A mold cup, its low-temperature molding production process and a female underwear containing the mold cup thereof

Abstract

The application relates to a mold cup and a low-temperature mold pressing production process thereof and a female underwear containing the mold cup. The mold cup body comprises a first cloth layer, a glue film layer, a first sponge layer, a first glue layer, a second sponge layer, a second glue layer, a third sponge layer, a third glue layer, a second cloth layer, a shaping piece and a supporting piece. The mold cup has good shaping effect and is not prone to deformation. The preparation method of the mold cup comprises the following steps that the second cloth layer, the third sponge layer, the shaping piece, the second sponge layer, the second glue layer and the third glue layer are sequentially stacked and molded to obtain an A piece; the A piece, the first glue layer, the supporting piece and the first sponge layer are sequentially stacked and molded to obtain a B piece; the B piece is combined with the glue film layer, plastic suction is performed to obtain a C piece; and the C piece is sequentially stacked with the first cloth layer, mold pressing is performed at a mold pressing temperature of 130-165 DEG C, cooling is performed, and cutting is performed to obtain the mold cup. The method is simple in operation, the obtained mold cup is stable in structure, and the mold pressing at a low temperature is not prone to yellowing and other phenomena.

Description

Technical Field

[0001] This application relates to the technical field of underwear, and more specifically, it relates to a molded cup, a low-temperature molding process thereof, and women's underwear containing the molded cup. Background Technology

[0002] Underwear refers to clothing worn close to the skin, including vests, t-shirts, shorts, tube tops, and bras. Among these, bras are the most widely used, and bras include molded cups. The molded cups are mainly used to cover and support the breasts. Bras are generally an important item in women's lives, serving to support and protect the breasts, while also making the breasts look beautiful.

[0003] Reference Figure 1 The molded cup includes a lower support 100, a lower bowl 102, a side panel 103, and a center gore 101. When worn, the lower bowl 102 fits against the lower part of the woman's breasts and provides support, while the lower support 100 is located at the lower edge of the lower bowl 102 and provides support. The side panel 103 is placed against the armpit and is usually connected to the back strap. The center gore 101 is located between the two breasts.

[0004] However, current molded cups are prone to deformation after prolonged wear, which reduces their support for the breasts and affects the wearer's comfort. Summary of the Invention

[0005] To address the above technical problems, this application provides a molded cup, its low-temperature molding production process, and women's underwear containing the molded cup.

[0006] In a first aspect, this application provides a molded cup, including a molded cup body. The inner surface to the outer surface of the molded cup body are sequentially provided with a first fabric layer, an adhesive film layer, a first sponge layer, a first adhesive layer, a second sponge layer, a second adhesive layer, a third sponge layer, a third adhesive layer, and a second fabric layer. The lower support portion of the molded cup body is provided with a shaping member. Both ends of the shaping member extend to the side edge of the molded cup and are fixedly connected. One side of the shaping member extends to the center portion and the lower bowl portion of the molded cup. The shaping member is fixed between the second adhesive layer and the third sponge layer. The molded cup body is provided with a support member. The support member extends to the side edge, the lower support portion, and the lower bowl portion of the molded cup. The support member is fixed between the first sponge layer and the first adhesive layer.

[0007] The molded cup of this application is an integrally molded cup. By using adhesive layers (first adhesive layer, second adhesive layer, and third adhesive layer), the first fabric layer, second fabric layer, second sponge layer, and third sponge layer can be bonded stably, thereby forming a structurally stable molded cup. By setting a shaping component, the shaping component has a strength of 50g / mm². 2The polyester shaping yarn can increase the thickness of the center, side, lower cup, and lower support of the molded cup. After molding, the structure of these parts is stabilized, making the shape of the molded cup stable. As a result, it is less likely to deform when worn, resulting in better support and a more snug fit to the woman's breasts. This helps prevent the breasts from sagging and makes them more aesthetically pleasing.

[0008] Preferably, the support member includes a sponge insert, side cartilage, and supporting cartilage. The side cartilage and the supporting cartilage are evenly connected to the sponge insert through a fourth adhesive layer. The side cartilage is located on the side of the mold cup, and the supporting cartilage is located at the connection between the lower support part and the lower bowl part of the mold cup.

[0009] By incorporating side and support cartilage, the lower support and side panels of the molded cup can be shaped, reducing the possibility of deformation and making the molded cup fit the woman's breast better. This improves the support and resistance to deformation, resulting in a more aesthetically pleasing breast. The sponge insert acts as a cushion, reducing direct contact between the side and support cartilage and the breast, thus enhancing the comfort of the molded cup. The side cartilage is made of PA6 material; the support cartilage is made of TPE material.

