Patent Publication Number: US-2022211120-A1

Title: A brassiere and method of manufacturing the brassiere

Description:
FIELD OF THE PRESENT DISCLOSURE 
     The present disclosure relates generally to a brassiere, and in particular, to a brassier including a bra cup having an outer side having at least one thread line, and an inner side devoid of thread line, and a method of manufacturing the brassiere. 
     BACKGROUND 
     A brassiere is worn by a wearer to be held firmly in place against her body and support the breasts in their proper position without exerting excessive pressure against them. The brassiere generally comprises a pair of bra cups and side wings attached to the bra cups and extending laterally outwardly from the bra cups. Typically, side wings are attached to the bra cups by sewing with threads. In such cases, threaded stitches are exposed both on the inner side and outer side of the brassiere. Exposed threaded stitches on the inner side of the brassiere are not comfortable, and hence not desirable. 
     SUMMARY 
     In an aspect, a brassiere is disclosed. The brassier includes a side-wing and a bra cup having a cup portion and a flange portion attached to the side-wing. The flange potion including a flange disposed at an inner side of the bra cup, and an outer layer being disposed at an outer side of the bra cup and coupled to the flange. The flange portion also includes a portion of the side-wing disposed between the outer layer and the flange. The portion of the side-wing is attached to the outer layer by using at least one thread line. The at least one thread line is disposed on the outer side of the bra cup, and the inner side of the bra cup is devoid of thread line. 
     In one or more embodiments, the at least one thread line includes a first thread line and a second thread line. 
     In one or more embodiments, the brassiere also includes a stabilizer sandwiched between the side-wing and one of the outer layer and the flange. 
     In one or more embodiments, the outer layer includes a second portion and a third portion. The second portion is formed by folding the outer layer. The second portion is disposed between the third portion of the outer layer and the side-wing. 
     In one or more embodiments, the flange includes a first portion and a second portion. The first portion is formed by folding the flange, and the first portion of the flange is sandwiched between the side-wing and the second portion of the flange. The at least one thread line runs through the first portion of the flange but not the second portion of the flange. 
     In one or more embodiments, the flange portion includes a wire channel disposed between the second portion of the outer layer and the third portion of the outer layer. 
     In one aspect, a method of manufacturing a brassiere is disclosed. The method includes providing a cup core having a cup and a flange extending along a periphery of the cup. The flange includes a first portion and a second portion separated by a fold line which is a virtual boundary line. The method further includes attaching a portion of a side-wing to the first portion of the flange, and attaching an outer layer to the first portion of the flange and the side-wing such that the side-wing is disposed between the flange and the outer layer. Also, the method includes attaching a wire channel to the outer layer and the flange, and folding the outer layer to enwrap the wire channel. Further, the method includes folding the outer layer and the first portion of the flange along the fold line to adhesively attach the first portion of the flange to the second portion of the flange. Furthermore, the method includes attaching a first portion of the outer layer to the cup. The portion of the side-wing is attached to the outer layer by using at least one thread line. The at least one thread line is disposed at an outer side of the bra cup and the inner side of the bra cup is devoid of thread line. 
     In one or more embodiments, the portion of the side-wing is attached to the first portion of the flange by using first threads. 
     In one or more embodiments, the method also includes positioning a stabilizer between the first portion of flange and the side-wing. The stabilizer is positioned abutting the inner surface of the flange. 
     In one or more embodiments, the outer layer includes a second portion and a third portion extending between the second portion of the outer layer and the first portion of the outer layer. The second portion of the outer layer is attached to the side-wing using second threads. 
     In one or more embodiments, the outer layer enwraps the wire channel such that the wire channel is sandwiched between the second portion of the outer layer and the third portion of the outer layer. 
     In one or more embodiments, the wire channel is attached to the outer layer and the flange by stitching the first portion of the flange, the side-wing, the second portion of the outer layer, and the wire channel by using third threads. 
     In one or more embodiments, the third portion of the outer layer, the second portion of the outer layer, the wire channel, and the first portion of the flange are stitched together using fourth threads. 
