Honeycomb three-dimensional laminated foaming skeleton, cup mat, bra and preparation method of honeycomb three-dimensional laminated foaming skeleton

Abstract

The invention belongs to the technical field of underwear, and particularly relates to a honeycomb three-dimensional laminated foaming skeleton, a cup mat, a bra and a preparation method of the honeycomb three-dimensional laminated foaming skeleton. The composite material comprises a plurality of stacked honeycomb framework layers and a porous foaming body, a plurality of honeycomb holes are formed in the thickness direction of the honeycomb-shaped framework layers, and after the multiple honeycomb-shaped framework layers are stacked, the honeycomb holes of the adjacent honeycomb-shaped framework layers are communicated with one another to form a plurality of channels; the porous foaming bodies are arranged in part of the channels and fixedly connected with the inner walls of the channels. Through the combination of the honeycomb three-dimensional laminated structure and the porous foaming body, the fabric has the characteristics of softness, breathability, elastic support and natural fluffiness, and is comfortable to wear and lasting in gathering effect.

Description

Technical Field

[0001] This invention belongs to the field of underwear technology, specifically relating to a honeycomb three-dimensional layered foam skeleton, cup pad, bra and its preparation method. Background Technology

[0002] As an essential part of women's daily underwear, the comfort and shaping effect of bras directly impact the wearing experience. With women's increasing demands for clothing quality, the function of bras has evolved from simply providing support and protection to a comprehensive approach that considers aesthetics, comfort, and health. Among these components, the cup pads, as a core functional part of the bra, are particularly crucial in products designed to make small busts appear larger, playing a vital role in providing support, shaping, and enhancing wearing comfort.

[0003] Currently, the main types of padded bra cup pads on the market include solid thick sponge cup pads, ordinary foam sponge cup pads, and those with added push-up inserts. Solid thick sponge cup pads create a fuller effect by increasing thickness, ordinary foam sponge cup pads reduce weight by utilizing the foam structure, and push-up inserts achieve a cup-enlarging effect by thickening specific areas.

[0004] However, all of the above solutions have varying degrees of shortcomings: solid thick sponge cup pads are dense and heavy, causing a strong feeling of pressure and poor breathability, leading to stuffiness and stickiness with prolonged wear; ordinary foam sponge cup pads have a chaotic foam pore structure, insufficient support, and are prone to collapse and deformation after wearing, failing to achieve stable support and gathering; the gathering insert solution is prone to displacement, has poor overall softness, and feels stiff. In addition, existing cup pads generally suffer from unnatural breast shaping, either being too bulky and lacking a real soft texture, or having a short-lived gathering effect and being prone to slipping down, making it difficult to balance visual fullness, wearing comfort, and lasting support. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the aforementioned background technology and provide a honeycomb three-dimensional layered foam skeleton, a cup pad, a bra, and a method for preparing the same.

[0006] The technical solution adopted in this invention is as follows: This invention provides a honeycomb three-dimensional layered foam skeleton, comprising multiple layers of honeycomb skeleton and porous foam; the honeycomb skeleton layer has multiple honeycomb pores in its thickness direction, and after multiple layers of the honeycomb skeleton layer are stacked, the honeycomb pores of adjacent honeycomb skeleton layers are interconnected to form multiple channels; the porous foam is disposed in some of the channels, and the porous foam is fixedly connected to the inner wall of the channel. The stacking of multiple honeycomb skeleton layers forms a three-dimensional through-channel structure, providing a path for air circulation and ensuring good breathability; the porous foam is disposed in some of the channels and fixedly connected to the inner wall of the channel, providing localized reinforcement support for the skeleton while maintaining overall breathability, thus achieving a balance between breathability and support.

[0007] Furthermore, the porous foam fills the channels, thus providing support. The complete filling of the channels with the porous foam forms a tight composite structure with the honeycomb skeleton layer, effectively improving the structural strength and load-bearing capacity of the filled area, enabling the skeleton to provide stable support under pressure.

[0008] Furthermore, the thickness of the multi-layered honeycomb skeleton gradually decreases from the center to the outer periphery. This gradually varying thickness design gives the skeleton a three-dimensional shape that conforms to the curve of the human chest, with a thicker central area to provide ample support and shaping, and a thinner edge area to ensure a smooth transition with the surrounding fabric, thus improving wearing comfort.

