Brassiere having a foam padded underwire

Abstract

An underwire brassiere and breast cup for use in the underwire brassiere. The breast cup provides improved comfort for the wearer by isolating the support wire from the skin of the wearer. Particularly the support wire is positioned along an outer side of a laminated foam core. The laminated foam core can be shaped to have an embossed ridge projecting toward the inner side of the foam core, in a region mirroring the location of the support wire.

We claim: 
     
         1 . A breast cup for a brassiere comprising:
 a) a molded cup, the molded cup comprising:
 a. an interior laminated fabric; 
 b. an exterior laminated fabric; and 
 c. at least one foam layer, wherein the interior laminated fabric, the exterior laminated fabric and the at least one foam layer are laminated together to create the molded cup, the molded cup further comprising a first raised portion adjacent to a lower peripheral portion thereof, the first raised portion extending toward an inner side of the molded cup; and 
   b) a support wire, wherein the support wire is disposed along the lower peripheral portion of the molded cup and disposed outwardly of the exterior laminated fabric.   
     
     
         2 . The breast cup according to  claim 1 , wherein the molded cup further comprises a second raised portion along the lower peripheral portion of the molded cup, the second raised portion extending toward an outer side of the molded cup such that the first and second raised portions correspond to one another. 
     
     
         3 . The breast cup according to  claim 1 , wherein the molded cup further comprises a recessed channel along an outer side of the molded cup opposing the first raised portion, the recessed channel configured to receive the support wire. 
     
     
         4 . The breast cup according to  claim 1 , wherein the first raised portion provides an area of increased thickness along the lower peripheral portion of the molded cup. 
     
     
         5 . The breast cup according to  claim 1 , wherein the at least one foam layer comprises:
 a first foam layer substantially coextensive with the interior laminated fabric and the exterior laminated fabric; and   a second foam layer disposed adjacent to the lower peripheral portion of the molded cup, the second foam layer providing additional material for the formation of the first raised portion.   
     
     
         6 . The breast cup according to  claim 1 , further comprising at least one fabric ply encasing the support wire. 
     
     
         7 . The breast cup according to  claim 6 , wherein the at least one fabric ply comprises a plurality of separate plies, wherein, each of said plurality of separate plies is wrapped around the support wire without attachment to the support wire. 
     
     
         8 . The breast cup according to  claim 1 , further comprising an outer fabric disposed outwardly of the exterior laminated fabric and disposed outwardly of the support wire. 
     
     
         9 . The breast cup according to  claim 8 , further comprising a cup liner disposed between the exterior laminated fabric and the outer fabric. 
     
     
         10 . The breast cup according to  claim 1 , wherein the support wire comprises a substantially flat, metallic or rigid plastic material. 
     
     
         11 . A brassiere comprising:
 a) a pair of breast cups, each breast cup comprising:
 a. a molded core, the molded core comprising:
 i. an interior laminated fabric; 
 ii. an exterior laminated fabric; and 
 iii. at least one foam layer, wherein the interior laminated fabric, the exterior laminated fabric and the at least one foam layer are laminated together to create the molded core, the molded core further comprising a first raised portion adjacent to a lower peripheral edge thereof, the first raised portion extending toward an inner side of the molded core; and 
 
 b. a support wire, wherein the support wire is disposed along the lower peripheral portion of the molded core and disposed outwardly of the exterior laminated fabric; 
   b) a bridge or gore attached between a center of each breast cup; and   c) a torso band, respective ends of the torso band attached to underarm lateral side of a respective breast cup.   
     
     
         12 . The brassiere according to  claim 11 , wherein the molded core further comprises a second raised portion along the lower peripheral portion of the molded core, the second raised portion extending toward an outer side of the molded core such that the first and second raised portions correspond to one another. 
     
     
         13 . The brassiere according to  claim 11 , wherein the molded core further comprises a recessed channel along an outer side of the molded core opposing the first raised portion, the recessed channel configured to receive the support wire. 
     
     
         14 . The brassiere according to  claim 11 , wherein the first raised portion provides an area of increased thickness along the lower peripheral portion of the molded core. 
     
     
         15 . The brassiere according to  claim 11 , wherein the at least one foam layer comprises:
 a first foam layer coextensive with the interior laminated fabric and the exterior laminated fabric; and   a second foam layer disposed adjacent to the lower peripheral portion of the molded core, the second foam layer providing additional material for the formation of the first raised portion.   
     
     
         16 . The brassiere according to  claim 11 , further comprising at least one fabric ply encasing the support wire. 
     
     
         17 . The brassiere according to  claim 16 , wherein the at least one fabric ply comprises a plurality of separate plies, each of said plurality of separate plies is wrapped around the support wire without attachment to the support wire. 
     
     
         18 . The brassiere according to  claim 11 , wherein each breast cup further comprises an outer fabric disposed outwardly of exterior laminated fabric and disposed outwardly of the support wire. 
     
     
         19 . The brassiere according to  claim 18 , wherein each breast cup further comprises a cup liner disposed between the exterior laminated fabric and the outer fabric. 
     
     
         20 . The brassiere according to  claim 11 , wherein the support wire comprises a substantially flat, metallic or rigid plastic material.