Breast Cup Core, Breast Cup, and Method of Making Same

Abstract

There is provided an injection molded breast cup core and a breast cup core having a plurality of through holes. There is also provided a breast cup, a bra, or a shapewear comprising such a breast cup core as well as a mold for manufacturing such a breast cup core. A method of injection molding a breast cup core is also provided.

1 . A breast cup comprising an inner layer of material, an outer layer of material, and an injection molded breast cup core sandwiched between the inner layer and the outer layer. 
     
     
         2 . A breast cup of  claim 1 , wherein the breast cup core is formed from a thermoplastic rubber material. 
     
     
         3 . A breast cup of  claim 1 , wherein the breast cup core has a plurality of through holes. 
     
     
         4 . A breast cup of  claim 1 , wherein the through hole density varies across the breast cup core. 
     
     
         5 . A breast cup of  claim 1 , wherein the breast cup core has regions of varied thickness. 
     
     
         6 . A breast cup of  claim 1 , wherein the breast cup core extends across substantially the whole of the breast cup. 
     
     
         7 . A breast cup of  claim 1 , further comprising an underwire molded with the breast cup core. 
     
     
         8 . A breast cup of  claim 1 , wherein a substantial portion of the breast cup core comprises a thickness of 1 mm. 
     
     
         9 . A breast cup of  claim 1 , further comprising an underwire wherein the underwire is attached to an inner side of the inner layer of material. 
     
     
         10 . A breast cup of  claim 1 , wherein the inner layer of material and the outer layer of material each comprises a fabric layer laminated with a foam layer. 
     
     
         11 . A breast cup of  claim 1 , wherein the inner layer of material, the breast cup core, and the outer layer of material are molded together. 
     
     
         12 . A method of manufacturing a breast cup comprising:
 injection molding a breast cup core for a breast cup;   sandwiching the breast cup core between an outer layer of material and an inner layer of material; and   joining the outer layer of material and the inner layer of material.   
     
     
         13 . A method of  claim 12 , further comprising providing an underwire. 
     
     
         14 . A method of  claim 13 , wherein the underwire is molded with the breast cup core in the process of injecting molding. 
     
     
         15 . A method of  claim 13 , wherein the underwire is attached to an inner side of the inner layer of material. 
     
     
         16 . A method of  claim 12 , wherein the inner and outer layers are each formed from a fabric layer laminated with a foam layer. 
     
     
         17 . A method of  claim 12 , further comprising joining the inner layer of material, the breast cup core, and the outer layer of material by molding. 
     
     
         18 . A method of manufacturing a breast cup comprising:
 molding a first layer of material comprising a fabric layer laminated with a foam layer to form a breast cup shaped region;   placing an injection molded breast cup core onto the molded first layer of material;   placing a second layer of material comprising a fabric layer laminated with a foam layer onto the breast cup core; and   joining the first layer, the breast cup core and the second layer by molding.   
     
     
         19 . A method of  claim 18 , further comprising providing an underwire. 
     
     
         20 . A method of  claim 19 , wherein the underwire is molded with the injection molded breast cup core.