[0010] Secondly, this application provides a low-temperature molding production process for producing molded cups, including the following preparation steps: 1) stacking the second fabric layer, the third adhesive layer, the third sponge layer, the shaping part, the second adhesive layer, and the second sponge layer in sequence, molding them, with a molding temperature of 187-193℃ and a molding time of 140-160s to obtain A-piece;

[0011] 2) Stack the A-piece, the first adhesive layer, the support sheet, and the first sponge layer in sequence, and mold them. The molding temperature is 187-193℃ and the molding time is 200-220s to obtain the B-piece; cover the B-piece with the adhesive film layer, and vacuum form it. The vacuum forming temperature is 155-165℃ and the vacuum forming time is 1-3s to obtain the C-piece.

[0012] 3) Place the first fabric layer on piece C, mold it at a temperature of 130-165℃ for 40-60 seconds, cool it, and cut it to obtain the molded cup.

[0013] Preferably, the specific steps in 1) are as follows: hot melt adhesive is sprayed onto one side of the third sponge layer to form a third adhesive layer, then the second fabric layer is bonded to the third adhesive layer to obtain a cut piece, then the cut piece is placed inside the mold with the second fabric layer facing the mold, then the shaping part is placed on the third sponge layer, then hot melt adhesive is sprayed to form a second adhesive layer, then the second sponge layer is placed on the second adhesive layer, and then molding is performed. The molding temperature is 185-195℃, and the molding time is 140-160s to obtain piece A.

[0014] Preferably, the specific steps in 2) are as follows: hot melt adhesive is sprayed onto the second sponge layer of piece A to form a first adhesive layer; self-adhesive is applied to one side of the first sponge layer, and then the side of the first sponge layer with self-adhesive is placed on the first adhesive layer, and the tray and the first sponge are stacked on the first adhesive layer in sequence, wherein the self-adhesive side of the first sponge layer is attached to the tray and the first adhesive layer, and molding is performed at a molding temperature of 187-193℃ and a molding time of 200-220s to obtain piece B; the adhesive film layer is placed on the first sponge of piece B, and vacuum forming is performed at a vacuum forming temperature of 155-165℃ and a vacuum forming time of 1-3s to obtain piece C.

[0015] Preferably, the specific steps in 3) are as follows: place the first fabric layer on the adhesive film layer of the C sheet, mold it, the molding temperature is 130-165℃, the molding time is 40-60s, cool it, and cut it to obtain the molded cup.

[0016] Existing technologies for manufacturing molded cups typically use temperatures exceeding 200 degrees Celsius for molding and bonding. Some processes use 170-180 degrees Celsius for pressing. The applicant has found that molding and bonding at temperatures above 170 degrees Celsius leads to the following problems: Since the fabric used in molded cups is generally delicate and soft, molding and bonding at temperatures above 170 degrees Celsius causes the fabric to yellow and harden. In addition, if dust adheres to the fabric, heating at temperatures above 170 degrees Celsius can also generate carbon, reducing the quality of the finished product. Furthermore, heating the production equipment to temperatures above 170 degrees Celsius requires a longer heating time, resulting in reduced production efficiency and a poor feel to the molded cups, affecting the comfort of women wearing them.

[0017] Therefore, this application uses a third adhesive layer and a second adhesive layer formed by spraying hot melt adhesive to bond the second fabric layer, the third sponge layer, the shaping sheet, and the second sponge together. After molding, piece A is obtained. Then, a first adhesive layer is formed by spraying hot melt adhesive, so that the support and the first sponge layer are sequentially bonded to the first adhesive layer. Piece B is then molded. Since the side of the first sponge closest to the support is coated with self-adhesive, the first sponge can be stabilized on piece A, reducing the phenomenon of the first sponge shifting during molding, thereby improving the molding accuracy. The molding temperature in the above steps is as high as about 190°C (both the upper and lower molds are about 190°C), which can better connect the layer structure of piece A and the layer structure of piece B tightly, making it less likely to become scattered. In addition, since the second fabric layer in this step is the surface fabric of the molded cup, it does not come into contact with the human skin when the molded cup is worn, and waterproof fabric is preferred. It has good temperature resistance and waterproofness. When the temperature reaches about 190℃, the fabric will not turn yellow due to excessive temperature, and at the same time, the molded cup has good waterproofness.