     In one or more embodiments, the method also includes inserting an underwire inside the wire channel. 
     In one or more embodiments, the cup core includes an outer fabric layer, an inner fabric layer, an inner foam layer disposed between the outer fabric layer and the inner fabric layer. The inner foam layer abuts the inner fabric layer. The cup core further includes an outer foam layer sandwiched between the outer fabric layer and the inner foam layer. The outer foam layer abuts the outer fabric layer and the inner foam layer. In one or more embodiments, the outer fabric layer, the outer foam layer, the inner foam layer, and the inner fabric layer are laminated together. 
     In another aspect, a brassiere is disclosed. The brassiere includes a side-wing and a bra cup having a cup portion and a flange portion attached to the side-wing. The flange portion includes a flange of a cup core, a portion of the side-wing, and an outer layer. The flange has a first portion and a second portion adhesively attached to the first portion. The second portion is disposed at an inner side of the bra cup. The portion of the side-wing is attached with the first portion of the flange. Further, the outer layer has a second portion and a third portion folded over the second portion, and enwrapping a wire channel therebetween. The third portion of the outer layer is disposed at an outer side of the bra cup. The second portion of the outer layer, the third portion of the outer layer, the wire channel, the first portion of the flange, and the side-wing are attached using at least one thread line. The at least one thread line is disposed on an outer side of the bra cup and the inner side of the bra cup is devoid of thread line. 
     In one or more embodiments, the brassiere also includes a stabilizer sandwiched between the first portion of the flange and the side-wing. The stabilizer abuts an inner surface of the flange and the side-wing. 
     In one or more embodiments, the brassiere also includes an underwire disposed inside the wire channel. 
     In one or more embodiments, the second portion of the outer layer is sandwiched between the wire channel and the side-wing. The second portion of the outer layer abuts the side-wing and the wire channel. 
     In one or more embodiments, the cup portion of the bra cup include a cup of the cup core and a first portion of the outer layer attached to the cup. 
     In one or more embodiments, the cup core includes an outer fabric layer, an inner fabric layer, and an inner foam layer disposed between the outer fabric layer and the inner fabric layer. The inner foam layer abuts the inner fabric layer. The cup core further includes an outer foam layer sandwiched between the outer fabric layer and the inner foam layer. The outer foam layer abuts the outer fabric layer and the inner foam layer. In one or more embodiments, the outer fabric layer, the outer foam layer, the inner foam layer, and the inner fabric layer are laminated together. 
     In one or more embodiments, the cup core further includes a foam pad sandwiched between the outer foam layer and the inner foam layer, and is located at an interface of the flange and the cup. 
     The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of example embodiments of the present disclosure, reference is now made to the following descriptions taken in connection with the accompanying drawings in which: 
         FIG. 1A  illustrates a front view of a brassiere, in accordance with one or more embodiments of the present disclosure; 
         FIG. 1B  illustrates a back view of the brassiere, in accordance with one or more embodiments of the present disclosure; 
         FIG. 2  illustrates a sectional view of the brassiere of  FIG. 1A  along a line A-A, in accordance with one or more embodiments of the present disclosure; 
         FIG. 3  illustrates a sectional view of the brassiere of  FIG. 1A  along a line A-A, in accordance with one or more embodiments of the present disclosure; 
         FIG. 4  illustrates a cup core of a first bra cup of the brassiere, the cup core has a cup and a flange, in accordance with one or more embodiments of the present disclosure; 
         FIG. 5  illustrates a sectional view of the cup core of  FIG. 4  along a line B-B, in accordance with one or more embodiments of the present disclosure; 
         FIG. 6  illustrates a step of the method of manufacturing the brassiere in which a stabilizer, a first side-wing, and the flange are attached, in accordance with one or more embodiments of the present disclosure; 
         FIG. 7  illustrates a sectional view of  FIG. 6  along a line C-C, in accordance with one or more embodiments of the present disclosure; 
         FIG. 8  illustrates a step of the method of manufacturing the brassiere in which an outer layer is attached to the side-wing and the flange, in accordance with one or more embodiments of the present disclosure; 