[0009] Furthermore, the cross-section of each honeycomb cell is a regular hexagon, and the honeycomb cells of adjacent honeycomb skeleton layers are interconnected, making the channels hexagonal prisms. Regular hexagonal honeycomb cells have excellent mechanical properties, enabling the maximum structural strength with minimal material; the hexagonal prism channels make the connection between adjacent skeleton layers more stable, while facilitating the filling and fixation of the porous foam.

[0010] Furthermore, the volume of the porous foam accounts for 8%-20% of the total volume of the channels. This proportion range ensures that the skeleton has sufficient support strength while retaining most of the channels as ventilation pathways, thus achieving an optimal balance between support performance and breathability.

[0011] This invention also provides a coaster, comprising a skin-friendly layer, a honeycomb three-dimensional laminated foam skeleton, and a supporting outer layer stacked sequentially; the skin-friendly layer is in contact with the wearer's skin when worn; the honeycomb three-dimensional laminated foam skeleton includes the aforementioned honeycomb three-dimensional laminated foam skeleton; the skin-friendly layer is attached to the skin-contact side surface of the honeycomb three-dimensional laminated foam skeleton, and the supporting outer layer is attached to the outer surface of the honeycomb three-dimensional laminated foam skeleton. Through this structure, the skin-friendly layer directly contacts the wearer's skin, providing a comfortable feel; the supporting outer layer, located on the outside, provides structural support and aesthetic protection; the honeycomb three-dimensional laminated foam skeleton, located between the two layers, has a through-channel structure that allows air to circulate within the coaster, effectively dissipating moisture and heat, and keeping the wearer dry.

[0012] Furthermore, the honeycomb three-dimensional layered foam skeleton is also provided with a support portion. The support portion is raised relative to the skin-friendly layer. When worn, the support portion contacts the skin on the lower side of the wearer's chest, providing upward support. The raised structure of the support portion can conform to the contour of the lower side of the wearer's chest, forming an effective support surface, evenly distributing and transferring the weight of the chest upward, achieving an upward lifting and gathering effect, and improving the shape of the chest.

[0013] Furthermore, the honeycomb three-dimensional layered foam skeleton has a thickness of 15-17mm in the middle area of ​​the cup pad and a thickness of 2-3mm in the edge area. The greater thickness in the middle area provides ample support space and shaping effect, while the thinner thickness in the edge area makes the transition between the cup pad and the bra body and skin more natural and smooth, avoiding obvious boundary feeling and improving the invisibility and comfort of wearing.

[0014] The present invention also provides a bra, including the aforementioned cup pads. The cup portion of this bra uses a honeycomb three-dimensional layered foam skeleton as the core support structure, which combines good breathability and support, and can provide the wearer with a comfortable and healthy wearing experience.

[0015] This invention also provides a method for preparing a coaster, comprising the following steps: S1, preparation of a honeycomb three-dimensional laminated foam skeleton: forming a honeycomb skeleton layer by molding; connecting and fixing multiple layers of the honeycomb skeleton layer by hot-melt bonding to form a honeycomb three-dimensional skeleton; the honeycomb holes of adjacent honeycomb skeleton layers are interconnected, so that the entire honeycomb three-dimensional skeleton forms a three-dimensional through channel along the thickness direction; injecting foaming material into part of the channel, the foaming material expands to form a porous foam body, filling the channel and forming an integrated structure with the honeycomb three-dimensional skeleton, thus obtaining a honeycomb three-dimensional laminated foam skeleton; S2, preparation of the coaster: sequentially stacking a skin-friendly layer, a honeycomb three-dimensional laminated foam skeleton, and a supporting outer layer, and fixing them by an integrated molding process to obtain a coaster. This preparation method is simple, forming a honeycomb three-dimensional skeleton by molding and hot-melt bonding, and then forming a porous foam body by in-situ expansion of foaming material, achieving an integrated combination of skeleton and foam body, resulting in a stable and reliable structure; finally, the three layers of materials are composited and fixed by an integrated molding process, resulting in high production efficiency and suitability for mass production.

