A bra cup manufactured using flexible foam particles. The manufacturing method comprises batching, cutting and sanitizing flexible foam particles. The flexible foam particles are blended together with a reactive material to form a mixture. The mixture may be cured to provide a bra cup of a substantially uniform structure in a desired shape and density. Using flexible polyurethane foam particles in the process of making bra cups, a reduced amount of virgin flexible polyurethane foam is required to manufacture brassieres.

A breast supporting garment and a method for producing it, the garment having at least one layer made of a fabric comprises a breast receiving portion bounded by a frame portion disposed at least partially below the breast receiving portion. The frame portion comprises a fabric reinforcing element in the form of a coating made of a material having, when in a liquid state during a coating process, having a capability to stay contained within an area of the fabric, to which the material is applied, and to penetrate the fabric to a part of the thickness of the fabric, at least in a portion of the area. The material, when solidified, has a lower elasticity than that of the fabric.

A breast cup assembly including an outer fabric layer, an inner fabric layer, and a molded core assembly having two cup regions and disposed between the outer and inner fabric layers, the core assembly including an inner core foam layer laminated with an outer core fabric layer. Each of the inner and outer fabric layers may have a range greater than the extent of the core assembly, and the inner core foam layer at each of the two cup regions of the core assembly has varying thickness but substantially the same density across the cup region.

The invention relates to a women's garment comprising a constructed bust part having two cups, and two shoulder straps attached to the cups. The cups are formed from at least two foam layers joined together via thermoforming. The two cups have a thickening at the lower edge thereof, which is formed during the thermoforming of the foam layers and runs along the breast. A stabilization element is arranged between the foam layers, having a section starting from the shoulder straps at an outer edge of the cups and extending down to the lower edge of the cups, and a section starting from the shoulder straps and extending along a part of an upper edge of the cups. A part of the upper edge of the cups and a central region of the cups are free from the stabilization element.

A bra cup for a bra includes an inner layer of material configured to face a wearer's breast when the bra is worn and an outer layer of material configured to face away from the wearer when the bra is worn. An outer face of the inner layer of material is adjacent an inner face of the outer layer of material. A thin polymer web is disposed on the outer face of the inner layer of material. A bra including the bra cup and a method of manufacturing the bra cup are also disclosed.

The present invention relates to the field of undergarments, bras, or swimsuit accessories, and is directed to providing a bra cup having sustainable three-dimensional corrugations and a manufacturing method thereof with simple processes. The bra cup is formed by compression molding with a composite layer material and has a protruding outer side face and a concave inner side face. The outer side face has outer corrugations of the cup that are formed by compression molding. The composite layer material comprises at least: an outer fabric layer; an inner fabric layer; and an intermediate foaming layer. The intermediate foaming layer has a first surface bonding to the outer fabric layer and a second surface bonding to the inner fabric layer, the first surface having second protruding or concave corrugations, the second protruding or concave corrugations mating with the first protruding or concave corrugations to form the outer corrugations of the cup.

Disclosed herein is a composite of a thermoformable fabric and an elastomer which together have been subjected to thermoformable moulding to provide a 3-dimensionally thermoformed fabric article in the form of a textile or in the form of the whole or part of a garment. The article presents an appearance that is substantially free of permanent wrinkles. Also disclosed herein is a process to make said article.

The present disclosure relates to a molded cup bra having a first bra cup portion and a second bra cup portion adapted to accommodate breasts of a user. The molded cup bra further includes a first fabric layer adapted to absorb perspiration that is at least adjacent to a skin surface of the user when the molded cup bra is worn, and a second fabric layer provided on inner side of said molded cup bra adapted to reprieve the skin surface of the user from the impact of synthetic materials touching the skin.

There is provided a breast cup for an undergarment such as a brassiere. The breast cup comprises a cup core that has a first surface and a second surface opposite the first surface. Each of the first and second surfaces is formed with a plurality of grooves. Each groove has an elongated opening, an elongated bottom, and a sidewall on each of two longitudinal sides of the groove. The breast cup also comprises a first fabric layer overlying the first surface of the cup core, and a second fabric layer overlying the second surface of the cup core. A top part of the sidewalls of one or more of the plurality of the first grooves is attached to the first fabric layer while at least a portion of the bottom of the one or more of the plurality of the first grooves is not attached to the first fabric layer.

The present invention provides a built-in brassiere cup, an undergarment having openings and an undergarment processing method. The built-in brassiere cup comprises a plurality of integral support layers and a plurality of brassiere cup structure layers which are arranged in a compositely stacked manner, the brassiere cup structure layers are arranged at cup body portions of the integral support layers, the brassiere cup structure layers are compositely arranged on each of part or all of the integral support layers by screen printing, the undergarment has openings that penetrate through an outer fabric layer, the built-in brassiere cup and an inner fabric layer, an annular support strip is arranged at each of the openings, and the annular support strip is arranged to surround each of the openings.