         FIG. 9  illustrates a sectional view of  FIG. 8  along a line D-D, in accordance with one or more embodiments of the present disclosure; 
         FIG. 10  illustrates a step of the method of manufacturing the brassiere in which a wire channel is attached to the outer layer and the flange, in accordance with one or more embodiments of the present disclosure; 
         FIG. 11  illustrates a sectional view of  FIG. 10  along a line E-E, in accordance with one or more embodiments of the present disclosure; 
         FIG. 12  illustrates a step of the method of manufacturing of the brassiere in which an outer layer is folded to enwrap the wire channel, in accordance with one or more embodiments of the present disclosure; 
         FIG. 13  illustrates a step of the method of manufacturing of the brassiere in which an adhesive is applied on a first portion of the flange, in accordance with one or more embodiments of the present disclosure; 
         FIG. 14  illustrates a step of the method of manufacturing of the brassiere in which the flange and the outer layer is folded along a fold line to adhesively attach the first portion of the flange to the second portion of the flange, in accordance with one or more embodiments of the present disclosure; and 
         FIG. 15  illustrates a step of the method of manufacturing of the brassiere in which first side-wing is flipped, in accordance with one or more embodiments of the present disclosure; 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one skilled in the art that the present disclosure can be practiced without these specific details. In other instances, apparatuses and methods are shown in block diagram form only in order to avoid obscuring the present disclosure. 
     Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not for other embodiments. 
     The embodiments are described herein for illustrative purposes and are subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but are intended to cover the application or implementation without departing from the spirit or the scope of the present disclosure. Further, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. Any heading utilized within this description is for convenience only and has no legal or limiting effect. 
     Where there is reference to the word “layer” it is to be understood that it may have its common definition and, but not limited to that the layer could consist of one panel or may have regions that are defined by two or more panels that are joined and that may each be of a different characteristic (e.g. color, thickness, material, orientation, size). 
     Referring to the  FIGS. 1A and 1B , a brassiere  100  is shown according to an exemplary embodiment of the disclosure. The brassiere  100  includes a body structure  102  which defines a shape of the brassiere  100 . The body structure  102  includes a pair of bra cups, for example, a first bra cup  104  and a second bra cup  106 , and a center gore  108  disposed between the first bra cup  104  and the second bra cup  106  and connecting the first bra cup  104  and the second bra cup  106 . Further, the brassiere  100  includes a pair of side-wings, including a first side-wing  110  and a second side-wing  112  are attached to lateral peripheries of the first bra cup  104  and the second bra cup  106 , respectively. Also, a pair of straps, including a first strap  114  and a second strap  116  are attached to top peripheries of the first bra cup  104  and the second bra cup  106 , respectively. In one or more examples, fasteners  118 ,  120  may be provided with the first side-wing  110  and the second side-wing  112 . It may be contemplated that the pair of straps  114 ,  116  support the brassiere  100  on shoulders of the wearer, while the pair of side-wings  110 ,  112  support the brassiere  100  around a torso of the wearer, when worn. In some examples, the pair of straps  114 ,  116  and may be omitted, and only the pair of side-wings  110 ,  112  may support the brassiere  100  on the wearer. 
     Further, as shown in  FIG. 1A  and  FIG. 1B , the first bra cup  104  includes an inner side  130 , an outer side  132 , a first cup portion  134  having a first neck line  136  and a first side edge  138 , and a first flange portion  140  extending from the first cup portion  134 . The outer side  132  of the first bra cup  104  may include a substantially convex shape, while the inner side  130  of the first bra cup  104  may include a substantially concave shape. As illustrated, the first neck line  136 , the first side edge  138 , and the first flange portion  140  together define an outer periphery of the first bra cup  104 . The first bra cup  104  is attached to the first side-wing  110  at the first flange portion  140 , and the first side-wing  110  extends laterally away from the first flange portion  140 . Also, the center gore  108  is attached to the first flange portion  140  and extend outwardly from the first cup portion  134  in a direction opposite to the first side-wing  110 . 
