Another embodiment of the invention is in the form of a Sport Camisole. The sport camisole embodiment of the present invention features all the innovations, designs, and advantages of the sport bra embodiment and incorporates all of the above definitions, descriptions, and limitations herein. The dual-layered sport camisole is depicted in FIGS. 5-8 and 10. All of the numbered elements shown in FIG. 10 correspond to the like numbered elements of FIG. 9 and so depict the features of the preferred embodiments of the sport camisole of the present invention.

[0052] The sport camisole embodiment of the present invention further features an inner 360 bra liner that provides the functions and features of the inner layer of the corresponding sport bra embodiments. As used herein, a liner is a supplementary layer of material over the bust of the wearer, which functions as a second material layer in this embodiment of the present invention. In alternative embodiments, the bra liner may or may not feature the engineered bra and ribbed support systems of the preferred embodiments of the sport bra.

[0053] The bra liner is adhered to the outer layer of material preferably along the shoulders, underarms, and/or back of the garment. In one embodiment, soft elastic edging may be used to adhere the two material layers together. Furthermore, the bra liner may or may not be adhered to the outer layer of material at the hem located directly beneath the bust (or attached at the ribbed support system in a preferred embodiment).

[0054] The sport camisole may or may not include wide shoulder straps. As shown in FIG. 10, the camisole embodiment may include spaghetti straps or use adjustable soft elastic straps to secure the garment over the shoulders of the wearer. It is contemplated that either embodiment (i.e., the sport bra or sport camisole) may eliminate the use of shoulder straps altogether and rely only on the exceptional support provided throughout the rest of the garment to adhere the article of clothing to the bust of the wearer.

[0055] Finally, the sport camisole embodiment includes the additional feature of a modest cover over the midriff and tummy of the wearer. This embodiment features additional light support over these areas to keep them in place during activity. An alternative embodiment may offer a loosely fitting cover over the tummy of the wearer. In one embodiment, the inner layer of the sport camisole may extend below the bust and over the tummy of the wearer. In one embodiment, a flat finish hem 140 may also be included at the base of the garment.

[0056] Both the sport bra and sport camisole embodiments of the present invention may be worn alone or underneath other materials to provide a smooth, attractive silhouette of the wearer.

[0057] With regards to FIGS. 9 and 10, the following types of stitches may be used in the different areas of the inner layer of the garment in a preferred embodiment according to the present invention: Maximum support areas (indicated as 106 and 108 in the figures) used for the following areas of the liner: under the bust and on the sides of the bust.

[0058] Suggested pattern of stitch:

[0059] 10612 in 4 feeds, plain stitch in 4 feeds.

[0060] 10822 in 4 feeds, plain stitch in 4 feeds.

[0061] Body: type of yarn: 20 Denier Spandex single covered with 15 diner, 7 filament Nylon (8 feeds) 2 ply 70 diner, 68 filament Nylon (12 feeds).

[0062] Hem: type of yarn: 360 denier Spandex double covered with 20 denier, 7 filament Nylon, (2 feeds).

[0063] Medium support areas (indicated as 102 and 104 in the figures) used for the following areas of the liner: above the bust, over the bust, and the back.

[0064] Suggested pattern of stitch:

[0065] 10222 in 8 feeds.

[0066] 104plain stitch in 8 feeds.

[0067] Body: type of yarn: 20 denier Spandex single covered with 15 denier, 7 filament Nylon (8 feeds) 2 ply 70 denier, 68 filament Nylon (12 feeds).

[0068] Hem: type of yarn: 360 denier Spandex double covered with 20 denier, 7 filament Nylon, (2 feeds).

[0069] Soft support areas (indicated as 110 in the figures) used for the following areas of the liner: between the breasts (center of the bust).

[0070] Suggested pattern of stitch:

[0071] 11024 repeat 8, feeds.

[0072] Body: type of yarn: 20 denier Spandex single covered with 15 denier, 7 filament Nylon (8 feeds) 2 ply 70 denier, 68 filament Nylon (12 feeds).

[0073] Hem: type of yarn: 360 denier Spandex doubled covered with 20 denier, 7 filament Nylon, (2 feeds).

[0074] From the foregoing, it will be seen that this invention is one well adapted to attain all ends and objects here and above set forth, together with other advantages which are obvious and which are inherent to the structure.

[0075] It will be understood that certain features and subcombinations are of utility and may be employed without further reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative, and not in a limiting sense.