Sport bra with moisture-transporting molded cups
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.
1. A bra cup comprising:
a first fabric layer comprising an inner-facing surface of the bra cup, the first fabric layer formed of yarns having a first average denier per filament (DPF);
a second fabric layer comprising an outer-facing surface of the bra cup, the second fabric layer formed of yarns having a second average DPF, wherein the first average DPF is greater than the second average DPF; and
a spacer mesh material disposed between the first fabric layer and the second fabric layer, wherein a hydrophilic gradient is formed from the first fabric layer to the second fabric layer.
2. The bra cup of claim 1 , wherein the first average DPF is greater than 1.04, and the second average DPF is less than 1.04.
3. The bra cup of claim 1 , wherein the spacer mesh material is formed separately from the first and second fabric layer.
4. The bra cup of claim 1 , wherein the spacer mesh material comprises a knit material.
5. The bra cup of claim 1 , wherein the spacer mesh material comprises a woven material.
6. The bra cup of claim 1 , wherein the spacer mesh material is integrally knit with at least one of the first fabric layer or the second fabric layer.
7. The bra cup of claim 1 , wherein the spacer mesh material is integrally woven with at least one of the first fabric layer or the second fabric layer.
8. A bra cup comprising:
a first fabric layer comprising an inner-facing surface of the bra cup, wherein the first fabric layer is formed of yarns having a first average denier per filament (DPF);
a second fabric layer comprising an outer-facing surface of the bra cup, wherein the second fabric layer is formed of yarns having a second average DPF, wherein the first average DPF is greater than the second average DPF;
and
a plurality of tie yarns extending from the first fabric layer to the second fabric layer.
9. The bra cup of claim 8 , wherein the first average DPF is greater than 1.04, and the second average DPF is less than 1.04.
10. The bra cup of claim 8 , wherein the tie yarns are formed from man-made materials.
11. The bra cup of claim 8 , wherein the tie yarns are formed from natural materials.
12. A bra cup comprising:
a first fabric layer comprising an inner-facing surface of the bra cup, the first fabric layer comprised of a hydrophilic material having a first degree of hydrophilicity;
a second fabric layer comprising an outer-facing surface of the bra cup, 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 foam layer disposed between the first fabric layer and the second fabric layer, the foam layer 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.