[0018] In this application, the C-sheet is formed by covering the B-sheet with an adhesive film layer before entering a vacuum forming device for vacuum forming. This allows the adhesive film layer to adhere to the B-sheet. The principle of this vacuum forming device is that the B-sheet is placed on a vacuum forming mold, which has an air suction hole and an air extraction machine at the bottom. This air extraction machine creates negative pressure at the air suction hole, thereby stabilizing the B-sheet on the vacuum forming mold. When the adhesive film layer is placed, the negative pressure generated by the air suction passes through the B-sheet, stabilizing the adhesive film layer on the B-sheet. Then, through a heating module, the adhesive film is heated and melted. Due to the negative pressure, the molten adhesive film layer adheres even more tightly to the B-sheet, thus completing the vacuum forming process and stabilizing the layer structure of the C-sheet. The process temperature is around 150℃. At this low temperature, the B-piece adheres well to the adhesive film. Finally, the C-piece is bonded to the first fabric layer and then molded. During molding, only the upper mold is heated. The purpose is twofold: firstly, the C-piece is close to the upper mold, ensuring a stable bond between the first sponge and the adhesive film of the C-piece during hot pressing; secondly, the upper mold is only heated to around 140℃ during hot pressing, preventing wrinkles or yellowing of the first fabric layer after hot pressing, thus reducing yellowing and hardening of the inner surface of the molded cup and improving wearer comfort. Alternatively, the molding process of the C-piece and the first fabric layer can also use a vacuum forming device. Specifically, the C-piece is first placed in a vacuum forming mold, and negative pressure is created in the suction holes of the mold by suction, thus fixing the C-piece. After the first fabric layer is placed, the continuous negative pressure in the suction holes also fixes the first fabric layer. Then, it enters the heating module for heating, melting the adhesive film layer. The continuous negative pressure in the suction holes further ensures that the first fabric layer adheres tightly to the C-piece.

[0019] Preferably, the first fabric layer has a density of 110-150 g / m². 2 The polyester double-layer fabric has a second layer of 100-120 g / m². 2 Waterproof fabric.

[0020] This waterproof fabric is made primarily of PE, PU, ​​TPU, PTFE, and other materials. The high-weight polyester double-stretch fabric is soft and comfortable, conforms better to the human body and leather clothing, and improves the comfort of the molded cups.

[0021] Preferably, the shaping component has a strength of 40-60 g / m³. 2 The polyester shaping yarn has a second sponge layer of 8-12mm, and the thickness of the first sponge layer, the third sponge layer, and the sponge support piece are all 2.5-4.5mm.

[0022] Selecting a molded part of this weight provides a better shaping effect, resulting in a stable mold cup structure.

[0023] By selecting the above range of sponge layer thicknesses (first sponge layer, second sponge layer, third sponge layer, and sponge support), the resulting molded cup has a better support effect and is not easily deformed. At the same time, it makes the molded cup more breathable and fits the human skin better.

[0024] Preferably, the first adhesive layer, the second adhesive layer, the third adhesive layer, and the fourth adhesive layer are all made of PUR hot melt adhesive, and the adhesive film layer is made of TPU adhesive film with a thickness of 0.01-0.02 mm.

[0025] PUR is short for polyurethane. PUR is a polymer with repeating urethane chain segments, produced by the reaction of isocyanate and polyol. PUR hot melt adhesive has good adhesion, thus stabilizing the layered structure of the semi-finished product. This, in turn, stabilizes the layered structure of the mold cup. Furthermore, the thickness of the first, second, third, and fourth adhesive layers is all 0.008-0.01 mm. This thickness range ensures stable layered bonding in the mold cup.

[0026] TPU is a thermoplastic elastomer. TPU film is an adhesive film made from TPU material, possessing good elasticity and adhesion. Therefore, it can stably bond C-sheets to semi-finished products, forming a stable mold cup with a layered structure, reducing deformation, and improving the structural stability of the mold cup. Simultaneously, the TPU film is waterproof, preventing it from easily detaching during cleaning, further enhancing the structural stability and usability of the mold cup. Furthermore, using a TPU film with a thickness of 0.01-0.02mm offers good adhesion, is cost-effective, and can stably bond the various layers of the mold cup.

[0027] Furthermore, the melting point of the TPU film is preferably 80-110℃.

[0028] Furthermore, the TPU film is a polyether-type TPU film.

[0029] The polyether-type TPU film has good adhesion and can be hot-melted at low temperatures, thus stabilizing the bonding of the mold cup layers.

[0030] Furthermore, in the molded cup manufacturing process of this application, in step 3) and during the molding or vacuum forming process of sheet C, only the upper mold / heating module is heated. To ensure uniform heating of the entire molded cup, this application further modifies the TPU film. This modified TPU film has good thermal conductivity, adhesion, water resistance, and toughness, enabling the heat from the upper mold / heating module to be quickly transferred to each layer of the molded cup structure, further stabilizing the bonding of the layer structure of the molded cup. It also provides good adhesion between layers, thus stabilizing the layer structure of the molded cup and reducing the likelihood of deformation during use.

[0031] This modified TPU film is composed of the following raw materials in parts by weight:

[0032] Polyether-type TPU granules: 100 parts

[0033] Titanium ester coupling agent: 0.01-0.03 parts

[0034] Nano zinc dioxide: 0.1-0.3 parts

[0035] Hexagonal boron nitride: 0.2-0.5 parts

[0036] Silica powder: 0.08-0.2 parts

[0037] Acrylic rosin: 1-3 parts

[0038] Synthetic plant esters: 5-8 parts.

