Sport bra with moisture-transporting molded cups

Patent metadata

Field	Value
Publication number	US-9345272-B2
Application number	US-201313833683-A
Country	US
Kind code	B2
Filing date	Mar 15, 2013
Priority date	May 25, 2012
Publication date	May 24, 2016
Grant date	May 24, 2016

Abstract

Different molding materials and methods are provided for producing a sport bra having moisture-transporting molded bra cups. The different molding materials comprise foams having different average cell sizes, fibers having different average deniers per filament, injection-molding materials having different degrees of hydrophilicity, and different hydrophilic treatments. The molding materials are arranged to create a hydrophilic gradient from a skin surface of the wearer of the sport bra to the exterior of the sport bra.

First claim

What is claimed is:

1. A moisture-transporting molded bra cup for a sport bra, the molded bra cup comprising:
a first zone formed of a foam material having a first average cell size, the first zone substantially adjacent to a skin surface of a wearer when the sport bra is worn; and
a second zone formed of a foam material having a second average cell size, the second average cell size greater than the first average cell size, the second zone comprising an exterior face of the molded bra cup.

2. The molded bra cup of claim 1 , wherein the first zone and the second zone comprise a water-permeable polyurethane.

3. The molded bra cup of claim 1 , wherein the first zone and the second zone comprise a single layer of material.

4. The molded bra cup of claim 1 , wherein the first zone comprises a first layer of material and the second zone comprises a second layer of material.

5. The molded bra cup of claim 4 , wherein the first layer is selectively attached to the second layer so as not to impede the passage of water from the first zone to the second zone.

6. The molded bra cup of claim 5 , wherein the first layer is selectively attached to the second layer using at least one of adhesive, ultrasonic welding, or heat.

7. A process for making a moisture-transporting molded bra cup for a sport bra, the process comprising:
injection molding the molded bra cup using water-permeable materials, the molded bra cup having a first degree of hydrophilicity, the molded bra cup having an exterior face and an interior face facing a skin surface of a wearer when the sport bra is worn;
subsequent to injection molding the molded bra cup, applying a hydrophilic treatment to the exterior face of the molded bra cup, the hydrophilic treatment having a second degree of hydrophilicity that is greater than the first degree of hydrophilicity, and
subsequent to applying the hydrophilic treatment to the exterior face of the molded bra cup, affixing an outer fabric layer to the exterior face of the molded bra cup.

8. The process of claim 7 , wherein the water-permeable materials comprise water-permeable polyurethane.

9. A process for making a moisture-transporting molded bra cup for a sport bra, the process comprising:
injection molding a first zone of the molded bra cup, the first zone having a first degree of hydrophilicity, the first zone being substantially adjacent to a skin surface of a wearer when the sport bra is worn; and
injection molding a second zone of the molded bra cup, the second zone comprising an exterior face of the molded bra cup, wherein the second zone of the molded bra cup overlays the first zone of the molded bra cup in its entirety, the second zone having a second degree of hydrophilicity that is greater than the first degree of hydrophilicity.

10. The process of claim 9 , further comprising:
treating the exterior face of the molded bra cup with a hydrophilic material having a third degree of hydrophilicity that is greater than the second degree of hydrophilicity.

11. The process of claim 9 , wherein the first zone and the second zone of the molded bra cup comprise a unitary piece of material.

12. The process of claim 9 , wherein the first zone comprises a first layer of material and the second zone comprises a second layer of material.

13. The process of claim 12 , wherein the first layer is selectively attached to the second layer so as not to impede the passage of sweat from the first layer to the second layer.

14. A moisture-transporting molded sport bra, the molded sport bra comprising:
a first fabric layer that is adjacent to a skin surface of a wearer when the molded sport bra is worn, the first fabric layer comprised of a hydrophilic material having a first degree of hydrophilicity;
a second fabric layer that comprises an exterior face of the molded sport bra when worn, the second fabric layer comprised of a hydrophilic material having a second degree of hydrophilicity that is greater than the first degree of hydrophilicity; and
a unitary and continuous molded layer disposed between the first fabric layer and the second fabric layer, the molded layer comprised of a material having a third degree of hydrophilicity that is between the first and second degrees of hydrophilicity associated with the first fabric layer and the second fabric layer respectively, wherein a hydrophilic gradient is formed from the first fabric layer to the second fabric layer.

15. The molded sport bra of claim 14 , wherein the molded layer comprises non-woven, moldable fibers of variable diameter.

16. The molded sport bra of claim 15 , wherein fibers having a first average denier per filament are arranged adjacent to the first fabric layer, and wherein fibers having a second average denier per filament are arranged adjacent to the second fabric layer.

17. The molded sport bra of claim 16 , wherein the first average denier per filament is greater than the second average denier per filament.

18. The molded sport bra of claim 17 , wherein the fibers are arranged prior to molding the fibers.

19. The molded sport bra of claim 14 , wherein the molded layer comprises polyurethane foam.

20. The molded sport bra of claim 19 , wherein the polyurethane foam comprises a first zone having a first average cell size, the first zone adjacent to the first fabric layer, and wherein the polyurethane foam comprises a second zone having a second average cell size, the second zone adjacent to the second fabric layer.

21. The molded sport bra of claim 20 , wherein the first average cell size is smaller than the second average cell size.

22. The molded sport bra of claim 14 , wherein the molded layer is injection-molded layer.

23. The molded sport bra of claim 22 , wherein the injection-molded layer is comprised of water-permeable polyurethane.

24. The molded sport bra of claim 22 , wherein the molded layer comprises a first face adjacent to the first fabric layer and a second face adjacent to the second fabric layer, and wherein the second face further comprises a hydrophilic treatment such that the hydrophilic treatment is disposed between the second face of the molded layer and the second fabric layer.

25. The molded sport bra of claim 24 , wherein the hydrophilic treatment has a fourth degree of hydrophilicity that is greater than the third degree of hydrophilicity.

26. A process for making a moisture-transporting molded bra cup for a sport bra, the process comprising:
arranging a first plurality of fibers in a first zone, the first plurality of fibers having a first average denier per filament, the first zone being substantially adjacent to a skin surface of a wearer when the sport bra is worn;
arranging a second plurality of fibers in a second zone, the second zone adjacent to the first zone and comprising an exterior face of the molded bra cup, the second plurality of fibers having a second average denier per filament, the second average denier per filament being less than the first average denier per filament; and
molding the first plurality of fibers and the second plurality of fibers to form the moisture-transporting molded bra cup.

27. The process of claim 26 , wherein the molding comprises applying heat to the first plurality of fibers and the second plurality of fibers.

28. A moisture-transporting molded sport bra cup, the molded sport bra cup comprising:
an interior zone comprising a firs

Assignees

• Nike Inc

Inventors

• Hurd Rebecca P

Classifications

• A41C5/005

  by moulding (shaping of textile material made from plastics fibres by thermoforming B29C51/004) · CPC title

• A41C3/14

  Stiffening or bust-forming inserts · CPC title

• A41C3/12

  Component parts · CPC title

• A41C3/0085

  with ventilation feature · CPC title

• A41C3/0057 Primary

  for sport activities · CPC title