HK1110000B - Method for joining fabric panels and brassiere manufactured using the method - Google Patents

Description

Method for joining fabric panels and manufacturing brassieres

Technical Field

The present invention relates to a method of joining fabric panels to produce an item of apparel, a method of producing breast cups of a brassiere, a breast cup and a brassiere.

Background

In the apparel industry, it is often desirable to attach fabric panels together by stitching using a sewing machine. For example, manufacturing a brassiere typically requires the provision of breast cups, each cup typically being made by sewing two fabric panels together along their peripheries, with one of the panels being the outer layer of the finished breast cup and the other being the inner layer. The two fabric panels require a common seam to form the desired cup contour. By sewing the two fabric panels together along their outer peripheries, a double support cup for a brassiere can be made. The inner layer is usually a cup-shaped pad made of fabric chosen for its comfort, while the outer layer is decorative, possibly made of fabric with a pleasing appearance, such as mesh fabric.

However, when the outer peripheries of the two fabric panels are sewn together, a bulky and noticeable seam allowance is formed along the outer peripheries. These bulky and noticeable seam allowances for breast cups can be uncomfortable and aesthetically undesirable. Accordingly, it is desirable to produce an article of apparel that is comfortable and aesthetically desirable.

US6805610 discloses a brassiere which includes seamless breast cups and which is characterized by a negligible amount of stitching which joins the different parts of the brassiere together. This patent also discloses a method of manufacturing a brassiere, characterized by the steps of: the first and second layers of molded foam are directly laminated to each other and then two molded flexible breast cups are attached to the chest band core. However, different molds are required to make different shaped breast cups. This substantially increases the manufacturing costs. Therefore, there is a need to provide an improved method for manufacturing breast cups of a brassiere that is cost effective, simple and flexible.

Disclosure of Invention

According to one aspect of the present invention, there is provided a method of attaching fabric panels to manufacture an article of apparel, the method comprising the steps of: providing first fabric cut-parts and second fabric cut-parts, will first fabric cut-parts and second fabric cut-parts superpose in order to form the peripheral part of coincide will first fabric cut-parts and second fabric cut-parts link together the peripheral part supersound of coincide cuts and fuses first fabric cut-parts and second fabric cut-parts of connecting form and connect the fuse line of first fabric cut-parts and second fabric cut-parts, follow the fuse line makes the inside overturn outwards first fabric cut-parts and second fabric cut-parts of connecting form seamless edge.

According to another aspect of the present invention, there is provided a method of manufacturing a breast cup of a brassiere, which may include the steps of: providing a pad comprising a first edge portion and a second edge portion, providing a fabric cover layer comprising a third edge portion and a fourth edge portion, superposing the first edge portion and the third edge portion, joining the superposed first edge portion and third edge portion together, superposing the second edge portion and fourth edge portion, joining the superposed second edge portion and fourth edge portion together, ultrasonically cutting and fusing the joined first edge portion and third edge portion to form a first weld line joining the pad and the fabric cover layer, ultrasonically cutting and fusing the joined second edge portion and fourth edge portion to form a second weld line joining the pad and the fabric cover layer, and turning the joined pad and fabric cover inside out along the first and second weld lines to form a seamless edge.

According to another aspect of the invention, a breast cup is provided that includes a pad and a fabric covering attached to the pad with a seamless edge.

According to another aspect of the invention there is provided a brassiere comprising two breast cups as described above, which are connected to each other and to a back strap and a shoulder strap.

Drawings

FIG. 1 is a cross-sectional view showing a first step in attaching two fabric panels together to produce an article of apparel.

FIG. 2 is a cross-sectional view showing a second step in attaching two fabric panels together to produce the article of apparel.

FIG. 3 is a cross-sectional view showing a third step in attaching two fabric panels together to produce the article of apparel.

FIG. 4 is a cross-sectional view showing a fourth step in attaching two fabric panels together to produce the article of apparel.

FIG. 5 is a cross-sectional view showing a fifth step in attaching two fabric panels together to produce the article of apparel.

FIG. 6 is a cross-sectional view showing a sixth step in attaching two fabric panels together to produce the article of apparel.

FIG. 7 is a cross-sectional view showing a seventh step in attaching two fabric panels together to produce the article of apparel.

Figure 8 shows a partial perspective view of two fabric panels joined together by ultrasonic cutting and fusing.

FIG. 9 shows a partial perspective view of the panel of FIG. 8 turned inside out along the weld line.