[0039] The polyether-type TPU granules have a melt index of 5-10 g / min, a Shore hardness of 95A, and a softening point of 70-80℃; the acrylic rosin has an acid value of 200-210 mgKOH / g and a softening point of 97-103℃, exhibiting good adhesion and improving the adhesion of modified TPU films.

[0040] Nano zinc oxide, with a particle size of 30-50 nanometers, possesses thermal conductivity and antibacterial properties. Hexagonal boron nitride, with a particle size of 10-30 nanometers, exhibits good thermal conductivity and insulation. Silica powder, with a particle size of 20-40 nm, also demonstrates good thermal conductivity. Therefore, the composite of nano zinc oxide, silica powder, and hexagonal boron nitride improves the thermal conductivity of the modified TPU film, enabling rapid heat transfer between the layers of the mold cup, resulting in uniform heating and stable adhesion of the mold cup's layers. Simultaneously, the antibacterial effect of nano zinc oxide enhances the antibacterial properties of the modified TPU. Furthermore, the addition of a titanate coupling agent provides excellent coupling, improving the compatibility of nano zinc oxide, silica powder, and hexagonal boron nitride within the polymer, thereby enhancing the thermal conductivity and toughness of the modified TPU film.

[0041] The addition of synthetic plant esters, with a specific gravity of 1.12 g / cm³, further enhances the process. 3 It has a flash point of 185-195°C and a lipid content of 99%. Synthetic plant esters are environmentally friendly plasticizers with good plasticizing effects, which in turn can improve the toughening effect of modified films.

[0042] Furthermore, the modified TPU film is prepared by the following method:

[0043] Weigh 0.01-0.03 parts by weight of titanate coupling agent, 0.1-0.3 parts of nano zinc white powder, 0.2-0.5 parts of hexagonal boron nitride, and 0.08-0.2 parts of silica powder, mix for 20-35 minutes to obtain mixture A; then add 100 parts of polyether-type TPU particles, 1-3 parts of acrylic rosin, and 5-8 parts of synthetic plant ester to mixture A, mix for 15-30 minutes, extrude, and cast into a film to obtain modified TPU film.

[0044] This modified TPU film has good adhesion, thermal conductivity and toughness. When used to produce molded cups, the heat from the upper mold is quickly transferred to the lower mold when the upper mold is pressed down. During this process, the heat between the molded cup layers can be uniformly heated, thereby improving the bonding stability of the molded cup layers and reducing the deformation of the molded cup when pulled.

[0045] Thirdly, this application provides a women's underwear, which includes a molded cup made by a low-temperature molding process.

[0046] The women's underwear made by this application is not easy to yellow or harden, and it is not easy to deform during wear, thus improving the practicality of women's underwear. In addition, the shape of the first fabric layer of the molded cup can be vest-shaped, which can make the molded cup into vest-style underwear, thus expanding the application of molded cups.

[0047] In summary, this application has the following beneficial effects:

[0048] 1. The use of an adhesive film layer ensures stable bonding of each sponge layer, forming a structurally stable molded cup. By setting up shaping components, side cartilage, and supporting cartilage, the lower structure of the molded cup can be stabilized, reducing the possibility of deformation and making the molded cup fit the woman's breast better, improving the support and anti-deformation properties of the molded cup, thus making the woman's breast more aesthetically pleasing.

[0049] 2. This application uses a relatively high temperature (both upper and lower molds are around 190℃) to press and bond the A and B sheets, thus better connecting the layered structures of the A and B sheets and preventing them from becoming disorganized. The C sheet and the vacuum forming or molding in step 3) are performed at a lower temperature (around 150℃) to reduce overheating of the first fabric layer, which could lead to yellowing or hardening. This improves the comfort of the molded cup. Attached Figure Description

[0050] Figure 1 This is a schematic diagram of the structure of a molded cup according to this application.

[0051] Figure 2 This is a schematic diagram of the layer structure of a mold cup according to this application.

[0052] Figure 3This is a schematic diagram of the mechanical structure of the mold cup body described in this application.

[0053] Figure 4 This is a schematic diagram of the test mold cup's length, width, and clamping position.

[0054] Figure 5 These are schematic diagrams of structures that have undergone deformation and those that have not.

[0055] Reference numerals: 1. First fabric layer; 2. Adhesive film layer; 3. First sponge; 4. First adhesive layer; 5. Second sponge layer; 6. Second adhesive layer; 7. Third sponge layer; 8. Third adhesive layer; 9. Second fabric layer; 10. Shaping component; 11. Sponge insert; 12. Support cartilage; 13. Lateral cartilage; 14. Fourth adhesive layer; 100. Lower support part; 101. Chicken heart part; 102. Lower bowl part; 103. Side part. Detailed Implementation

[0056] Example

[0057] Example 1

[0058] This embodiment discloses a molded cup, referring to... Figure 2 and Figure 3 The molded cup body includes a first fabric layer 1, a film layer 2, a first adhesive layer 4, a second sponge layer 5, a second adhesive layer 6, a third sponge layer 7, a third adhesive layer 8, and a second fabric layer 9, arranged sequentially from the inner surface to the outer surface. A shaping member 10 is fixed within the second adhesive layer 6 and the third sponge layer 7 of the molded cup body. This shaping member 10 is located in the lower support portion 100 of the molded cup, and both ends of the shaping member 10 extend to the edge of the side portion 103 of the molded cup for fixation, thus stabilizing it. One side of the shaping member 10 extends to the center portion 101 and the lower bowl portion 102 of the molded cup. The shaping member 10 reduces deformation of the molded cup and improves its practicality.