     Similar to the first bra cup  104 , the second bra cup  106  also includes an inner side  142 , an outer side  144 , a second cup portion  146  having a second neck line  148  and a second side edge  150 , and a second flange portion  152  extending from the second cup portion  146 . The outer side  144  of the second bra cup  106  may include a substantially convex shape, while the inner side  142  of the second bra cup  106  may include a substantially concave shape. The second neck line  148 , the second side edge  150 , and the second flange portion  152  together define an outer periphery of the second bra cup  106 . The second bra cup  106  is attached to the second side-wing  112  at the second flange portion  152 , and the second side-wing  112  extends laterally away from the second flange portion  152 . Also, the center gore  108  is attached to the second flange portion  152  and extend outwardly from the second cup portion  146  in a direction opposite to the second side-wing  112 . Further, the first flange portion  140  includes two sewing thread lines, for example, a first sewing thread line  160  and a second sewing thread line  162 , disposed at the outer side  132  of the first bra cup  104 , while the inner side  130  of the first bra cup  104  is devoid of any sewing thread lines. Similar to the first bra cup  104 , the second bra cup  106  also include two sewing thread lines, for example, a third sewing thread line  164  and a fourth sewing thread line  166 , disposed at the outer side  144  of the second bra cup  106 , while the inner side  142  of the second bra cup  106  is devoid of any sewing thread lines. 
     Referring to  FIG. 2 , a cross-sectional view of the first bra cup  104  along the sectional line A-A is shown according to one embodiment of the disclosure. As shown, the first cup portion  134  may include a cup  170 ′ of a cup core  172 ′, a portion of an outer layer  176 ′ abutted and attached to an outer side of the cup  170 ′. In this manner, the cup  170 ′ defines an inner side  180 ′ (or inner layer) of the first cup portion  134 , while the outer layer  176 ′ defines an outer side  182 ′ of the first cup portion  134 . Further, the first flange portion  140  may include a flange  186 ′ of the cup core  172 ′. The flange  186 ′ may extend from the cup  170 ′ and is integrally formed with the cup  170 ′. In an embodiment, the flange  186 ′ may extend an angle to the cup  170 ′. Further, the first flange portion  140  may include a portion of the outer layer  176 ′ attached/coupled to the flange  186 ′ and is disposed at an outer side of the first flange portion  140 . Further, the first flange portion  140  includes a portion of the first side-wing  110  disposed between the flange  186 ′ and the outer layer  176 ′, and is coupled to the flange  186 ′ and the outer layer  176 ′. In an embodiment, the outer layer  176 ′ and the portion of the first side-wing  110  are attached by using at least one thread line, for example the first thread line  160  and the second thread line  162 , disposed at the outer side  132  of the first bra cup  104 . It may be appreciated that the thread lines  160 ,  162  extend, at least partly, along a length of the first flange portion  140 . As seen, the thread lines  160 ,  162  runs through the outer layer  176 ′ and the first side-wing  110 , and do not run through the flange  186 ′. Further, the flange  186 ′ and the first side-wing  110  are attached together without using any threads. In an embodiment, the flange  186 ′ and the first side-wing  110  may be adhesively attached to each other. In this manner, the inner side  130  of the first bra cup  104  is devoid of any thread lines. Additionally, or optionally, the first flange portion  140  may include a plurality of elements and/or layers disposed between the outer layer  176 ′ and the flange  186 ′. 
     Referring to  FIG. 3 , a cross-sectional view of the first bra cup  104  along the sectional line A-A is shown, according to another embodiment of the disclosure. As shown, the first cup portion  134  may include a cup  170  of a molded cup core  172  and a first portion  174  of an outer layer  176  abutted and attached to an outer side of the cup  170 . In this manner, the cup  170  defines an inner side  180  of the first cup portion  134 , while the first portion  174  of the outer layer  176  defines an outer side  182  of the first cup portion  134 . Further, the first flange portion  140  may include a flange  186  of the cup core  172  having a first portion  188  and a second portion  190  extending between the first portion  188  and the cup  170 . As shown, the first portion  188  is folded over the second portion  190 , and is adhesively attached to the second portion  190 . In this manner, an adhesive layer  192  is disposed between the first portion  188  and the second portion  190 , and attaches the first portion  188  to the second portion  190 . As the second portion  190  of the flange  186  is disposed at the inner side  130  of the first bra cup  104  and the second portion  190  is attached to the first portion  188  by using adhesive, the inner side  130  of the first bra cup  104  is devoid of any thread lines. 
