Gel-Cushioned Support Component Channel for a Brassiere

Abstract

The present disclosure is of a support component channel for a bra and methods for producing the support component channel and attaching it to a bra. The support component channel comprises a gel tube, an underwire tunnel casing, and a cover fabric. The gel tube provides cushion between the support component and the wearer's chest, thereby providing comfort despite the geometry and materials of the support component. The gel tube, underwire tunnel casing, and cover fabric can be sewn to one another simultaneously to being attached to the bra, prior to being attached to the bra, or can be attached to the bra in stages, according to different methods of production. The methods allow for both sides of the support component channel to be sewn to the bra simultaneously.

We claim: 
     
         1 . A support component channel for a brassier, the channel comprising:
 a gel tube having a first side and a second side;   an underwire tunnel casing adjacent the first side of the gel tube and coextensive in length with the gel tube; and   a cover fabric adjacent the second side of the gel tube and coextensive in length with the gel tube;   wherein side edges of the cover fabric are folded over respective side edges of the gel tube such that the cover fabric covers the gel tube.   
     
     
         2 . The support component channel of  claim 1 , wherein each of the tunnel casing and gel tube are substantially straight along their respective lengths. 
     
     
         3 . The support component of  claim 1 , wherein the side edges of the cover fabric are folded over respective side edges of the tunnel casing and gel tube such that the cover fabric covers both the tunnel casing and the gel tube. 
     
     
         4 . The support component channel of  claim 3 , further comprising a gap between the tunnel casing and the cover fabric. 
     
     
         5 . The support component channel of  claim 1 , wherein the gel tube comprises a gel cushion. 
     
     
         6 . The support component channel of  claim 5 , wherein the gel cushion has a cross-sectional shape of an oval. 
     
     
         7 . The support component channel of  claim 6 , wherein the oval has a major axis dimension between about 0.1 mm to about 10 mm and a minor axis dimension between about 0.1 mm to about 10 mm. 
     
     
         8 . The support component channel of  claim 5 , wherein the gel cushion comprises a silicone gel. 
     
     
         9 . The support component channel of  claim 5 , wherein the gel tube further comprises an outer membrane surrounding the gel cushion. 
     
     
         10 . The support component channel of  claim 9 , wherein the outer membrane comprises thermoplastic polyurethane. 
     
     
         11 . A method of creating a brassiere having a support component channel, the method comprising:
 providing a gel tube having a first side and a second side;   providing an underwire tunnel casing coextensive in length with the gel tube;   placing the tunnel casing adjacent the first side of the gel tube;   providing a cover fabric coextensive in length with the gel tube;   placing the cover fabric adjacent the second side of the gel tube;   covering the gel tube with side edges of the cover fabric that are folded over respective side edges of the gel tube; and   attaching the tunnel casing, gel tube, and cover fabric to a brassiere cup.   
     
     
         12 . The method of  claim 11 , wherein the step of attaching the tunnel casing, gel tube, and cover fabric to the brassiere cup comprises sewing along two seam allowances of the cover fabric simultaneously. 
     
     
         13 . The method of  claim 11 , further comprising inserting an underwire into a tunnel in the tunnel casing. 
     
     
         14 . The method of  claim 11 , further comprising covering both the tunnel casing and the gel tube with side edges of the cover fabric that are folded over respective side edges of the tunnel casing and gel tube. 
     
     
         15 . The method of  claim 14 , further comprising sewing two seam allowances of the cover fabric to the respective side edges of the tunnel casing prior to attaching the tunnel casing, gel tube, and cover fabric to the brassiere cup. 
     
     
         16 . The method of  claim 15 , wherein the step of sewing the seam allowances of the cover fabric to the respective side edges of the tunnel casing comprises sewing both seam allowances of the cover fabric simultaneously. 
     
     
         17 . The method of  claim 15 , wherein the cover fabric and the tunnel casing are sewn together prior to providing the gel tube and placing the gel tube and the tunnel casing adjacent one another. 
     
     
         18 . The method of  claim 17 , wherein the cover fabric and tunnel casing are attached to the brassiere cup prior to attaching the gel tube to the brassiere cup. 
     
     
         19 . The method of  claim 18 , wherein the gel tube is attached to the brassiere cup by inserting it into a gap between the tunnel casing and the cover fabric. 
     
     
         20 . The method of  claim 15 , wherein the cover fabric and the tunnel casing are sewn together after providing the gel tube and placing the gel tube and the tunnel casing adjacent one another. 
     
     
         21 . The method of  claim 20 , wherein the cover fabric, tunnel casing, and gel tube are attached to the brassiere cup as a single unit. 
     
     
         22 . The method of  claim 20 , wherein the cover fabric, tunnel casing, and gel tube are sewn together simultaneously to being attached to the bra cup. 
     
     
         23 . A method of creating a brassiere having a support component channel, the method comprising:
 providing a cushioning tube having a first side and a second side;   providing an underwire tunnel casing separate from the cushioning tube and coextensive in length with the cushioning tube;   placing the tunnel casing adjacent the first side of the cushioning tube;   providing a cover fabric coextensive in length with the cushioning tube;   placing the cover fabric adjacent the second side of the cushioning tube;   creating a support component channel by covering both the tunnel casing and the cushioning tube with side edges of the cover fabric that are folded over respective side edges of the tunnel casing and cushioning tube;   sewing the cover fabric to the tunnel casing by sewing along two seam allowances of the cover fabric simultaneously;   attaching the support component channel to a brassiere cup by sewing along the seam allowances of the cover fabric simultaneously; and   inserting an underwire into a tunnel in the tunnel casing after the support component channel has been attached to the brassiere cup.