[0059] A support member is fixed between the film layer 2 and the first adhesive layer 4 of the molded cup body. The support member extends to the side panel 103, the lower support portion 100, and the lower bowl portion 102 of the molded cup. The support member includes a sponge insert 11 connecting the film layer 2, a fourth adhesive layer 14 bonding the sponge insert 11, and side cartilage 13 and support cartilage 12 bonding the fourth adhesive layer 14. The side of the side cartilage 13 and support cartilage 12 away from the fourth adhesive layer 14 is fixedly connected to the first adhesive layer 4. The side cartilage 13 is located at the side panel 103 of the molded cup and can play a gathering role, making the woman's breasts fuller when worn. The support cartilage 12 is located at the connection between the lower support portion 100 and the lower bowl portion 102 of the molded cup and plays a supporting role for the breasts, reducing cup deformation and improving the practicality of the molded cup.

[0060] Example 2

[0061] A low-temperature molding process for producing the mold cup of Example 1 is obtained by the following method:

[0062] 1) A roller with adhesive is used to roll-coat the surface of the third sponge layer, thereby removing the dust on the third sponge layer and keeping the surface of the third sponge layer clean. Hot melt adhesive is sprayed on one side of the third sponge layer to form a third adhesive layer. Then, the second fabric layer is placed on the surface of the third adhesive layer to bond the second fabric layer with the third adhesive layer, thus obtaining the cut piece.

[0063] Next, place the cut piece inside the mold, and install the positioning pins (these positioning pins are installed at the four corners of the cut piece to fix the material to the mold). The second fabric layer abuts against the lower mold. Align the shaping part with the center position (the center position refers to the center position of the mold) and place it on the third sponge layer of the cut piece. Then spray hot melt adhesive onto the surface of the shaping part and the third sponge layer (when the shaping part is placed on the surface of the third sponge layer, the shaping part does not completely cover the surface of the third sponge layer. Therefore, when spraying hot melt adhesive, both the surface of the shaping part and the surface of the third sponge layer that is not covered by the shaping part are sprayed) to form a second adhesive layer. Then, stack the second sponge layer on the surface of the second adhesive layer and then perform molding. The molding temperature of both the upper and lower molds is 185℃, and the molding time is 140s to obtain piece A.

[0064] 2) After the A-piece is molded, its shape is similar to that of the mold cup. At the same time, after molding, a side groove and a support groove are formed on one side of the second sponge layer of the A-piece. Hot melt adhesive is sprayed on the second sponge layer of the A-piece to form a first adhesive layer. The side groove is located at the side of the mold cup (A-piece), and the support groove is located at the junction of the lower support part and the lower bowl part of the mold cup (A-piece). The support cartilage is placed in the support groove, and the side cartilage is placed in the side groove.

[0065] Hot melt adhesive is sprayed onto the surface of the sponge support to form a fourth adhesive layer, resulting in a composite. The composite is then stacked on the surfaces of the lateral cartilage and the supporting cartilage, ensuring that the composite completely covers the lateral cartilage and the supporting cartilage. One side of the fourth adhesive layer of the composite is in contact with the lateral cartilage and the supporting cartilage. Adhesive is applied to one side of the first sponge layer, and then the adhesive-coated side of the first sponge layer is stacked with the side of the composite away from the lateral cartilage. Molding is then performed, with the temperature of both the upper and lower molds at 187°C and the molding time at 200 seconds, resulting in piece B.

[0066] The adhesive film layer is placed on the first sponge of piece B, and vacuum-formed at a temperature of 155°C for 1 second to obtain piece C.

[0067] 3) Place the first fabric layer on the adhesive film layer of the C sheet and then mold it. The lower mold is not heated, but the upper mold needs to be heated to 130°C. The molding time is 40 seconds to obtain a semi-finished product. Then take out the semi-finished product and put it into a cold mold for cooling (this will help it maintain a good shape). Then trim its edges to obtain a mold cup.

[0068] Among them, the shaping part is 50g / mm 2 The polyester shaped yarn, the first fabric layer is 110g / m 2 The polyester double-layer fabric has a second layer of 110g / m². 2 The waterproof fabric; the second sponge layer is 10mm thick, and the thickness of the first sponge layer, the third sponge layer, and the sponge insert is 3mm thick; the first adhesive film, the second adhesive film, the third adhesive film, and the fourth adhesive film all use PUR hot melt adhesive, and the adhesive film layer uses TPU adhesive film with a thickness of 0.015mm.