     Further, the first flange portion  140  may include a stabilizer  194  abutted and attached with the first portion  188 , and a portion of the first side-wing  110  is attached to the stabilizer  194  and is disposed above the stabilizer  194 . In this manner, the stabilizer  194  may be sandwiched between the first side-wing  110  and the first portion  188 . In certain implementations, the stabilizer  194  may be disposed above the first side-wing  110 . In such a case, the first side-wing  110  may be sandwiched between the first portion  188  of the flange  186  and the stabilizer  194 . In an embodiment, the first portion  188 , the portion of the first side-wing  110 , and the stabilizer  194  are attached/stitched together using first threads  202 ,  204 . Alternatively, the first side-wing  110  and the stabilizer  194  may be attached adhesively with each other. Further, the flange portion  140  may include a second portion  210  of the outer layer  176  abutting and attached with the first side-wing  110  such that the first side-wing  110  is disposed/sandwiched between the second portion  210  of the outer layer  176  and the stabilizer  194 . The stabilizer is generally a piece of non-stretchable or substantially non-stretchable material, which is of a shape generally conforming to the arch shape of the flange or the flange portion. Thus, the stabilizer may include an arch shaped profile that is complimentary to an arch shaped profile of the flange  186 . The function of the stabilizer is to ‘stabilize’ the flange during the manufacturing process, i.e., to maintain the shape and extent of the flange during manufacturing, in particular when the flange is to be subject to various sewing operations which will be described hereinafter. Further, a third portion  212  of the outer layer  176  is folded over the second portion  210 . Furthermore, the flange portion  140  may include a wire channel  216  that is sandwiched between the second portion  210  of the outer layer  176  and the third portion  212  of the outer layer  176 . It may be appreciated that the first portion  188 , the wire channel  216 , the stabilizer  194 , the second portion  210 , the third portion  212 , and the first side-wing  110  are attached/stitched together by using at least one thread line, for example, the first thread line 160  and the second thread line  162  such that the thread lines  160 ,  162  are disposed at the outer side  132  of the first bra cup  140 . Further, as illustrated, the thread lines  160 ,  162  do not run through the second portion  190  of the flange  186 . Additionally, or optionally, the first bra cup  104  may include an underwire  220  disposed inside a channel of the wire channel. In an embodiment, the underwire  220  may extend along an entire length of the wire channel  216 . 
     Referring to  FIGS. 4 to 15 , various steps of a method of manufacturing the brassiere  100  is explained. For sake of clarity and brevity, the various steps of method of manufacturing are explained and discussed with reference to the first bra cup  104  and the first side-wing  110 , and it may be appreciated that similar steps will be applicable for the second bra cup  106 , the center gore  108 , and the second side-wing  112 .  FIG. 4  discloses a step of the method in which the molded cup core  172  is provided. As shown in  FIGS. 4 and 5 , the cup core  172  may include the cup  170  having an inner side  221  and an outer side  222 , and the flange  186  having an inner surface  226  and an outer surface  228 . The flange  186  may extend substantially horizontally from the cup  170  and defines a flange boundary  230  at an interface of the cup  170  and the flange  186 . Further, the flange  186  may include the first portion  188  and the second portion  190  extending from the first portion  188  to the flange boundary  230 . In an implementation, the first portion  188  and the second portion  190  are separated by a virtual boundary line  240  (hereinafter referred to as fold line  240 ). Also, as shown, the molded cup core  172  may be made of a plurality of layers and may include an outer fabric layer  250 , an inner fabric layer  252 , and an inner foam layer  254  disposed between the outer fabric layer  250  and the inner fabric layer  252  and abutted with the inner fabric layer  252 . The cup core  172  may also include an outer foam layer  256  sandwiched between the inner foam layer  254  and the outer fabric layer  250 , and abutting both the outer fabric layer  250  and the inner foam layer  254 . As shown, the outer fabric layer  250 , the inner fabric layer  252 , the inner foam layer  254 , and the outer foam layer  256  extend along an entire cup  170  and the flange  186  of the cup core  172 . The outer fabric layer, the outer foam layer, the inner foam layer, and the inner fabric layer are laminated together. Further, a foam pad  260  may also be disposed inside the cup core  172  at an interface of the flange  186  and cup  170  such that the foam pad  260  is disposed/sandwiched between the outer foam layer  256  and the inner foam layer  254 . 
