Padded breast cup for a brassiere

1. A breast cup assembly for use in a bra, the assembly including:

an outer panel having an outer fabric layer attached to a first foam layer, an inner panel having an inner fabric layer attached to a second foam layer, and a pad located between the inner panel and the outer panel, the inner panel having a surface area the majority of which is overlaid with the pad, the outer panel and the inner panel being attached to each other about a periphery of each panel to retain the pad in its location, wherein the pad has an upper edge that is generally non-uniformly divergent from a convex upper edge of the inner panel, the upper edge of the pad including a concave portion, a divergence of the concave portion from the convex upper edge of the inner panel being greater than a divergence of portions of the upper edge of the pad, which are outside of the concave portion, from the convex upper edge of the inner panel.

2. A breast cup according to claim 1 , wherein the pad is a thermoplastic rubber.

3. A breast cup according to claim 1 , wherein the pad is a styrene block copolymer.

4. A breast cup according to claim 1 , wherein the pad includes at least one channel extending between the inner panel and the outer panel.

5. A breast cup according to claim 1 , wherein the pad is semi-liquid silicon.

6. A breast cup according to claim 5 , wherein the semi-liquid silicon is a functional polydimethylsiloxane with an acetoxysilane cross linker.

7. A breast cup according to claim 1 , wherein the first and second foam layer are thermoplastic polyurethane.

8. A breast cup according to claim 1 , wherein the first and second foam layers are attached to the outer and inner fabrics respectively by lamination.

9. A breast cup according to claim 1 , wherein the pad has a melting point higher than the foam layers of the inner panel or the outer panel.

10. A breast cup according to claim 1 , wherein the inner panel and the outer panel are concave.

11. A breast cup according to claim 1 , wherein the pad overlies the surface area of the inner panel by more than 55%.

12. A breast cup according to claim 1 , wherein the foam layers of the inner panel and the outer panel are of substantially uniform thickness adjacent the pad, while the thickness of the pad is relatively non-uniform, when viewed in cross section, from an upper edge of the cup to a lower edge of the cup.

13. A breast cup according to claim 12 , wherein the pad is relatively thick in a middle region of the cup and relatively thin in an edge region of the cup.

14. A breast cup according to claim 1 , wherein the pad has a lower edge that is aligned to extend substantially parallel with a convex lower edge of the inner panel.

15. A breast cup according to claim 1 , wherein the concave portion is to one side of a center of the upper edge.

16. A bra including two breast cups as claimed in claim 1 with a connecting portion connecting a first edge of each breast cup and a back wing connected to a second edge of each cup remote from said first edge, each back wing having a free end, the free ends being releasably attached to one another when attaching the bra to a wearer's body.

17. A method of manufacturing a single breast cup for inclusion in a bra, the method including the steps of:

i) providing an outer panel including an outer fabric and a first foam layer,

ii) molding the outer panel so that the outer panel assumes a single concave form in a form of the single breast cup,

iii) providing an inner panel including an inner fabric and a second foam layer,

iv) molding the inner panel so that the inner panel assumes a single concave form in a form of the single breast cup,

v) locating a pad between the inner panel and the outer panel so that the pad is adjacent the first foam layer and the second foam layer and overlies a majority of the surface area of the inner panel,

vi) attaching the inner panel to the outer panel about a periphery of each panel,

wherein the pad has an upper edge that is generally non-uniformly divergent from a convex upper edge of the inner panel, the upper edge of the pad including a concave portion, a divergence of the concave portion from the convex upper edge of the inner panel being greater than a divergence of portions of the upper edge of the pad, which are outside of the concave portion, from the convex upper edge of the inner panel.

18. A method of manufacturing a single breast cup according to claim 17 , wherein the step of attaching the inner panel and outer panel includes heating the inner panel and the outer panel to a bonding temperature, and the pad is selected from a thermoplastic rubber or semi-liquid silicon having a melting point above the bonding temperature.

19. A method of manufacturing a single breast cup according to claim 17 , wherein the steps of molding the inner panel and the outer panel so that the inner panel and the outer panel each assume a single concave form include heating the inner panel and outer panel to a molding temperature which is lower that the melting point of the pad.

20. A breast cup assembly for use in a bra, the assembly including: an outer panel having a single concave form and an outer fabric layer attached to a first foam layer, an inner panel having an inner fabric layer attached to a second foam layer, and a pad located between the inner panel and the outer panel, the inner panel having a surface area the majority of which is overlaid with the pad, the outer panel and the inner panel being attached to each other about a periphery of each panel to retain the pad in its location, wherein the pad has an upper edge that is generally non-uniformly divergent from a convex upper edge of the inner panel, the upper edge of the pad including a concave portion, a divergence of the concave portion from the convex upper edge of the inner panel being greater than a divergence of portions of the upper edge of the pad, which are outside of the concave portion, from the convex upper edge of the inner panel.