[0069] Examples 2-4

[0070] The difference between Examples 2-4 and Example 1 lies in the different process conditions, as shown in Table 1.

[0071] Table 1 Process conditions for Examples 2-4

[0072]

[0073] Example 5

[0074] The difference between Example 5 and Example 2 is that the thickness of the TPU film is 0.01 mm.

[0075] Example 6

[0076] The difference between Example 6 and Example 2 is that the thickness of the TPU film is 0.02 mm.

[0077] Example 7

[0078] The difference between Example 7 and Example 2 is that the TPU film is a modified TPU film, which is prepared by the following steps:

[0079] Weigh 0.01 kg of titanate coupling agent, 0.1 kg of nano zinc white powder, 0.2 kg of hexagonal boron nitride, and 0.08 kg of silicon micro powder, and mix them in a high-speed mixer for 20 min to obtain mixture A. Then add 100 kg of polyether-type TPU granules, 1 kg of acrylic rosin, and 5 kg of synthetic plant ester to mixture A, mix for 15 min, and then put it into an extruder for extrusion. The temperatures of the first to twelfth sections of the extruder are 185℃, 180℃, 175℃, 175℃, 175℃, 175℃, 175℃, 175℃, 175℃, 180℃, and 185℃, respectively, and the extrusion die is 190℃. Then use a film casting machine to cast the film to obtain a modified TPU film.

[0080] The difference between Examples 8-9 and Example 7 is that the amount of raw materials used is different, as shown in Table 2.

[0081] Table 2. Raw material usage (kg) for Examples 7-9

[0082] raw material Example 7 Example 8 Example 9 Polyether-type TPU particles 100 100 100 Acrylic rosin 1 2 3 Synthetic plant esters 5 6.5 8 Silica powder 0.08 0.15 0.2 Hexagonal boron nitride 0.2 0.3 0.5 Nano zinc white powder 0.1 0.2 0.3 Titanate coupling agent 0.01 0.02 0.03

[0083] Comparative Example

[0084] Comparative Example 1

[0085] The difference between Comparative Example 1 and Example 2 is that the heating temperature in 2) is 200°C.

[0086] Comparative Example 2

[0087] The difference between Comparative Example 2 and Example 2 is that the heating temperature in 2) is 100°C.

[0088] Comparative Example 3

[0089] The difference between Comparative Example 3 and Example 2 is that the TPU film was replaced with a TPE film.

[0090] Comparative Example 4

[0091] The difference between Comparative Example 4 and Example 2 is that Comparative Example 4 uses one-time molding, and the specific steps are as follows:

[0092] 1) A roller with adhesive is used to roll-coat the surface of the third sponge layer, thereby removing the dust on the third sponge layer and keeping the surface of the third sponge layer clean. Hot melt adhesive is sprayed on one side of the third sponge layer to form a third adhesive layer. Then, the second fabric layer is placed on the surface of the third adhesive layer to bond the second fabric layer with the third adhesive layer, thus obtaining the cut piece.

[0093] Next, place the cut piece inside the mold, attach the positioning pins, and the second fabric layer abuts against the lower mold; align the shaping part with the center of the cut piece and place it on the third sponge layer of the cut piece, then spray hot melt adhesive onto the surface of the shaping part and the third sponge layer to form a second adhesive layer, and then stack the second sponge layer on the surface of the second adhesive layer, and then perform molding. The molding temperature of both the upper and lower molds is 185℃, and the molding time is 140s to obtain piece A.

[0094] 2) After the A-piece is molded, its shape is similar to that of the mold cup. At the same time, after molding, a side groove and a support groove are formed on one side of the second sponge layer of the A-piece. Hot melt adhesive is sprayed on the second sponge layer of the A-piece to form a first adhesive layer. The side groove is located at the side of the mold cup (A-piece), and the support groove is located at the junction of the lower support part and the lower bowl part of the mold cup (A-piece). The support cartilage is placed in the support groove, and the side cartilage is placed in the side groove.

[0095] Hot melt adhesive is sprayed onto the surface of the sponge support to form a fourth adhesive layer, resulting in a composite. The composite is then stacked on the surfaces of the lateral cartilage and the supporting cartilage, ensuring that the composite completely covers the lateral cartilage and the supporting cartilage. One side of the fourth adhesive layer of the composite is in contact with the lateral cartilage and the supporting cartilage. Adhesive is applied to one side of the first sponge layer, and then the adhesive-coated side of the first sponge layer is stacked with the side of the composite away from the lateral cartilage. The adhesive film layer and the first fabric layer are then stacked on top of the first sponge layer, and the mixture is heated to 170°C and molded for 241 seconds to obtain a molded cup.