[0016] The beneficial effects of this invention are as follows: This invention forms a three-dimensional, interconnected channel structure through multiple layers of honeycomb-shaped skeleton, with the honeycomb holes of adjacent skeleton layers interconnected, providing a smooth path for air circulation and effectively solving the problem of poor breathability in traditional bra cup pads. The porous foam body is placed within some channels and fixedly connected to the inner wall of the channels, providing localized enhanced support while maintaining overall breathability, achieving a good balance between breathability and support. The thickness of the multiple honeycomb skeleton layers gradually decreases from the center to the outer periphery, giving the skeleton a three-dimensional shape that conforms to the curve of the human chest, making it comfortable and natural to wear. The cup pad adopts a three-layer composite structure: a skin-friendly layer, a honeycomb three-dimensional layered foam skeleton, and a supporting outer layer. The supporting part is raised relative to the skin-friendly layer, conforming to the lower contour of the wearer's chest to form an effective support surface, achieving an upward lifting and gathering effect. The manufacturing method achieves the integrated combination of the skeleton and the foam body through mold pressing, hot-melt bonding, and in-situ expansion of the foaming raw material. Then, the three layers of materials are composited and fixed through an integrated molding process. The process is simple, has high production efficiency, and is suitable for mass production. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the honeycomb skeleton layer of the present invention; Figure 2 This is a cross-sectional view of the honeycomb skeleton layer of the present invention; Figure 3 This is a schematic diagram of the porous foam filling of the present invention; Figure 4 This is a schematic diagram of the bra cup pad of the present invention exploding; Figure 5 This is a schematic diagram of the bra structure of the present invention; Figure 6 This is a schematic diagram of the honeycomb three-dimensional layered foam skeleton in the bra of the present invention; Figure 7 This is a flowchart illustrating the preparation process of the honeycomb three-dimensional laminated foam skeleton of the present invention. Figure 8 This is a flowchart illustrating the preparation process of the coaster according to the present invention; Figure 9 This is a cross-sectional view of the porous foam filling in Example 5.

[0018] In the diagram: 1-Honeycomb skeleton layer; 2-Porous foam; 3-Honeycomb pores; 4-Channels; 5-Skin-friendly layer; 6-Supporting outer layer; 7-Supporting part. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. Figures 1 to 9 As shown, this invention provides a honeycomb three-dimensional layered foam skeleton, cup pad, bra and its preparation method, aiming to solve the problems of poor breathability, poor support effect, low wearing comfort and difficulty in achieving both natural fluffiness and shaping effect in traditional bra cup pads in the prior art.

[0020] Example 1: like Figures 1-3 As shown, this embodiment provides a honeycomb three-dimensional laminated foam skeleton, including multiple layers of honeycomb skeleton 1 and porous foam 2.

[0021] The honeycomb skeleton layer 1 has multiple honeycomb holes 3 in the thickness direction. After multiple honeycomb skeleton layers 1 are stacked, the honeycomb holes 3 of adjacent honeycomb skeleton layers 1 are interconnected to form multiple channels 4. The porous foam 2 is disposed in some of the channels 4 and is fixedly connected to the inner wall of the channel 4.

[0022] The honeycomb-shaped skeleton layer 1 is made of sponge, preferably polyurethane sponge or polyester sponge. Sponge has a low density, making it a lightweight and flexible material for the skeleton. Its good plasticity and elasticity allow it to be molded into an ergonomic three-dimensional cup shape, providing natural support and a full feel. Each honeycomb-shaped skeleton layer 1 is formed by molding. Specifically, sheet-like polyurethane or polyester sponge is placed in a mold with honeycomb-shaped protrusions and hot-pressed at 80℃-150℃ and 1.0-3.0MPa for 20-90 seconds. The density of the honeycomb-shaped skeleton layer 1 is 25-80 kg / m³, and the skeleton wall thickness is 0.5-2.0 mm.

[0023] The honeycomb-like skeleton layer 1 has multiple honeycomb holes 3. Multiple honeycomb-like skeleton layers 1 are stacked and connected sequentially along the thickness direction to form multiple channels 4. The honeycomb holes 3 of two adjacent honeycomb-like skeleton layers 1 are aligned and connected to each other, thus forming multiple three-dimensional through channels 4 in the thickness direction of the entire honeycomb three-dimensional laminated foam skeleton. The cross-section of the honeycomb holes 3 is all regular hexagonal with a diameter of 3-10mm. After the honeycomb holes 3 of two adjacent honeycomb-like skeleton layers 1 are connected to each other, the channels 4 are hexagonal prisms. The regular hexagonal honeycomb units have natural mechanical stability, and the hexagonal prism channels 4 form a regular three-dimensional through structure between the layers, which not only ensures the air permeability of the overall structure, but also provides uniformly distributed support.

[0024] The multi-layered honeycomb skeleton 1 is fixed together by hot-melt bonding. Specifically, 2-5 layers of honeycomb skeleton 1 are stacked one on top of the other, and hot-melt adhesive is sprayed or rolled onto the interlayer contact surfaces. Then, hot-press bonding is performed at 70℃-120℃ and 0.2-1.0MPa for 15-50 seconds to form a stable honeycomb three-dimensional skeleton. The interlayer connections of the multi-layered honeycomb skeleton 1 are strong and do not block the channels 4. The stacked honeycomb three-dimensional skeleton forms a three-dimensional through channel 4 inside. The through-cavity provides molding space for the foaming process while giving the overall structure excellent air permeability.