     Thereafter, as shown in  FIGS. 6 &amp; 7 , the stabilizer  194  and the first side-wing  110  are attached to the flange  186  of the cup core  172 . For so doing, the stabilizer  194  is positioned abutting the inner surface  226  of the flange  186 , and the first side-wing  110  is positioned abutting the stabilizer  194 . Therefore, the flange  186 , the stabilizer  194 , and first side-wing  110  are arranged such that stabilizer  194  is sandwiched between the first portion  188  of the flange  186  and a portion of the first side-wing  110 . In certain embodiments, the first side-wing  110  may be sandwiched between the first portion  188  and the stabilizer  194 . Further, in so doing, the first side-wing  110  and the cup  170  of the cup core  172  are disposed in substantially same direction (best shown in  FIG. 6 ). After arranging the stabilizer  194 , the first portion  188  of the flange  186 , and the first side-wing  110  together, the stabilizer  194 , the first portion  188  of the flange  186 , and the first side-wing  110  may be stitched together using first thread  262 . In some implementations, the first portion  188 , the stabilizer  194 , and the first side-wing  110  may be adhesively attached to each other. As illustrated, the stabilizer  194  is attached to the first portion  210  of the flange  186  such that stabilizer  194  abuts the inner surface  226  of the flange  186  and extends from a free edge  270  of the flange  186  to the fold line  240 . 
     Upon attaching the first side-wing  110  and the stabilizer  194  to the flange  186 , the outer layer  176  is attached/coupled to the flange  186  (as shown in  FIGS. 8 and 9 ). For so doing, the second portion  210  of the outer layer  176  is positioned below the first side-wing  110 . In an embodiment, outer layer  176  may be arranged in such a manner that the second portion  210  abuts the first side-wing  110 . In this manner, the first side-wing  110  may be sandwiched between the second portion  210  of the outer layer  176  and the stabilizer  194 . As shown, the outer layer  176  is arranged in such a manner that the outer layer  176  and the first side-wing  110  extend in the same direction from the flange  186 . Thereafter, the second portion  210  of the outer layer  176 , the first side-wing  110 , the stabilizer  194 , and the first portion  188  of the flange  186  are stitched together by using second threads  264 ,  266 . In an embodiment, the second threads  266 ,  268  overlap the first threads  262 ,  264 . Alternatively, the second portion  210  of the outer layer  176  may attached to the stabilizer  194  and/or the first side-wing  110  by using adhesive. Further, it may be envisioned that the outer layer  176  may include relatively larger dimensions as compared to the cup  170  such that outer layer  176  extends beyond the edges of the cup  170 . 
     Thereafter, as shown in  FIGS. 10 and 11 , the method may include attaching the wire channel  216  to the outer layer  176  and the flange  186 . For so doing, as shown in  FIG. 10 , the wire channel is positioned abutting the second portion  210  of the outer layer  176  such that the second portion  210  of the outer layer  176  is sandwiched between the first side-wing  110  and the wire channel  216 . In an embodiment, the wire channel  216  may include an arch shaped profile that is complementary to an arch shape profile of the flange  186  or the second portion  210  of the outer layer  176 . As illustrated, a width of the wire channel  216  is smaller than a width of the flange  186 , and may be substantially equal to a width of the first portion  188  of the flange  186  and/or a width of the second portion  210  of the outer layer  176 . After arranging the wire channel  216  relative to the outer layer  176 , the wire channel  216  is attached to the flange  186 . In an embodiment, the wire channel  216  is attached to the flange  186  by sewing the first portion  188  of the flange  186 , the stabilizer  194 , the first side-wing  110 , and the second portion  210  of the outer layer  176  together by using third threads  274 ,  276  (best shown in  FIG. 11 ). In an embodiment, the third threads  274 ,  276  overlap the first thread  262  and the second threads  264 ,  266 . In certain implementations, the wire-channel  216  may be adhesively attached to the second portion  210  of the outer layer  176 . 