Fig. 10 is a front view showing a first step of manufacturing a breast cup of the brassiere.

Fig. 11 is a front view showing a second step of manufacturing a breast cup of the brassiere.

Fig. 12 is a front view showing a third step of manufacturing a breast cup of the brassiere.

Fig. 13 is a front view showing a fourth step of manufacturing a breast cup of the brassiere.

Fig. 14 is a front view showing a fifth step of manufacturing a breast cup of the brassiere.

Fig. 15 is a front view showing a sixth step of manufacturing a breast cup of the brassiere.

Fig. 16 is a front view showing a seventh step of manufacturing a breast cup of the brassiere.

Fig. 17 shows a breast cup of the brassiere made by the method of fig. 10 to 16.

Fig. 18 is an enlarged view showing the edge of the breast cup of fig. 17.

Figure 19 shows a view of a breast cup made by an ultrasonic cutting fusion machine.

Figure 20 shows another view of ultrasonic cut fusion using an ultrasonic cut fusion machine to make a breast cup.

Detailed Description

Reference will now be made in detail to the present embodiments of the invention, examples of which are also provided in the following description. Exemplary embodiments of the present invention are described in detail, although it will be apparent to those skilled in the relevant art that some features that are not essential to an understanding of the present invention may not be shown for the sake of clarity.

Furthermore, it is to be understood that the invention is not limited to the precise embodiments described below, and that various changes and modifications may be effected therein by one skilled in the art without departing from the spirit or scope of the invention. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted for each other within the scope of this disclosure and appended claims. In addition, modifications and variations that may be apparent to a person of ordinary skill in the art after reading this disclosure, the drawings, and the appended claims are intended to be within the spirit and scope of the invention.

A method of joining two fabric panels for the manufacture of an article of apparel may comprise the steps of: providing a first fabric panel 20 and a second fabric panel 22, overlaying the first fabric panel 20 and the second fabric panel 22 to form superimposed peripheral portions, attaching the first fabric panel and the second fabric panel at the superimposed peripheral portions, ultrasonically cutting and fusing the attached peripheral portions 20a and 22a to form a fused line 34 connecting the first fabric panel 20 and the second fabric panel 22, and turning the attached first fabric panel 20 and second fabric panel 22 inside out along the fused line 34 to form a seamless edge 36, as shown in fig. 1-7.

As used herein, the term "seam" refers to a seam formed by sewing pieces of fabric together along their edges. The term "seam allowance" refers to the portion of the fabric between the fabric edge and the adjacent seam.

As used herein, the term "seam" refers to a line formed when panels of fabric are joined together by stitching. The term "weld line" refers to a line formed when fabric panels are joined together by fusion, a process of joining the fabric layers together by softening or melting the thermoplastic material of the fabric layers with heat and then solidifying upon removal of the applied heat.

The first step includes providing a first fabric panel 20 and a second fabric panel 22, each having a peripheral portion 20a and 22a, as shown in fig. 1-4. The first fabric panel 20 can have a peripheral portion 20a, a peripheral edge 20b, a first side 20c, and an opposing second side 20d, as shown in fig. 1. The second fabric panel 22 may have a peripheral portion 22a and a peripheral edge 22b, as shown in fig. 3. The first and second fabric panels 20, 22 may be independently made of an elastic and/or thermoplastic material such as nylon, polyester, spandex (spandex), lycra (r), or a combination thereof) Foam, or a combination thereof. For example, the fabric panel may be made of about 50% polyurethane (foam), about 46% nylon (first outer fabric), and about 4% spandex (second outer fabric).

Alternatively, the first step may include providing a stabilizer strip 24 and fixedly attaching the stabilizer strip 24 to the first side 20c along the peripheral portion 20a of the fabric panel 20, as shown in fig. 2. Stabilizing strip 24 may be attached to peripheral portion 20a by applying heat and/or pressure to a thin heat sensitive adhesive film disposed on bottom side 24a of stabilizing strip 24. The stabilizing strip 24 may be made of a substantially inelastic material and may have a width of about 10 mm. For example, the stabilizing strip 24 may be made of 100% nylon. For example, the heat sensitive adhesive film may be made of polyurethane. The stabilizing strip 24 may serve to stabilize the peripheral portion 20a of the fabric panel 20, which may otherwise stretch and easily deform.

The second step involves stacking the first and second fabric panels 20, 22 and forming a superimposed peripheral portion, as shown in fig. 3. The first and second fabric panels 20 and 22 may be placed in a superimposed condition such that the peripheral portions 20a and 22a are in a superimposed condition and the peripheral edges 20b and 22b are aligned. Any nature of sheet material may be sandwiched between the fabric panels. For example, the sheet material may comprise a thermoplastic material.

The third step involves attaching the panel at the superimposed peripheral portion, for example by stitching the superimposed peripheral portion to form a seam 26, as shown in fig. 4. Peripheral portions 20a and 22a and stabilizing strip 24 may be sewn together by a single sewing process to form a seam or stitch 26 and a seam allowance 28. Stitch line 26 may be about 2 to 4mm from peripheral edges 20b and 22 b. The seaming step serves to prevent the fabrics from moving laterally relative to one another. Methods known to those skilled in the art other than stitching may be satisfactorily used to prevent lateral movement of the fabric layer. Any sewing machine may be used for sewing, however, other devices known to those of ordinary skill in the art may also be used.

The fourth step includes ultrasonically cutting and fusing the joined peripheral portions 20a and 22a, for example, by ultrasonically cutting and fusing the stitched peripheral portions 20a and 22a, thereby removing the stitching 26 to form a fused line 34 joining the first and second fabric panels 20 and 22, as shown in fig. 5. Ultrasonic cutting and fusing may be performed along a line generally parallel to suture 26 and spaced inwardly from suture 26. Weld line 34 has a width of less than 1mm and may be formed about 4 to 7mm from peripheral edges 20b and 22 b. The fused edge thus formed is substantially flat and smooth.

The fifth step includes turning the first and second fabric panels 20, 22 inside out along the weld line 34 to form a seamless edge, as shown in fig. 6 and 7 and the arrows. The turning of the attached first and second fabric panels 20, 22 inside out along the weld line to form a seamless edge is a process known as "rolling out".

Two fabric panels 20 and 22 are shown in fig. 7 connected by a weld line 34. By turning the two fabric panels 20 and 22 inside out, a rough outer fused surface can be hidden between the two fabric panels 20 and 22, exposing only the smooth inner surfaces of the two fabric panels 20 and 22, and forming a seamless edge 36. No distinct edges are formed along the peripheral portions of fabric panels 20 and 22. It should be noted that the actual thickness of the stabilizing strip 24a is extremely small; the remaining stabilizing strip 24a between the two fabric panels 20 and 22 is exaggerated in fig. 7 for illustrative purposes only.

In fig. 8, a partial perspective view of two fabric panels 20 and 22 joined together along a weld line 34 by an ultrasonic cutting and fusing process is shown. In fig. 9, there is shown a partial perspective view of the two fabric panels 20 and 22 of fig. 8 turned inside out along the weld line 34. It can be seen that there is no stitching or seam allowance along the edge portions of the two attached fabric panels 20 and 22. The weld line 34 is substantially invisible after the two fabric panels 20 and 22 are turned inside out.

The same steps described above in connection with attaching two layers of fabric can be used in a process involving attaching multiple fabric panels, wherein the fabric panels can be divided into two groups for inside-out turning or everting. This method has simplicity and flexibility as it is not limited to the size and number of fabric panels.

A method of manufacturing a breast cup of a brassiere may comprise the steps of: providing a cup-shaped pad 50 having a first side 52, an opposing second side 54, a first rim portion 56, and a second rim portion 58; providing a fabric cover layer 70 having a third edge portion 72 and a fourth edge portion 74; placing a fabric cover layer 70 on the second side 54 of the pad; overlapping the first edge portion 56 and the third edge portion 72; stitching the superimposed first and third edge portions 56, 72 together to form a first stitch line 76; overlapping the second edge portion 58 and the fourth edge portion 74; stitching the overlapping second edge portion 58 and fourth edge portion 74 together to form a second stitch line 78; ultrasonically cutting and fusing the stitched first and third edge portions 56, 72 together to remove the first stitch line 76 and form a first fused line 90 connecting the pad 50 and the fabric cover 70; ultrasonically cutting and fusing the stitched second and fourth edge portions 58, 74 together to remove the second stitch line 78 and form a second fused line 92 connecting the pad 50 and the fabric cover layer 70; the joined pad 50 and fabric cover 70 are turned inside out along the first and second weld lines 90, 92 to form seamless edges 190 and 192, as shown in fig. 10-16. Ultrasonic cutting and fusing may be performed along a line generally parallel to the first suture 76 and spaced inwardly from the first suture 76, and a line generally parallel to the second suture 78 and spaced from the second suture 78.

The first step includes providing a cup-shaped pad 50 having a first side 52, an opposing second side 54, a first rim portion 56, and a second rim portion 58, as shown in fig. 10. The first side 52 may be a front face or a raised side 52. The second side 54 may be a rear or concave side. The first edge portion 56 may be a neckline edge portion. The second edge portion 58 may be an underarm edge portion. The pad 50 may also have a bottom edge portion 60. The pad 50 may be made of a resilient and/or thermoplastic material such as nylon, polyester, spandex, lycra, foam, or combinations thereof. For example, the fabric panel may be made of about 50% polyurethane (foam), about 46% nylon (first outer fabric), and about 4% spandex (second outer fabric).

Alternatively, the first step may include providing two stabilizing strips 62 and 64, fixedly attaching the first stabilizing strip 62 to the convex side of the pad 50 along edge portion 56, and fixedly attaching the second stabilizing strip 64 to the convex side of the pad 52 along edge portion 58, as shown in FIG. 11. Stabilizing strips 62 and 64 may be attached to edge portions 56 and 58, respectively, by applying heat and/or pressure to a thin heat sensitive adhesive film provided on the underside of each of stabilizing strips 62 and 64. The thermo-adhesive film may be made of polyurethane.

Stabilizing strips 62 and 64 may have a width of about 10mm and a length substantially the same as the length of edge portions 56 and 58. Stabilizing strips 62 and 64 may be independently made of a substantially inelastic material such as 100% nylon. Stabilizing strips 62 and 64 serve to stabilize first edge portion 56 and second edge portion 58 of pad 50, which might otherwise stretch and deform.

The second step includes providing a fabric cover layer 70 having a third edge portion 72 and a fourth edge portion 74, as shown in fig. 12.

The third step includes placing a fabric cover layer 70 on the second side 54 of the pad; overlapping the first edge portion 56 and the third edge portion 72; the superimposed first and third edge portions 56, 72 are joined together, such as by stitching the superimposed first and third edge portions 56, 72 together to form a first stitch line 76, as shown in fig. 13. The pad 50 and the fabric cover 70 may be placed in an overlying relationship such that the edge portion 56 of the pad 50 and the edge portion 72 of the fabric cover 70 are superimposed. The fabric cover 70 may be made of an elastomeric and/or thermoplastic material such as nylon, polyester, lycra, spandex, or combinations thereof. For example, the fabric cover 70 may be made from about 72% nylon, and about 28% lycra. Edge portions 56 and 72 and optional stabilizing strip 62 may be sewn together by a single sewing process to form first seam 76.

The fourth step includes folding the second edge portion 58 and the fourth edge portion 74; the superimposed second edge portion 58 and fourth edge portion 74 are joined together, such as by stitching the superimposed second edge portion 58 and fourth edge portion 74 together to form a second stitch line 78, as shown in fig. 13. The pad 50 and the fabric cover 70 may be placed in an overlying relationship such that the edge portion 58 of the pad 50 and the edge portion 74 of the fabric cover 70 are superimposed. Edge portions 58 and 74 and optional stabilizing strip 64 may be sewn together by a single sewing process to form second seam 78. The stitching lines 76 and 78 may be formed about 2 to 4mm from the peripheral edges of the edge portions 56 and 58, respectively. The sewing can be carried out by any sewing machine; however, other devices known to those skilled in the art may also be used.

The fifth step includes ultrasonically cutting and fusing the connected first and third edge portions 56, 72, for example, by ultrasonically cutting and fusing the connected first and third edge portions 56, 72 together to remove the first stitch line 76, forming a first fused line 90 connecting the pad 50 and the fabric cover layer 70, as shown in fig. 14. If optional stabilizer bar 62 is present, a first weld line connects the pad, fabric cover, and stabilizer bar. Ultrasonic cutting and fusing may occur along a line L1 that is generally parallel to suture 76 and spaced inwardly from suture 76.

The sixth step includes ultrasonically cutting and fusing the joined second and fourth edge portions 58, 74, for example, by ultrasonically cutting and fusing the joined second and fourth edge portions 58, 74 together to remove the second stitching line 78 to form a second fused line 92 connecting the pad 50 and the fabric cover layer 70, as shown in fig. 14. If the optional stabilizer strip 64 is present, a second weld line 92 connects the pad 50, the fabric cover 70, and the stabilizer strip 64. Ultrasonic cutting and fusing may occur along a line L2 that is generally parallel to suture 78 and spaced inwardly from suture 78. The weld lines 90 and 92 may have a width of less than 1mm and may be formed approximately 4 to 7mm from the peripheral edges of the edge portions 56 and 58, respectively.

The seventh step includes turning the attached pad 50 and fabric cover 70 inside out along the first and second weld lines 90 and 92 to form seamless edges 190 and 192, as shown in fig. 15 and 16 and the arrows.

According to another aspect of the present invention, there is provided a brassiere comprising breast cups 100, as shown in fig. 17. The breast cup 100 includes a pad 50 having seamless edges 290 and 292 and a fabric cover layer 70. The pad 50 may include an inner breast receiving layer and is preferably made of a fabric, such as a thermoplastic material, selected for comfort of a woman wearing the bra. The fabric cover 70 may comprise the outer layer of the breast cup and may be made of a fabric, such as an elastic and/or thermoplastic material, that exhibits a pleasing color and appearance. Two breast cups 100 may be connected to each other and to the back strap and shoulder strap to form a brassiere.

An enlarged view of the fused edge of the breast cup 100 of figure 17 is shown in figure 18. The breast cup 100 may have fused edges 290 and 292 that are less than about 1mm wide. The breast cup 100 has no bulky and noticeable seam allowance or stitch lines. This substantially improves the overall appearance and comfort of the brassiere incorporating breast cup 100.

In fig. 19 and 20, an ultrasonic cutting and fusing machine 200 for performing ultrasonic cutting and fusing is shown, which is available as a GC-50S model manufactured by Golden Casting Company (hong kong, china). The ultrasonic cutting fuser 200 has an ultrasonic cutting fusing blade 202 adapted to simultaneously cut and fuse the fabric layers by consuming ultrasonic energy. The fabric layers may contain a substantial amount of thermoplastic material in order to ultrasonically fuse the fabric layers together. Under the action of ultrasonic energy, the thermoplastic material may soften or melt and subsequently solidify when no longer subjected to ultrasonic energy, thus leaving a fused surface on the narrow edge adjacent the cut. The fused surface may be rough. Since the edges created by such ultrasonic fusing can be narrow, if not negligible, by turning the fabric layers inside out, the rough outer fused surface can be hidden between the fabric layers, exposing only the smooth inner surface and creating a seamless edge.

The two fabric layers may be joined together by ultrasonically cutting and punching the peripheral edge portions of the fabric layers using an ultrasonic die cutter. An example of an ultrasonic die cutter is SUW4215 manufactured by k. In another embodiment, an ultrasonic die cutter may be used to join the fabric panels together by ultrasonically punching the peripheral edge portions of the fabric panels while removing the peripheral edges by cutting.

The ultrasonic die cutter may have an ultrasonic cutting die blade adapted to simultaneously cut and punch the fabric layer to remove rough edges and form weld lines. The seamless edge may be formed by reversing the fabric layer inside out along the weld line. While it has been shown that ultrasonic cutting fusion machines can be used to join two layers of fabric together, it will be appreciated that other suitable machines can be used.

While examples of methods and products have been described, it will be understood that the methods and products are not limited thereto and that modifications may be made. The scope of the methods and products is defined by the appended claims, and all methods and products that come within the meaning of the claims, either literally or by equivalence, are intended to be embraced therein.

Claims (26)

1. A method of attaching fabric panels to manufacture a bra, the method comprising the steps of:

superimposing a first fabric panel and a second fabric panel to form a superimposed peripheral portion, wherein the first and second fabric panels are to become an outer layer and an inner layer of a breast cup of the brassiere;

attaching the first and second fabric panels together at the superimposed peripheral portion;

ultrasonically cutting and fusing the joined first and second fabric panels at the superimposed peripheral portion, thereby forming a fused line joining the first and second fabric panels; and

turning the attached first and second fabric panels inside-out along the weld line to form an everted seamless edge.

2. The method of claim 1, wherein said attaching comprises stitching the first and second panels together to form a seam.

3. The method of claim 2, wherein the ultrasonic cutting and fusing is along a line generally parallel to and spaced inwardly from the suture line.

4. The method of claim 2, wherein the ultrasonically cutting and fusing comprises removing the suture.

5. The method of claim 1, wherein said first fabric panel comprises a first perimeter portion;

the method further includes providing a stabilizing strip and fixedly attaching the stabilizing strip along a first peripheral portion of the first fabric panel prior to the attaching.

6. The method of claim 5, wherein said applying comprises applying at least one of heat and pressure to a thin heat sensitive adhesive film disposed on an underside of said stabilizing strip.

7. A method of manufacturing a breast cup of a brassiere, the method comprising the steps of:

providing a pad comprising a first edge portion and a second edge portion, wherein the pad is to become an inner layer of the cup;

providing a fabric covering including a third edge portion and a fourth edge portion, wherein the fabric covering is to become an outer layer of the breast cup;

overlapping the first and third edge portions;

joining the superimposed first and third edge portions together;

overlapping the second edge portion and the fourth edge portion;

joining said superimposed second and fourth edge portions together;

ultrasonically cutting and fusing the joined first and third edge portions to form a first weld line joining the pad and the fabric cover layer;

ultrasonically cutting and fusing the joined second and fourth edge portions to form a second weld line joining the pad and the fabric cover layer; and

turning the joined pad and fabric cover inside out along the first and second weld lines to form a seamless edge.

8. The method of claim 7, wherein said joining said superimposed first and third edge portions comprises stitching said superimposed first and third edge portions together to form a first stitch line.

9. The method of claim 8, wherein the ultrasonically cutting and fusing the joined first and third edge portions is along a line generally parallel to and spaced inwardly from the first line of stitching.

10. The method of claim 9, wherein the ultrasonically cutting and fusing the joined first and third edge portions includes removing the first suture.

11. The method of claim 7, wherein said joining said folded second and fourth edge portions comprises stitching said folded second and fourth edge portions together to form a second stitch line.

12. The method of claim 11, wherein the ultrasonically cutting and fusing the joined second and fourth edge portions is along a line generally parallel to and spaced inwardly from the second line of stitching.

13. The method of claim 12, wherein the ultrasonically cutting and fusing the joined second and fourth edge portions includes removing the second suture.

14. The method of claim 7, further comprising providing a first stabilizing strip and fixedly attaching the stabilizing strip along the first edge portion of the mat prior to connecting the superimposed first and third edge portions.

15. The method of claim 14, wherein said applying comprises applying at least one of heat and pressure to a thin thermal adhesive film disposed on an underside of said first stabilizing strip.

16. The method of claim 7, further comprising providing a second stabilizing strip and fixedly attaching said stabilizing strip along said second edge portion of said mat prior to joining said superimposed second and fourth edge portions.

17. The method of claim 16, wherein said applying comprises applying at least one of heat and pressure to a thin thermal adhesive film disposed on an underside of said second stabilizing strip.

18. A breast cup, comprising:

a pad comprising a first edge portion and a second edge portion, wherein the pad is to become an inner layer of the cup;

a fabric covering attached to said pad and including a third edge portion and a fourth edge portion, wherein said fabric covering is to become an outer layer of said bra cups;

wherein the first edge portion and the third edge portion are superimposed and joined together, the second edge portion and the fourth edge portion are superimposed and joined together,

the joined first and third edge portions being ultrasonically cut and fused to form a first weld line joining the pad and the fabric cover layer, the joined second and fourth edge portions being ultrasonically cut and fused to form a second weld line joining the pad and the fabric cover layer,

the joined pad and fabric cover layers are turned inside-out along the first and second weld lines, forming an everted seamless edge between the pad and the fabric cover layer.

19. A breast cup as claimed in claim 18, wherein said everted seamless edge comprises a weld line between said pad and said fabric cover.

20. A breast cup as claimed in claim 18, wherein said pad includes an inner breast receiving layer.

21. A breast cup as claimed in claim 20, wherein said inner breast receiving layer comprises a thermoplastic material.

22. A breast cup as claimed in claim 18, wherein said pad is made of a material selected from the group consisting of nylon, polyester, spandex, foam and combinations thereof.

23. A breast cup as claimed in claim 18, wherein said fabric cover comprises an elastomeric material selected from the group consisting of nylon, polyester, spandex and combinations thereof.

24. A breast cup as claimed in claim 19, wherein said weld line comprises a stabilising strip attached to said pad.

25. A breast cup as claimed in claim 24, wherein said stabilizing strip is made of nylon.

26. A brassiere, comprising:

two breast cups as claimed in claim 18, connected to each other and to the back strap and shoulder strap.