Bra cup for a brassiere and manufacturing method thereof

Abstract

A bra cup for a brassiere to be worn by a wearer is disclosed. The bra cup comprises a core layer. The core layer has an inner side and an outer side. A plurality of apertures are formed in the core layer. In one example, one or more of the plurality of apertures have a truncated conical cross-section with a relatively larger diameter towards the inner side and a relatively smaller diameter towards the outer side. In another example, the plurality of apertures comprises a plurality of elongated apertures formed in a frontal area of the bra cup and a plurality of circular apertures formed in a lateral area of the bra cup. The plurality of elongated apertures have a dumbbell shape. In yet another example, the bra cup comprises a plurality of protrusions defined in the core layer towards the inner side thereof.

1 . A bra cup for a brassiere to be worn by a wearer, the bra cup comprising:
 a core layer formed of a foam material and having a three-dimensional configuration so as to conform to a breast of the wearer when the brassiere is worn, the core layer having an inner side and an outer side; and   a plurality of apertures formed in the core layer, wherein the plurality of apertures comprises a plurality of circular holes and a plurality of elongated apertures;   wherein one or more of the plurality of circular holes have a truncated conical cross-section with a relatively larger diameter towards the inner side and a relatively smaller diameter towards the outer side, of the core layer;   wherein the plurality of circular holes are formed in a lateral area of the bra cup, and the plurality of elongated apertures are formed in a frontal area of the bra cup; and   wherein one or more of the plurality of circular holes in a lower portion of the lateral area have the truncated conical cross-section.   
     
     
         2 . (canceled) 
     
     
         3 . The bra cup as claimed in  claim 1 , wherein one or more of the plurality of elongated apertures have a dumbbell shape with a slit and two openings formed at two ends of the slits respectively. 
     
     
         4 . The bra cup as claimed in  claim 1  further comprising a plurality of protrusions defined in the core layer towards the inner side thereof, wherein the protrusions are arranged in a matrix form such that one or more of the plurality of apertures are surrounded by three or more protrusions at the inner side of the core layer. 
     
     
         5 . The bra cup as claimed in  claim 4 , wherein the plurality of protrusions comprises a first set of protrusions with substantially square shape and a second set of protrusions with substantially parallelogram shape, and wherein the first set of protrusions are located in a frontal area of the bra cup and the second set of protrusions are located in a lateral area of the bra cup. 
     
     
         6 . The bra cup as claimed in  claim 1 , wherein the core layer and the plurality of apertures therein are formed by an injection molding process. 
     
     
         7 . The bra cup as claimed in  claim 6  further comprising a mesh joined with the core layer in the injection molding process. 
     
     
         8 . The bra cup as claimed in  claim 1  further comprising an underwire embedded within the core layer. 
     
     
         9 . The bra cup as claimed in  claim 8 , wherein the underwire is made either of metallic material or plastic material. 
     
     
         10 . The bra cup as claimed in  claim 1  further comprising:
 an inner layer comprising at least a fabric sheet and optionally a foam sheet, and arranged with respect to the core layer such that the inner layer is disposed to be in contact with the breast of the wearer, when the brassiere is worn; and 
 an outer layer comprising at least a fabric sheet and optionally a foam sheet, and arranged with respect to the core layer such that the outer layer is located at a distal end from the breast of the wearer, when the brassiere is worn. 
 
     
     
         11 . A method of manufacturing a bra cup for a brassiere, the method comprising:
 providing a foam material in liquid form;   providing a mold arrangement comprising a first mold and a second mold, at least one of the first mold and the second mold having a plurality of projections defined therein;   injecting the foam material into the mold arrangement between the first mold and the second mold; and   curing the foam material to be contoured into a three-dimensional configuration to form a core layer of the bra cup with a plurality of apertures, complementary to the plurality of projections, formed therein, wherein one or more of the plurality of apertures have a truncated conical cross-section with a relatively larger diameter towards the inner side and a relatively smaller diameter towards the outer side, of the core layer;   wherein the plurality of apertures comprises:
 a plurality of elongated apertures disposed in a frontal area of the bra cup; and 
 a plurality of circular holes disposed in a lateral area of the bra cup, wherein one or more of the plurality of circular holes in a lower portion of the lateral area have the truncated conical cross-section. 
   
     
     
         12 . (canceled) 
     
     
         13 . The method as claimed in  claim 11 , wherein one or more of the plurality of elongated apertures have a dumbbell shape with a slit and two openings formed at two ends of the slits respectively. 
     
     
         14 . (canceled) 
     
     
         15 . The method as claimed in  claim 11  further comprising:
 providing a mesh; and 
 supporting the mesh on one or more first anchors between the first mold and the second mold during the injection of the foam material, such that the mesh is joined with the core layer from at least one of an inner side and an outer side thereof when the foam material is cured. 
 
     
     
         16 . The method as claimed in  claim 11  further comprising:
 providing an underwire; and 
 supporting the underwire on one or more second anchors between the first mold and the second mold during the injection of the foam material, such that the underwire is embedded within the core layer when the foam material is cured. 
 
     
     
         17 . The method as claimed in  claim 11 , further comprising:
 providing a fabric sheet which is to be part of an inner layer of the bra cup; and   providing a fabric sheet which is to be part of an outer layer of the bra cup;   wherein the foam material is injected between the fabric sheet of the inner layer and the fabric sheet of the outer layer such that the formed core layer is joined therewith when the foam material is cured.   
     
     
         18 . A bra cup for a brassiere to be worn by a wearer, the bra cup comprising:
 a core layer formed of a foam material and having a three-dimensional configuration so as to conform to a breast of the wearer when the brassiere is worn, the core layer having an inner side and an outer side;   a plurality of apertures formed in the core layer, the plurality of apertures extending between the inner side and the outer side of the core layer; and   a plurality of protrusions defined in the core layer towards the inner side thereof, wherein the protrusions are arranged in a matrix form such that one or more of the plurality of apertures are surrounded by three or more protrusions at the inner side of the core layer;   wherein the plurality of apertures comprises:
 a plurality of elongated apertures formed in a frontal area of the bra cup; and 
 a plurality of circular holes formed in a lateral area of the bra cup 
 wherein one or more of the plurality of elongated apertures have a dumbbell shape with a slit and two openings formed at two ends of the slits respectively, such that each of the one or more of the plurality of elongated apertures allows for expansion of the core layer along a direction substantially orthogonal to a direction of extension of the corresponding slit therein; and 
 wherein one or more of the plurality of circular holes in a lower portion of the lateral area have a truncated conical cross-section with a relatively larger diameter towards the inner side of the core layer and a relatively smaller diameter towards the outer side of the core layer. 
   
     
     
         19 - 21 . (canceled) 
     
     
         22 . The bra cup as claimed in  claim 18 , wherein the plurality of protrusions comprises a first set of protrusions with substantially square shape and a second set of protrusions with substantially parallelogram shape, and wherein the first set of protrusions are located in a frontal area of the bra cup and the second set of protrusions are located in a lateral area of the bra cup.