     Subsequently, as shown in  FIG. 12 , the method includes folding the outer layer  176  to enwrap the wire channel  216 . For so doing, the outer layer  176  is folded such that the wire channel  216  is sandwiched between the second portion  210  of the outer layer  176  and the third portion  212  of the outer layer  176 . In this manner, after folding of the outer layer  176 , the first portion  174  of the outer layer  176  may extend in direction opposite to the direction of extension of the first side-wing  110  and the cup  170  from the flange  186 . Upon folding the outer layer  176  around the wire channel  216 , the first portion  188  of the flange  186 , the stabilizer  194 , the first side-wing  110 , the second portion  210  of the outer layer  176 , the wire channel  216 , and the third portion  212  of the outer layer  176  may be stitched together by using fourth threads  280 ,  282 . In this manner a flange panel  290  is formed. The flange panel  290  may include the first portion  188  of the flange  186 , the stabilizer  194 , the first side-wing  110 , the second portion  210  of the outer layer  176 , the wire channel  216 , and the third portion  212  of the outer layer  176 . 
     Thereafter, as shown in FIG. 13  and  FIG. 14 , the method includes adhesively attaching the first portion  188  of the flange  186  to the second portion  190  of the flange  186 , and attaching the first portion  174  of the outer layer  176  with the cup  170  of the cup core  172 . For so doing, as shown in  FIG. 13  an adhesive is applied on the first portion  188  of the flange  186 . As shown, the adhesive is applied in the form of the adhesive layer or film  192  on the outer surface  228  of the first portion  188  of the flange  186 . The adhesive layer  192  may include an arch shaped profile that is complimentary to an arch shaped profile of the flange  186 . Thereafter, as indicated in  FIG. 14 , the first portion  174  of the outer layer  176  along with the flange panel  290  are folded along the fold line  240 , and the first portion  188  of the flange  186  is adhesively bonded with the second portion  190  of the flange  186 . Also, the first portion  174  of the outer layer  176  covers the cup  170 . Thereafter, for adhesively securing the first portion  188  of the flange  186  and the second portion  190  of the flange  186 , pressing and curing may be performed. Upon covering the cup  170  with the first portion  174  of the outer layer  176 , the edges of the outer layer  176  may be trimmed and folded to enwrap the cup  170  and adhesively attached to an inner side of the cup  170 . Thereafter, the first side-wing  110  is flipped 180 degrees (as shown in  FIG. 15 ) such that the cup  170  and the first side-wing  110  extend in opposite directions from the flange portion  140 . Additionally, or optionally, as shown in  FIG. 3 , the underwire  220  is inserted into the wire channel  216  to provide additional rigidity to the first flange portion  140 . In this manner, the first bra cup  104  is attached with the first side-wing  110  and the first flange portion  140  of the first bra cup  104  is formed. As the second portion  190  of the flange  186  is disposed on the inner side  130  of the first bra cup  104 , the inner side  130  of the first bra cup  104  is devoid any sewing thread lines, providing extra comfort and aesthetic effect to a wearer of the brassiere  100 . 
     Further, the center gore  108  is also attached to the first bra cup in a manner similar to the attachment of the first bra cup  104  with the first side-wing  110  as explained above. In an embodiment, the center gore  108  may be attached to the first bra cup  104  simultaneously during the attachment of the first bra cup  104  with the first side-wing  110 . Further, it may be appreciated that the second side-wing  112 , the second bra cup  106 , and the center gore  108  may be attached in a similar manner as described above. In this manner, the brassiere  100  is formed. 
     The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present disclosure and its practical application, to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated.