Brassiere cups and methods of manufacturing the same

Abstract

A brassiere cup for a bra is disclosed. The cup comprises an inner foam-fabric layer which is in contact with a wearer's skin. The cup further comprises an outer spacer fabric layer and a middle plastic underwire. The outer spacer fabric layer is arranged on an outer side of the inner foam-fabric layer, the side being distal from the wearer's skin; and the middle underwire is sandwiched between the inner foam-fabric layer and the outer spacer fabric layer at the lower region. The outer spacer fabric layer comprises at least two fabric layers between which a support containing fusible yarn is sandwiched.

1 . A brassiere cup for a bra, the cup comprising an inner foam-fabric layer for contact with a wearer's skin, wherein an outer spacer fabric layer is provided on an outer side of the inner foam-fabric layer, the outer side being distal from the wearer's skin, and an underwire is sandwiched between the inner foam-fabric layer and the outer spacer fabric layer at a lower region of the cup, and wherein the outer spacer fabric layer comprises at least two fabric layers and one of the at least two fabric layers comprises fusible yarn. 
     
     
         2 . The brassiere cup of  claim 1 , wherein the underwire is made of plastic. 
     
     
         3 . The brassiere cup of  claim 1 , wherein the outer spacer fabric layer has been subjected to a molding process under heat and pressure. 
     
     
         4 . The brassiere cup of  claim 1 , wherein the fusible yarn is woven into the outer spacer fabric layer together with at least another yarn. 
     
     
         5 . The brassiere cup of  claim 1 , wherein the content of fusible yarn varies across the outer spacer fabric layer. 
     
     
         6 . The brassiere cup of  claim 1 , wherein a lower region of the cup has a higher content of fusible yarn than an upper region of the cup. 
     
     
         7 . A bra, comprising:
 a brassiere cup as claimed in  claim 1 ;   a side wing attached to a side of the brassiere cup; and   a shoulder strap, one end of which is attached to an upper part of the brassiere cup, and another end of which is attached to an upper part of the side wing.   
     
     
         8 . A method for manufacturing a brassiere cup, wherein the cup comprises an inner foam-fabric layer for contact with a wearer's skin and an outer spacer fabric layer on an outer side of the inner foam-fabric layer that is distal from the wearer's skin, the method comprises:
 providing a spacer fabric layer containing fusible yarn between a male mold and a female mold;   molding the spacer fabric layer under heat and pressure to form a 3-D cup shape;   placing a foam-fabric layer over the molded spacer fabric layer and an underwire between the foam-fabric layer and the molded spacer fabric layer; and   molding the foam-fabric layer, the underwire and the molded spacer fabric layer together under heat and pressure to form a 3-D cup shape.   
     
     
         9 . The method of  claim 8 , wherein the content of fusible yarn varies across the outer spacer fabric layer. 
     
     
         10 . The method of  claim 8 , wherein a lower region of the cup has a higher content of fusible yarn than an upper region of the cup. 
     
     
         11 . The method of  claim 8 , wherein the underwire is made of plastic. 
     
     
         12 . A bra, comprising:
 a brassiere cup as claimed in  claim 2 ;   a side wing attached to a side of the brassiere cup; and   a shoulder strap, one end of which is attached to an upper part of the brassiere cup, and another end of which is attached to an upper part of the side wing.   
     
     
         13 . A bra, comprising:
 a brassiere cup as claimed in  claim 3 ;   a side wing attached to a side of the brassiere cup; and   a shoulder strap, one end of which is attached to an upper part of the brassiere cup, and another end of which is attached to an upper part of the side wing.   
     
     
         14 . A bra, comprising:
 a brassiere cup as claimed in  claim 4 ;   a side wing attached to a side of the brassiere cup; and   a shoulder strap, one end of which is attached to an upper part of the brassiere cup, and another end of which is attached to an upper part of the side wing.   
     
     
         15 . A bra, comprising:
 a brassiere cup as claimed in  claim 5 ;   a side wing attached to a side of the brassiere cup; and   a shoulder strap, one end of which is attached to an upper part of the brassiere cup, and another end of which is attached to an upper part of the side wing.   
     
     
         16 . A bra, comprising:
 a brassiere cup as claimed in  claim 6 ;   a side wing attached to a side of the brassiere cup; and   a shoulder strap, one end of which is attached to an upper part of the brassiere cup, and another end of which is attached to an upper part of the side wing.