[0096] Comparative Example 5

[0097] The difference between Comparative Example 5 and Example 2 is that Comparative Example 5 does not contain a shaping part, but all other aspects are the same.

[0098] Comparative Example 6

[0099] The difference between Comparative Example 6 and Example 7 is that acrylic rosin was replaced with an equal amount of polyether-type TPU particles.

[0100] Comparative Example 7

[0101] The difference between Comparative Example 7 and Example 7 is that hexagonal boron nitride was replaced with an equal amount of nano zinc white powder.

[0102] Application examples

[0103] Application Example 2-16

[0104] A type of women's underwear, made from the molded cups of Examples 2-16.

[0105] Performance testing

[0106] Detection methods / test methods

[0107] The mold cups prepared in Examples 2-9 and Comparative Examples 1-5 were subjected to the following performance tests.

[0108] 1. Appearance

[0109] Observe the surface of the mold cup to see if it turns yellow, wrinkles, or delamination (referring to the separation between layers). Touch the surface to see if there are any lumps or other phenomena. If yellowing, wrinkling, or lumps are present, it is unqualified. If none of the above phenomena are present, it is qualified.

[0110] 2. Deformation resistance test

[0111] Measure the longitudinal length of the mold cup (the definition of longitudinal length is shown in the attached diagram). Figure 4 As shown in the figure, the longitudinal length of the mold cup is recorded as A1; a force of 5N is applied to pull the mold cup longitudinally for 30s (two tension clamps are clamped on the upper section and the lower support of the mold cup respectively), and after 5min, the longitudinal length of the mold cup is measured again and recorded as A2; the deformation rate of the longitudinal length is A2-A1 / A1*100%, and the specific data is shown in Table 3.

[0112] Measure the lateral length of the mold cup (the definition of lateral length is shown in the attached diagram). Figure 4 As shown in the figure, it is recorded as B1; a force of 5N is applied to pull the mold cup laterally for 30s (two tension clamps are clamped on the side of the mold cup respectively), and then the longitudinal length of the mold cup is measured. After 5min, it is recorded as B2; the deformation rate of this lateral length = B2-B1 / B1*100%, and the specific data is shown in Table 3.

[0113] Table 3. Experimental data of Examples 2-10 and Comparative Examples 1-5

[0114]

[0115] As can be seen from Table 3 above, when the temperature of molding or hot pressing reaches 200℃, the mold cup will turn yellow. When the temperature drops to 100℃, the layer structure of the mold cup becomes unstable, resulting in delamination. Delamination will also occur when the TPU film is replaced with a TPE film.

[0116] Comparing Comparative Example 4 and Example 2, it can be seen that the longitudinal and transverse length deformation rates of Comparative Example 4 are greater than those of Example 2, indicating that the comparative example undergoes more significant deformation. It can be seen that the mold cup prepared by the method is less prone to deformation.

[0117] Comparing Comparative Example 5 and Example 2, it can be seen that the longitudinal and transverse length deformation rates of Comparative Example 5 are greater than those of Example 2, indicating that the mold cup has already deformed when no shaping component is added. The deformation is shown in the attached figure. Figure 5 As shown, the addition of a shaping component in this application has a better shaping effect.

[0118] 1. Thermal conductivity

[0119] According to the national standard GB / T2588-2008, the modified TPU films obtained in Examples 7-9 and Comparative Examples 6-7 were tested using a thermal conductivity tester, as shown in Table 4.

[0120] 4. Adhesion test

[0121] The modified TPU films obtained in Examples 7-9 and Comparative Examples 6-7 were subjected to the following tests, with the specific steps as follows: TPU sheets, modified TPU films, and TPU sheets were stacked in sequence and hot-pressed at 150°C for 40 seconds, followed by cooling for 50 minutes to obtain a composite board; the TPU sheet thickness was 2 mm, and the width and length were both 10 cm; a 2 mm opening was made at the bonding joint of the composite board, and the peel strength was tested using an 80-degree peel strength tester (model XM-DZ01) at 180°C and a test speed of 150 mm / min. When the TPU sheets were separated, the relevant data were recorded, as shown in Table 4.

[0122] Table 4. Experimental data for Examples 7-9 and Comparative Examples 6-7

[0123] Test Items Thermal conductivity (W / mK) Peel strength (N / mm) Example 7 12.1 7.4 Example 8 11.3 6.9 Example 9 11.6 7.2 Comparative Example 5 11.0 3.5 Comparative Example 6 7.3 6.8

[0124] Table 4 shows that the modified TPU film exhibits poor adhesion without the addition of acrylic rosin, indicating that the addition of acrylic rosin effectively improves the adhesion of the modified TPU film. Furthermore, the thermal conductivity of the modified TPU film decreases without the addition of hexagonal boron nitride, demonstrating that the composite of nano-zinc dioxide, hexagonal boron nitride, and silicon micropowder provides better thermal conductivity, resulting in more uniform heating of the mold cup's layer structure and a more stable mold cup structure.

[0125] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

Claims

1. A low-temperature molding process for producing molded cups, characterized in that: The molded cup includes a molded cup body. The inner surface of the molded cup body is provided with a first fabric layer (1), a film layer (2), a first sponge (3) layer, a first adhesive layer (4), a second sponge layer (5), a second adhesive layer (6), a third sponge layer (7), a third adhesive layer (8), and a second fabric layer (9) in sequence from the outer surface to the inner surface. The lower support part (100) of the molded cup body is provided with a shaping member (10). The two ends of the shaping member (10) extend to the edge of the side part (103) of the molded cup and are fixedly connected. One side of the shaping member (10) extends to the center part (101) and the lower bowl part (102) of the molded cup. The shaping member (10) is fixed between the second adhesive layer (6) and the third sponge layer (7). The molded cup body is provided with a support member. The support member extends to the side part (103), the lower support part (100), and the lower bowl part (102) of the molded cup. The support member is fixed between the first sponge (3) layer and the first adhesive layer (4). The low-temperature molding process for this molded cup includes the following preparation steps: 1) Stack the second fabric layer, the third adhesive layer, the third sponge layer, the shaping part, the second adhesive layer, and the second sponge layer in sequence, and mold them. The molding temperature is 187-193℃ and the molding time is 140-160s to obtain piece A. 2) Stack the A-piece, the first adhesive layer, the support sheet, and the first sponge layer in sequence, and mold them together. The molding temperature is 187-193℃ and the molding time is 200-220s to obtain the B-piece. Cover the B-piece with the adhesive film layer and vacuum form it. The vacuum forming temperature is 155-165℃ and the vacuum forming time is 1-3s to obtain the C-piece. 3) Place the first fabric layer on piece C, mold it at a temperature of 130-165℃ for 40-60 seconds, cool it, and cut it to obtain the molded cup; The first fabric layer is a 110-150g / m2 polyester double-layer fabric, and the second fabric layer is a 100-120g / m2 waterproof fabric; The shaping component is made of 40-60g / m2 polyester shaping yarn, the second sponge layer is 8-12mm thick, and the thickness of the first sponge layer, the third sponge layer, and the sponge insert is 2.5-4.5mm. The first adhesive layer, the second adhesive layer, the third adhesive layer, and the fourth adhesive layer are all made of PUR hot melt adhesive, and the adhesive film layer is made of TPU adhesive film with a thickness of 0.01-0.02mm.

2. The low-temperature molding process for producing a molded cup according to claim 1, characterized in that: The support includes a sponge insert (11), a lateral cartilage (13), and a supporting cartilage (12). The lateral cartilage (13) and the supporting cartilage (12) are evenly connected to the sponge insert (11) through a fourth adhesive layer (14). The lateral cartilage (13) is located on the side of the mold cup (103), and the supporting cartilage (12) is located at the connection between the lower support part (100) and the lower bowl part (102) of the mold cup.

3. The low-temperature molding process for producing a molded cup according to claim 1, characterized in that, The specific steps in step 1) are as follows: hot melt adhesive is sprayed onto one side of the third sponge layer to form a third adhesive layer, then the second fabric layer is bonded to the third adhesive layer to obtain a cut piece, then the cut piece is placed inside the mold with the second fabric layer facing the mold, then the shaping part is placed on the third sponge layer, hot melt adhesive is sprayed onto it to form a second adhesive layer, then the second sponge layer is placed on the second adhesive layer, and then it is molded. The molding temperature is 185-195℃ and the molding time is 140-160s to obtain piece A.

4. The low-temperature molding process for producing a molded cup according to claim 1, characterized in that, The specific steps in step 2) are as follows: hot melt adhesive is sprayed onto the second sponge layer of piece A to form the first adhesive layer; self-adhesive is applied to one side of the first sponge layer, and then the self-adhesive side of the first sponge layer is placed on the first adhesive layer, with the tray and the first sponge layer stacked on the first adhesive layer in sequence, wherein the self-adhesive side of the first sponge layer is attached to the tray and the first adhesive layer, and molding is performed at a molding temperature of 187-193℃ and a molding time of 200-220s to obtain piece B; the adhesive film layer is placed on the first sponge of piece B, and vacuum forming is performed at a vacuum forming temperature of 155-165℃ and a vacuum forming time of 1-3s to obtain piece C.

5. The low-temperature molding process for producing a molded cup according to claim 1, characterized in that, The specific steps in 3) are as follows: place the first fabric layer on the adhesive film layer of the C sheet, mold it, the molding temperature is 130-165℃, the molding time is 40-60s, cool it, cut it, and obtain the molded cup.

6. A type of women's underwear, characterized in that, The underwear includes molded cups, which are manufactured by a low-temperature molding process according to any one of claims 1-5.

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