[0025] A porous foam body 2 is disposed within a portion of the channels 4, and is fixedly connected to the inner wall of the channels 4. The porous foam body 2 fills the channels 4, thus providing support. The porous foam body 2 is a TPU elastic foam, prepared using an in-mold foaming process. Specifically, thermoplastic polyurethane (TPU) foam granules or pre-foamed slurry are injected into a portion of the channels 4 of the honeycomb three-dimensional skeleton using a metering injection device. Then, it is foamed at a foaming temperature of 150℃-200℃ for 15-50 minutes, allowing the TPU raw material to expand and fill the space within the channels 4. The foam body interlocks with the inner wall structure of the honeycomb skeleton layer 1, forming an integrated structure, resulting in a honeycomb three-dimensional layered foam skeleton. After foaming, cooling and shaping are performed by placing the blank in an environment of 10℃-30℃ for 10-25 minutes to stabilize the overall structure. The overall density after filling is 60-180 kg / m³. TPU elastic foam has excellent air permeability, support, and elastic recovery properties, and its bond with the honeycomb skeleton layer 1 is firm, preventing separation or detachment even after multiple washes. Of course, other foam materials with similar properties can also be used.

[0026] The volume of the porous foam 2 accounts for 8%-20% of the total volume of the channel 4. Within the channel 4, the porous foam 2 provides some support for the honeycomb skeleton layer 1, thus exhibiting better dimensional stability and elastic recovery performance when the honeycomb three-dimensional laminated foam skeleton is subjected to external forces. However, this also leads to a decrease in its softness. When the volume percentage of the porous foam 2 is less than 8%, the amount of foam filling the channel 4 is too small, making it difficult to form an effective support structure, resulting in insufficient overall support and a tendency for collapse and deformation. When the volume percentage of the porous foam 2 is greater than 20%, the excessive amount of foam filling the channel 4 will block the airflow path within the channel 4, leading to decreased breathability and increased overall weight, reducing user comfort. When the volume percentage of the porous foam 2 in the channel 4 is between 8% and 20%, a relatively ideal effect is achieved in terms of support, softness, and breathability. Specifically, 8%, 10%, 12%, 14%, 16%, 18%, and 20% can be used, with 10% being preferred. At this ratio, the porous foam 2 can provide stable support while retaining sufficient air circulation space, so that the honeycomb structure through cavity and the porous characteristics of the foam material form a dual air-permeable channel, ensuring smooth air circulation and balancing support and breathability.

[0027] The thickness of the multi-layered honeycomb skeleton layer 1 gradually decreases from the center to the periphery, forming a gradient thickness distribution. Through this structure, the gradual thickening from the edge to the center generates a natural cohesive guiding force, while the edge transition is natural, avoiding the abruptness of traditional structures.

[0028] Example 2: like Figures 4-6 As shown, this embodiment provides a coaster and a bra using the coaster.

[0029] The coaster comprises a skin-friendly layer 5, a honeycomb three-dimensional laminated foam skeleton, and a supporting outer layer 6, stacked sequentially. The honeycomb three-dimensional laminated foam skeleton adopts the structure of the honeycomb three-dimensional laminated foam skeleton in Example 1. When worn, the skin-friendly layer 5 is in contact with the wearer's skin; the skin-friendly layer 5 adheres to the skin-contacting side surface of the honeycomb three-dimensional laminated foam skeleton, and the supporting outer layer 6 adheres to the outer surface of the honeycomb three-dimensional laminated foam skeleton. The inner contour of the supporting outer layer 6 completely conforms to the outer contour of the honeycomb three-dimensional laminated foam skeleton, and the edge of the supporting outer layer 6 is aligned with the edges of the skin-friendly layer 5 and the honeycomb three-dimensional laminated foam skeleton to ensure a smooth composite structure. The skin-friendly layer 5, the honeycomb three-dimensional laminated foam skeleton, and the supporting outer layer 6 are fixedly connected by a thermoforming composite method to form an integrated structure.

[0030] The honeycomb-shaped, layered foam framework serves as the core functional layer, composed of multiple honeycomb-shaped framework layers, forming a dual structure of three-dimensional support and fluffy foam. This honeycomb-shaped, layered foam framework covers the entire cup area of ​​the pad, with a thickness of 15-17mm in the central area and 2-3mm at the edges. The thickness gradually decreases from the center to the periphery and gradually increases from the edges to the center. This gradient thickness design creates a natural guiding force for the breasts, combined with the overall curved contour of the pad, drawing the breasts towards the center for a long-lasting lifting effect. Simultaneously, the edges transition naturally, avoiding the constricting feeling of traditional push-up pads.

[0031] The honeycomb-like layered foam framework also features a support section 7, which protrudes relative to the skin-friendly layer 5 and is located near the lower side of the honeycomb-like layered foam framework. When the wearer wears the bra, the skin-friendly layer 5 is in direct contact with the wearer's skin, while the support section 7, in the wearing state, contacts the skin on the lower side of the wearer's breasts, providing upward support. Through the design of the support section 7, the breasts are firmly supported, preventing sagging, and simultaneously lifting the breasts to achieve a cup size increase effect. Furthermore, the breast shape remains stable during walking and activity, without shifting or collapsing.

[0032] In this embodiment, the through-cavity structure of the three-dimensional honeycomb structure and the porous nature of the foam material form a dual breathable channel, allowing for smooth airflow and solving the problem of stuffiness and stickiness associated with traditional thick bra pads. The low density of the foam material significantly reduces the overall weight of the bra pad compared to traditional solid sponge pads, resulting in a weightless wearing experience. Using a bra pad with a honeycomb-like three-dimensional layered foam skeleton provides stable support for the breasts and lifts them upwards, offering soft elasticity, stable support, and a gathered, lifted feel.

[0033] This embodiment also provides a bra, including the aforementioned cup pads. The bra's cup portion uses a honeycomb three-dimensional layered foam skeleton as its core support structure, which combines good breathability and support, providing the wearer with a comfortable and healthy wearing experience.

[0034] Example 3: like Figures 7-8 As shown, this embodiment provides a method for preparing a coaster, including the following steps.

[0035] S1. Preparation of honeycomb three-dimensional stacked foam skeleton: A honeycomb-shaped skeleton layer 1 is formed by molding. Specifically, sheet-like polyurethane foam or polyester foam is placed in a mold with honeycomb-shaped protrusions and hot-pressed for 20-90 seconds at a temperature of 80℃-150℃ and a pressure of 1.0-3.0MPa to form the honeycomb-shaped skeleton layer 1. The honeycomb pores 3 of the honeycomb-shaped skeleton layer 1 are regular hexagonal with a pore diameter of 3-10mm, a skeleton wall thickness of 0.5-2.0mm, and a density of 25-80kg / m³.

[0036] The interlayer connections of the multi-layer honeycomb skeleton 1 are fixed by hot melt bonding to form a honeycomb three-dimensional skeleton. Specifically, 2-5 layers of honeycomb skeleton 1 are stacked vertically aligned, hot melt adhesive is applied to the interlayer contact surfaces, and hot-pressed for 15-50 seconds at a temperature of 70℃-120℃ and a pressure of 0.2-1.0MPa to form a honeycomb three-dimensional skeleton.

[0037] The honeycomb holes 3 of two adjacent honeycomb skeleton layers 1 are interconnected, so that the entire honeycomb three-dimensional skeleton forms a three-dimensional through channel 4 along the thickness direction. The channel 4 is hexagonal prism.

[0038] Foaming material is injected into channel 4, where it expands to form porous foam 2, filling channel 4 and forming an integrated structure with the honeycomb three-dimensional skeleton, resulting in a honeycomb three-dimensional laminated foam skeleton. Specifically, TPU foaming particles or pre-foamed slurry are injected into part of the channels 4 of the honeycomb three-dimensional skeleton and foamed at 150℃-200℃ for 15-50 minutes, allowing the foaming material to expand within the channels 4 to form porous foam 2. The porous foam 2 is embedded with the inner wall of the honeycomb skeleton layer 1 to form an integrated structure, with an overall density of 60-180 kg / m³ after filling, and the volume of the porous foam 2 accounting for 8%-20% of the total volume of channel 4. The foamed and filled preform is cooled and shaped at 10℃-30℃ for 10-25 minutes to obtain a honeycomb three-dimensional laminated preform.

[0039] The honeycomb-shaped, multi-layered blank is then placed in a bra cup mold. Through die-cutting or milling, the blank is trimmed into a bra cup shape with a thickness that gradually decreases from the center to the outer periphery, forming a honeycomb-shaped, multi-layered foam skeleton. By first layering to form a blank of uniform thickness and then die-cutting it into a cup shape, the processing technology is simple, suitable for mass production, and the trimmed cup shape has a smooth outline and natural edge transition.

[0040] The support portion 7 is located near the lower side of the honeycomb three-dimensional laminated foam skeleton. Its molding is performed simultaneously with the above steps or as a separate subsequent process. In the simultaneous molding scheme, a special mold with a locally raised structure is used to prepare the bottom honeycomb skeleton layer. This mold has an upwardly raised cavity at the corresponding support portion position, with a raised height of 3-8mm. The outline of the raised area is arc-shaped and conforms to the lower curve of the human chest. During the hot pressing and shaping process, the sponge material forms a preliminary support portion shape that protrudes upward relative to the main skeleton layer in this cavity area. During subsequent lamination and bonding, the skeleton layers in the support portion area are stacked in descending order of the raised outline, so that the support portion as a whole presents a smooth transition shape that gradually tapers from the base to the top. In the foam filling step, the channels in the support portion area are preferentially filled with TPU foam, and the filling ratio can be appropriately increased to 15%-20% to enhance the support rigidity of the support portion. In the standalone molding scheme, the support part is pre-prepared as an independent component, using the same materials and processes as the honeycomb three-dimensional laminated foam skeleton. After molding, it is fixed to the lower skin-contact area of ​​the honeycomb three-dimensional laminated foam skeleton by hot melt bonding.

[0041] S2. Preparation of coasters: The skin-friendly layer 5, the honeycomb three-dimensional layered foam skeleton, and the supporting outer layer 6 are sequentially stacked and fixed through an integrated molding process to obtain the coaster. Specifically, the skin-friendly layer fabric and the supporting outer layer fabric are cut according to the unfolded outline of the coaster, with the cut pieces 5-15mm larger than the outer contour of the honeycomb three-dimensional layered foam skeleton on each side. The cut skin-friendly layer fabric is laid flat in the lower mold cavity of the molding mold. The honeycomb three-dimensional layered foam skeleton obtained in S1 is placed on the skin-friendly layer fabric, with the supporting part facing the corresponding groove position at the bottom of the cavity. Finally, the supporting outer layer fabric is covered on the honeycomb three-dimensional layered foam skeleton. After mold closing, hot pressing is performed at a temperature of 90℃-140℃ and a pressure of 1.0-3.0MPa for 20-60 seconds to form an integrated composite structure of the three layers. After hot pressing, the edges of the coaster blank are trimmed and bound to obtain the finished coaster.

[0042] Example 4: This embodiment provides another method for preparing a honeycomb three-dimensional laminated foam skeleton. The difference from Embodiment 3 is that a gradient size lamination process is used to directly form a cup-shaped structure.

[0043] Based on the design outline of the bra cup, the dimensions of each honeycomb skeleton layer 1 are pre-planned to present a gradient distribution from large to small. Specifically, multiple sheets of polyurethane or polyester foam with successively decreasing areas are selected and placed into honeycomb molds matching their respective dimensions. They are then hot-pressed and shaped for 20-90 seconds at a temperature of 80℃-150℃ and a pressure of 1.0-3.0MPa to produce multiple honeycomb skeleton layers 1 with varying areas. The honeycomb pores 3 of each honeycomb skeleton layer 1 are all hexagonal, with a pore diameter of 3-10mm, a skeleton wall thickness of 0.5-2.0mm, and a density of 25-80kg / m³.

[0044] The multi-layered honeycomb skeleton 1 is assembled by stacking layers one by one in descending order of size, with the largest honeycomb skeleton 1 as the bottom layer and the smallest honeycomb skeleton 1 as the top layer, and each layer is positioned with its center point aligned. During the stacking process, it is ensured that the honeycomb holes 3 of adjacent honeycomb skeleton layers 1 are interconnected, forming a channel 4 that runs through the thickness direction. Hot melt adhesive is applied to the contact surfaces between each layer by spraying or roller coating, and hot-pressed for 15-50 seconds at a temperature of 70℃-120℃ and a pressure of 0.2-1.0MPa to fix each layer into a whole. Because the area of ​​each layer decreases progressively, the stacked skeleton naturally presents a bra cup-shaped honeycomb three-dimensional stacked skeleton that is thicker in the center and thinner at the periphery.

[0045] TPU foam granules or pre-foamed slurry are injected into some channels 4 of the honeycomb three-dimensional laminated skeleton using a quantitative injection device. Foaming is then carried out at 150℃-200℃ for 15-50 minutes, allowing the TPU material to expand within the channels 4 to form porous foam bodies 2. The porous foam bodies 2 interlock with the inner walls of the honeycomb skeleton layer 1 to form an integrated structure. After filling, the overall density is 60-180 kg / m³, and the volume of the porous foam bodies 2 accounts for 8%-20% of the total volume of the channels 4. After foaming, the preform is cooled and set at 10℃-30℃ for 10-25 minutes to obtain the honeycomb three-dimensional laminated foamed skeleton.

[0046] This embodiment achieves a cup-shaped structure with gradually varying thickness directly during the lamination and bonding stage by prefabricating honeycomb skeleton layers of different sizes and stacking them in a gradient sequence. This eliminates the need for subsequent die-cutting or milling trimming processes, reducing material waste and improving raw material utilization. Simultaneously, the stepped cross-sectional structure formed by the gradient stacking clearly defines the number of layers and thickness in each region, providing a more significant zoned support effect. The central region has more layers and stronger support, while the edge regions have fewer layers and a smoother transition.

[0047] Example 5: like Figure 9 As shown, this embodiment provides another honeycomb three-dimensional laminated foam skeleton, which differs from Embodiment 1 in the connection method between the multi-layer honeycomb skeleton layers 1 and the distribution pattern of the porous foam 2.

[0048] In this embodiment, adjacent honeycomb skeleton layers 1 are fixedly connected only at the edge regions, while the central regions are not bonded. Specifically, after stacking 2-5 honeycomb skeleton layers 1 one on top of the other, hot melt adhesive is sprayed or rolled onto annular areas with an edge width of 5-15mm for each layer. The layers are then hot-pressed for 15-50 seconds at a temperature of 70℃-120℃ and a pressure of 0.2-1.0MPa, thus fixing the edge regions of adjacent honeycomb skeleton layers 1 together while keeping the central regions separate.

[0049] The porous foam 2 is disposed in the central region of the honeycomb skeleton layer 1. During the foaming process, TPU foam particles or pre-foamed slurry are injected into the channels 4 in the central region of the honeycomb three-dimensional skeleton, and foamed for 15-50 minutes at a temperature of 150℃-200℃. During the foaming process, the TPU raw material expands within the channels 4. Since the central regions of adjacent honeycomb skeleton layers 1 are not bonded, the expansion force generated by foaming pushes the central regions of each honeycomb skeleton layer 1 outward, forming interlayer cavities between adjacent honeycomb skeleton layers 1. The porous foam 2 continues to expand and fill the channels 4 and interlayer cavities, interlocking with the inner walls of the honeycomb skeleton layers 1 and the cavity walls of the interlayer cavities to form an integrated structure. After foaming, the preform is placed in an environment of 10℃-30℃ for cooling and shaping for 10-25 minutes. After the porous foam 2 is shaped, the raised shape of the honeycomb skeleton layer 1 is fixed, resulting in a honeycomb three-dimensional laminated foam skeleton.

[0050] In this embodiment, because the middle of each honeycomb skeleton layer 1 is lifted up by the porous foam 2, the middle of the entire honeycomb three-dimensional laminated foam skeleton presents a natural three-dimensional convex shape, while the outer peripheral edge area is relatively flat, thus forming a three-dimensional cup-shaped structure with a high center and low edges. The presence of interlayer cavities increases the overall fluffiness and thickness of the honeycomb three-dimensional laminated foam skeleton, giving the central area a more substantial three-dimensional effect. At the same time, the porous foam 2 fills the interlayer cavities, providing support from the inside out for the raised honeycomb skeleton layer 1, keeping the three-dimensional convex shape stable and preventing collapse.

[0051] Compared to Example 1, this example utilizes the expansion force of foaming to naturally form a three-dimensional cup-shaped structure, resulting in a simpler process. The interlayer cavities make the overall structure more fluffy and lightweight, with better breathability. The adhesive connection in the edge area ensures the integrity of the connection between each honeycomb skeleton layer 1, preventing interlayer separation. The edge area is not filled with porous foam 2, resulting in a thinner thickness and a smooth, natural transition, allowing for a comfortable fit against the skin without pressure when worn.

[0052] In summary, this invention constructs a honeycomb-shaped layered foam skeleton that combines structural support and breathability by thermally melting and bonding multiple layers of sponge material into a honeycomb skeleton layer, and injecting TPU foaming material into some channels to expand and form a porous foam. The honeycomb skeleton layer provides the overall structural framework, and the porous foam forms an integrated structure with the skeleton in some channels to enhance support strength and elastic recovery performance. Unfilled channels remain open to ensure breathability. The open channels of the three-dimensional honeycomb structure and the porous characteristics of the foam material form a dual breathable channel. This skeleton is combined with a skin-friendly layer and a supporting outer layer through an integrated thermoforming process to form a cup pad, which is then applied to a bra. During wear, it provides stable support and a cup-lifting effect while allowing good air circulation. The overall weight of the cup pad is significantly reduced compared to traditional solid sponge cup pads, improving wearing comfort.

[0053] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains. The terms “first,” “second,” and similar terms used in this patent application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms “an” or “a” and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms “comprising” or “including” and similar terms mean that the elements or objects preceding “comprising” or “including” encompass the elements or objects listed following “comprising” or “including” and their equivalents, and do not exclude other elements or objects. The terms “connected” or “linked” and similar terms are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. The terms “upper,” “lower,” “left,” and “right” are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0054] The above description is merely an optional embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A honeycomb three-dimensional laminated foamed skeleton, characterized by: It includes a multi-layered honeycomb skeleton layer (1) and a porous foam (2); The honeycomb skeleton layer (1) has multiple honeycomb holes (3) in the thickness direction. After multiple honeycomb skeleton layers (1) are stacked, the honeycomb holes (3) of adjacent honeycomb skeleton layers (1) are interconnected to form multiple channels (4). The porous foam (2) is disposed in a portion of the channel (4), and the porous foam (2) is fixedly connected to the inner wall of the channel (4).

2. The honeycomb three-dimensional laminated foamed framework according to claim 1, wherein: The porous foam (2) fills the channel (4) in which it is located, thereby providing support.

3. The honeycomb three-dimensional laminated foamed framework according to claim 1, wherein: The thickness of the multi-layered honeycomb skeleton layer (1) gradually decreases from the center to the outer periphery.

4. The honeycomb three-dimensional laminated foamed framework according to claim 1, wherein: The cross-section of each honeycomb hole (3) is a regular hexagon. The honeycomb holes (3) of two adjacent honeycomb skeleton layers (1) are interconnected, making the channel (4) hexagonal prism.

5. The honeycomb three-dimensional laminated foam skeleton according to claim 2, characterized in that: The volume of the porous foam (2) accounts for 8%-20% of the total volume of the channel (4).

6. A coaster, characterized in that: It includes a skin-friendly layer (5) stacked in sequence, a honeycomb three-dimensional stacked foam skeleton and a supporting outer layer (6); The skin-friendly layer (5) comes into contact with the wearer's skin when worn; The honeycomb three-dimensional laminated foam skeleton includes the honeycomb three-dimensional laminated foam skeleton according to any one of claims 1-5; the skin-friendly layer (5) is attached to the skin-friendly side surface of the honeycomb three-dimensional laminated foam skeleton, and the supporting outer layer (6) is attached to the outer surface of the honeycomb three-dimensional laminated foam skeleton.

7. A coaster according to claim 6, characterized in that: The honeycomb three-dimensional layered foam skeleton is also provided with a support part (7). The support part (7) is raised relative to the skin-friendly layer (5). When worn, the support part (7) contacts the skin on the lower side of the wearer's chest and provides upward support.

8. A coaster according to claim 7, characterized in that: The honeycomb three-dimensional laminated foam skeleton has a thickness of 15-17mm in the middle area of ​​the coaster and a thickness of 2-3mm in the edge area.

9. A bra, characterized in that: Includes the coaster as described in any one of claims 6-8.

10. A method for preparing a coaster according to any one of claims 6-8, characterized in that, Includes the following steps: S1. Preparation of honeycomb three-dimensional laminated foam skeleton: honeycomb skeleton layer is formed by molding (1). The interlayer connections of the multi-layer honeycomb skeleton (1) are fixed by hot melt bonding to form a honeycomb three-dimensional skeleton; The honeycomb holes (3) of the two adjacent honeycomb skeleton layers (1) are interconnected, so that the entire honeycomb three-dimensional skeleton forms a three-dimensional through channel (4) along the thickness direction. The foaming material is injected into part of the channel (4), and the foaming material expands to form a porous foam (2), which fills the channel (4) and forms an integrated structure with the honeycomb three-dimensional skeleton to obtain a honeycomb three-dimensional layered foam skeleton. S2. Preparation of coasters: The skin-friendly layer (5), the honeycomb three-dimensional layered foam skeleton, and the supporting outer layer (6) are stacked in sequence and fixed by an integrated molding process to obtain coasters.

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