Highly breathable perforated shell cup forming elastic mechanism

Abstract

The utility model provides a kind of high-breathability punching cover cup forming elastic mechanism, cooperate hot-pressing die to use, the hot-pressing die includes die and male die, the elastic mechanism includes spring mechanism and curve pressing plate, the curve pressing plate is located between die and male die, the spring mechanism connects curve pressing plate and male die;Male die part passes through curve pressing plate, and the hot-pressing forming of porous flexible pattern piece material group is carried out, can avoid the hole structure collapse and wrinkle of porous flexible pattern piece material group.The utility model can guarantee medium-thick cup good support and three-dimensional modeling at the same time, realize the one-time forming of high-density hole, ensure that hole profile is clear, distribution is uniform, surface is smooth, and truly reach the unity of high-breathability and excellent appearance quality.

Description

Technical Field

[0001] This utility model relates to the field of textile and garment manufacturing technology, and more specifically, to a highly breathable perforated cup forming elastic mechanism. Background Technology

[0002] In the women's underwear manufacturing industry, bra cups, as a core structural component, not only serve the functions of shaping, support, and aesthetics, but also increasingly emphasize comfort and breathability during wear. With consumers' growing demand for healthy, lightweight, and freely breathing experiences, the development of highly breathable bra cups has become an important direction for technological upgrading in the industry.

[0003] Currently, most mainstream heat-pressed bra cups on the market employ a process where sheet materials (such as polyurethane foam, memory foam, etc.) are directly cut into a predetermined shape and then placed in a high-temperature mold for heat pressing. This technology enables precise shaping of the bra cup and possesses good resilience and structural stability. It is widely used in medium-thickness cup products to meet the wearing effect needs of women with small breasts for "gathering and filling, and visually enlarging" the cup.

[0004] However, traditional heat-pressed molded bra cups have significant drawbacks: their dense structure and lack of effective ventilation channels result in poor breathability, leading to stuffiness, sweating, and discomfort during prolonged wear, severely impacting comfort. To address this issue, the industry has experimented with perforating the sponge or fabric during the cutting stage to create a microporous structure and improve airflow. While these perforated cups offer some improvement in breathability, several technical limitations remain.

[0005] First, existing perforated cups are mostly concentrated on thin cups with small apertures and sparse distribution, which are mainly suitable for low-strength support scenarios. For medium-thick cups that require higher structural strength and three-dimensional shaping capabilities, there is no technical solution that can achieve one-time hot pressing molding, high-density through holes and good appearance quality, which is a gap in the industry.

[0006] Secondly, when the sponge layer or composite fabric is densely perforated, the local strength of the material decreases significantly, especially in the area where the surface fabric and the sponge layer meet. The perforation disrupts the structural continuity, making it highly susceptible to defects such as peri-perforation, uneven surface, blurred perforation, or even closure during high-temperature, high-pressure hot pressing. This not only affects the aesthetic quality of the product but also weakens its actual breathability, making it difficult to achieve the user experience goal of "visible breathability."

[0007] In addition, existing drilling processes are mostly mechanical punching or laser perforation, lacking a design concept for synergistic optimization with hot pressing processes, and failing to systematically solve the contradiction between "breathability" and "molding stability" from the perspectives of structural support, material matching, and molding mechanics.

[0008] Chinese patent CN209090090U discloses a bra cup forming device, which includes a first template, a second template, and a third template. The second and third templates are connected by a guide rod and a first elastic element. When the first template moves downward, it can drive the punch to move downward and press it into the die on the second template, pushing the second template to move downward against the elastic force of the first elastic element. When the first template moves upward, the punch and die separate. The bra cup forming device provided by this utility model can avoid the bra cup from breaking or cracking, ensuring the quality of the formed bra cup. However, in the production of highly breathable perforated bra cups, defects such as perforation, uneven surface, blurred perforation, or even closure are very likely to occur.

[0009] Therefore, there is a need for a highly breathable perforated cup molding elastic mechanism to meet the market's urgent demand for a new generation of functional bras that combine support and breathability. Utility Model Content

[0010] The purpose of this utility model is to provide a highly breathable perforated cup forming elastic mechanism that can achieve one-time forming of high-density holes while ensuring good support and three-dimensional shape of medium-thick cups. This ensures that the hole outlines are clear, the distribution is uniform, and the surface is flat, truly achieving a unity of high breathability and excellent appearance quality.

[0011] To achieve the above objectives, this utility model provides a highly breathable perforated cup forming elastic mechanism. The technical solution of this utility model is implemented as follows:

[0012] A highly breathable perforated cup forming elastic mechanism is used in conjunction with a hot press mold. The hot press mold includes a concave mold and a convex mold. The elastic mechanism includes a spring mechanism and a curved pressure plate. The curved pressure plate is located between the concave mold and the convex mold. The spring mechanism connects the curved pressure plate and the convex mold. The convex mold passes through the curved pressure plate to perform hot pressing forming on the porous flexible cut piece material group, which can prevent the hole structure of the porous flexible cut piece material group from collapsing and wrinkling.

[0013] Furthermore, the spring mechanism includes an extension plate and a spring assembly, the extension plate being fixedly connected to the punch, and the spring assembly connecting the extension plate and the curved pressure plate.

[0014] Furthermore, the spring assembly includes a spring and an adjustable bolt.

[0015] Furthermore, the curved pressure plate is provided with through holes, and the adjustable bolt can pass through the curved pressure plate and move along the through holes.

[0016] Furthermore, the curved pressure plate is provided with a hollow area that matches the contour of the cup to be formed, and the punch closes with the die through the hollow area.

[0017] Furthermore, the lower surface of the curved pressure plate is provided with an inner edge, which cooperates with the die to guide the pressure distribution and prevent excessive extrusion.

[0018] Furthermore, the shape of the inner edge of the pressure plate is consistent with the outer curved surface of the die, and extends outward into a curved loop.

[0019] Furthermore, the porous flexible cut-piece material group is a multi-layer porous material.

[0020] Compared with existing technologies, the high-breathability perforated cup forming elastic mechanism of this utility model has the following advantages:

[0021] 1. Adaptive pressure adjustment: The spring mechanism can adjust the applied force in real time according to the material deformation, avoiding local damage or stress concentration caused by rigid pressing.

[0022] 2. Precise contour fit: The curved pressure plate is designed according to the curved surface of the cup, and the curvature of its lower surface complements the upper surface of the bottom mold, ensuring that the pressure is evenly transmitted along the three-dimensional curved surface and improving the molding accuracy.

[0023] 3. Hole Protection Function: Driven by the elasticity of the spring mechanism, the punch applies progressive contact and uniform pressure to the porous flexible cut material assembly via a curved pressure plate. In a heated and softened state, the porous flexible cut material assembly undergoes a combined deformation process of local compression and peripheral stretching on the curved surface of the die. Particularly in the hole area, a bidirectional tensile stress field is formed, causing the hole walls to extend and the hole shape to flatten, effectively preventing hot-pressing collapse and wrinkling. This ultimately achieves an integrated cup structure with clear holes, high air permeability, and a smooth surface. Simultaneously, by rationally arranging the positions of the through holes and spring components, internal air pressure accumulation is reduced, further preventing hole closure or collapse during hot pressing, ultimately achieving a "highly breathable and visible" product effect.

[0024] 4. Simple and reliable structure: The entire mechanism consists only of a spring assembly and a curved pressure plate, requiring no complex hydraulic or pneumatic system, resulting in low maintenance costs and convenient installation.

[0025] 5. Wide range of applications: It is suitable for hot pressing of multi-layer flexible cut pieces of different thicknesses (such as medium-thick cups B~D cups) and different materials (TPU, EVA, sponge composite fabric, etc.), and has good process compatibility.

[0026] 6. High-efficiency production in one step: The concave and convex dies complete the entire process of heating, pressurizing and shaping, eliminating the need for subsequent trimming or hole filling processes, which significantly improves production efficiency. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the high-breathability perforated cup forming elastic mechanism of Embodiment 1 of this utility model;

[0028] Figure 2This is a schematic diagram of the high-breathability perforated cup forming elastic mechanism and mold installation in Embodiment 1 of this utility model;

[0029] Figure 3 This is a schematic diagram of the curved pressure plate of Embodiment 1 of this utility model;

[0030] Figure 4 This is a schematic diagram of the porous flexible cut sheet material assembly of Embodiment 1 of this utility model;

[0031] Figure 5 This is a schematic diagram of the working state of the high-breathability perforated cup forming elastic mechanism of Embodiment 1 of this utility model;

[0032] Figure 6 This is a schematic diagram of the stress on the high-breathability perforated cup of Embodiment 1 of this utility model;

[0033] Figure 7 This is a product image of the high-permeability perforated cup forming elastic mechanism of Embodiment 1 of this utility model.

[0034] Explanation of reference numerals in the attached figures:

[0035] 1. Spring mechanism; 2. Curved pressure plate; 3. Die; 4. Punch; 5. Multi-hole flexible cut piece material assembly; 11. Extension plate; 12. Spring assembly; 13. Mold mounting hole; 21. Through hole; 22. Inner edge of pressure plate; 51. Inner layer; 52. Middle layer; 53. Surface layer. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the described embodiments are only some, not all, of the embodiments of this utility model. The specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model. It should be noted that, unless otherwise specified, the embodiments and features described in the present utility model can be combined with each other.

[0037] This invention provides a highly breathable perforated bra cup forming elastic mechanism. By optimizing the structure and pressure distribution, it achieves one-time hot-press forming of a multi-layered flexible fabric material assembly with perforations, ensuring a smooth appearance, clear and rounded holes, and excellent breathability in the finished bra cup, thus improving wearing comfort. The elastic mechanism is used in conjunction with a hot-pressing mold, which includes a concave mold 3 and a convex mold 4. The elastic mechanism includes a spring mechanism 1 and a curved pressure plate 2. The curved pressure plate 2 is located between the concave mold 3 and the convex mold 4, and the spring mechanism 1 connects the curved pressure plate 2 and the convex mold 4. The convex mold 4 partially passes through the curved pressure plate 2 to hot-press the multi-layered flexible fabric material assembly 5, preventing the collapse and wrinkling of the perforated structure of the multi-layered flexible fabric material assembly 5.

[0038] The spring mechanism 1 includes an extension plate 11 and a spring assembly 12. The extension plate 11 is fixedly connected to the punch 4, and the spring assembly 12 connects the extension plate 11 and the curved pressure plate 2. The spring mechanism 1 achieves pressure buffering and local adaptive adjustment through elastic deformation. Multiple sets of spring assemblies 12 can be arranged between the extension plate 11 and the curved pressure plate 2 to maintain the stability of the elastic mechanism. The spring mechanism 1 can also be provided with multiple extension plates 11, which cooperate with the spring assemblies 12 to enhance the overall structural stability.

[0039] The extension plate 11 is made of metal, and its dimensions and structure are compatible with the mold. The spring assembly 12 includes a spring and an adjustable bolt; the spring model and specifications are compatible with the hot-pressing mold. The spring force is adjusted by the spring model and compression depth. The required spring force is calculated based on the stretchability of the flexible cut material and the depth of the mold.

[0040] The spring length L depends on the relative position between the die 3 and the punch 4 and the spring deformation x. The spring deformation x is calculated from the required elastic force F, using the formula: x = F / k. Here, F is the elastic force generated by the spring, in Newtons (N) or kilonewtons (kN); k is the spring constant (elastic coefficient), in Newtons per meter (N / m), representing the force generated when the spring is compressed or stretched by one meter; and x is the spring deformation, in meters (m), referring to the difference between the current length of the spring and its original free length.

[0041] For common cylindrical helical springs, the formula for calculating the spring constant (k) is:

[0042] k=(G×d 4 ) / (8×D 3 ×N), where G is the shear modulus of the spring material, in Pascals (Pa); d is the wire diameter; D is the mean diameter; and N is the number of effective turns.

[0043] The complete calculation process is as follows:

[0044] S01, Calculate the spring constant k based on the spring's geometric parameters: k = (G × d 4 ) / (8×D 3 ×N);

[0045] S02, calculate the compression amount x according to the required elastic force F: x=F / k.

[0046] The punch 4 is fixed to the top crossbeam by bolts or clips, and the bottom is connected to the extension plate 11. The two ends of the extension plate 11 are connected to the curved pressure plate 2 by spring assembly 12, realizing the three-level linkage of "punch 4-spring mechanism 1-curved pressure plate 2".

[0047] The curved pressure plate 2 is located below the spring mechanism 1, and its middle section has a hollow area that matches the contour of the cup to be formed. The punch 4 closes with the die 3 through the hollow area. The lower surface of the curved pressure plate 2 has an inner edge 22 to guide pressure distribution and prevent excessive compression. The gap width between the curved pressure plate 2 and the die 3 is determined by factors including the thickness of the porous flexible cut piece material group 5, the stretchability of the porous flexible cut piece material group 5, and the thickness of the target cup.

[0048] Preferably, the curved pressure plate 2 is made of wood. The width of the curved pressure plate 2 matches that of the extension plate 11, and the length of the curved pressure plate 2 is not less than the sum of the bottom mold length of the punch 4 and twice the width of the extension plate 11. The bottom mold length of the punch 4 is set according to the cup mold model and different cup sizes. The curved pressure plate 2 is provided with a through hole 21, and an adjustable bolt can pass through the curved pressure plate 2 and move along the through hole 21.

[0049] Preferably, the shape of the inner edge 22 of the pressure plate is consistent with the outer curved surface of the die 3, and extends outward into a curved ring. The inner edge 22 of the pressure plate cooperates with the die 3, which can uniformly pressurize the porous flexible cut material group 5 during the hot pressing process and prevent the holes from collapsing.

[0050] The porous flexible fabric panel 5 is a multi-layered porous material, consisting of at least three layers: an inner layer 51, a middle layer 52, and a surface layer 53. These layers can be pre-laminated or bonded together during hot pressing. Preferably, the surface layer 53 is a perforated sponge bonded to the fabric, the middle layer 52 is a perforated sponge core that can be added, and the inner layer 51 is a large-pore perforated sponge bonded to the fabric. The size and shape of the porous flexible fabric panel 5 are determined by the shape of the bra cup surface and the process requirements.

[0051] The concave mold 3 is fixedly installed on the hot press platform and has a concave cavity that matches the shape of the target cup. It is used to support and shape the porous flexible cut piece material group 5.

[0052] The punch 4 is located above the die 3 and is connected to the curved pressure plate 2 through the spring mechanism 1. It applies pressure during the downward movement to complete the final shaping.

[0053] The inner edge 22 of the curved pressure plate 2 matches the shape of the material to achieve a balance between local pressure concentration and uniform distribution; while the spring mechanism 1 dynamically responds according to the elastic deformation of the material and automatically adjusts the pressure to prevent local overload caused by material shrinkage or thickness fluctuation.

[0054] In particular, the through holes 21 on the curved pressure plate 2 are designed to allow some gas to escape, reducing the accumulation of internal air pressure, while preventing the hole area from being completely sealed, thus ensuring that the finished product has good air permeability and visual appeal.

[0055] The spring mechanism 1 not only provides pressure but also constructs a force-displacement feedback system to achieve dynamic control of the molding process. In the initial contact stage, it acts as a buffer to protect the porous structure from rigid impact damage. Through the coordinated compression of multiple spring assemblies 12, it effectively compensates for pressure differences caused by unevenness in the mold surface, achieving pressure balance. Because the springs possess dynamic adaptive capabilities, they can independently respond to different deformation resistances in different areas of the material, locally adjusting the force to ensure uniform stress distribution.

[0056] Based on this, the spring mechanism 1 continuously applies appropriate and stable pretension during the hot pressing and cooling stages to prevent the material from collapsing or deforming due to shrinkage. This mechanism completely changes the traditional "pressing" hot pressing mode, transforming the entire molding process into "flexible stretching and shaping." It not only maintains the clear and complete structure of the holes but also improves the breathability and wearing comfort of the cups, becoming the key difference between this technology and existing processes.

[0057] This invention can meet the needs of different flexible cut material combinations, different curved molds and cup sizes. The cups produced by hot pressing and shaping, after being processed according to the designed product process, have a highly breathable structure, allowing consumers to obtain a breathable and visible bra product.

[0058] Example 1

[0059] This embodiment provides a highly breathable perforated cup molding elastic mechanism, used in conjunction with a hot press mold, such as... Figure 2 As shown, the hot pressing mold includes a concave mold 3 and a convex mold 4. The elastic mechanism includes a spring mechanism 1 and a curved pressure plate 2. The curved pressure plate 2 is located between the concave mold 3 and the convex mold 4, and the spring mechanism 1 connects the curved pressure plate 2 and the convex mold 4. The convex mold 4 partially passes through the curved pressure plate 2 to hot press the porous flexible cut sheet material group 5, avoiding the collapse and wrinkling of the porous material's pore structure.

[0060] like Figure 1 As shown, the spring mechanism 1 includes two extension plates 11 and four sets of vertically arranged spring assemblies 12. The spring assemblies 12 are respectively disposed between the extension plates 11 at both ends of the punch 4 and the curved pressure plate 2, forming a stable elastic support system, which realizes pressure buffering and local adaptive adjustment through elastic deformation.

[0061] The extension plate 11 is made of aluminum sheet, and its size and shape are matched with the mold. The extension plate 11 is connected to the bottom mold of the punch 4, and the bottom surface is kept flat so as not to affect the contact between the punch 4 and the heating plate. Preferably, both extension plates 11 are provided with mold mounting holes 13, and the two sides of the punch 4 are connected by countersunk hexagonal bolts. Each extension plate 11 has holes and taps at both ends for connecting the spring assembly 12. The spring assembly 12 consists of a spring and an adjustable bolt, and the spring model and specifications are matched with the hot pressing mold. The spring force is adjusted by the spring model and compression depth. The required spring force is calculated based on the stretchability of the flexible cut material and the depth of the mold.

[0062] The spring is made of spring steel (G=79×10). 9 Pa); wire diameter d=0.001m; mean diameter D=0.012m; effective number of turns N=15; free length L0=0.1m.

[0063] Using the formula k=(G×d) 4 ) / (8×D 3 The spring constant k is calculated to be approximately 381 N / m. That is, the spring generates a force of about 381 Newtons for every 1 meter of compression.

[0064] A spring tension piece with F=15N is required. The spring compression length x≈0.04m can be calculated using the formula x=F / k.

[0065] The curved pressure plate 2 is located below the spring mechanism 1, and its middle part has a hollow area that matches the contour of the cup to be formed. The punch 4 closes with the die 3 through the hollow area. Figure 3 As shown, the lower surface of the curved pressure plate 2 is provided with an inner edge 22 to guide pressure distribution and prevent excessive compression. The gap width between the curved pressure plate 2 and the die 3 is determined by the thickness of the porous flexible cut material group 5, the stretchability of the porous flexible cut material group 5, and the thickness of the target die cup.

[0066] The punch 4 is fixed to the top crossbeam by bolts or clips, and the bottom is connected to the extension plate 11. The two ends of the extension plate 11 are connected to the curved pressure plate 2 by spring assembly 12, realizing the three-level linkage of "punch 4-spring mechanism 1-curved pressure plate 2".

[0067] The curved pressure plate 2 is made of wood. The width of the curved pressure plate 2 matches that of the extension plate 11, and the length of the curved pressure plate 2 is not less than the sum of the bottom mold length of the punch 4 and twice the width of the extension plate 11. The bottom mold length of the punch 4 is set according to the cup mold model and different cup sizes. Through holes 21 are provided at the four corners of the curved pressure plate 2, and adjustable bolts can pass through the curved pressure plate 2 and move up and down along the through holes 21.

[0068] The shape of the inner edge 22 of the pressure plate is consistent with the outer curved surface of the die 3, and extends outward into a curved ring of equal width. The machining dimension of the curved ring is d. The value of d is calculated from the material combination thickness h of the porous flexible cut sheet material group 5. The inner edge 22 of the pressure plate cooperates with the die 3, which can uniformly pressurize the porous flexible cut sheet material group 5 during hot pressing and prevent the holes from collapsing.

[0069] The calculation formula is: d = h × i;

[0070] Where i is the compression ratio coefficient, and i < 1; i is determined by the thickness of the flexible cut piece material group of the cup, the hardness of the sponge, the stretch of the fabric, and the model of the mold.

[0071] like Figure 4 As shown, the porous flexible fabric panel assembly 5 consists of three layers of porous material, including an inner layer 51, a middle layer 52, and a surface layer 53. The layers can be pre-laminated or bonded together during hot pressing. Preferably, the surface layer 53 is a perforated sponge bonded to the fabric, the middle layer 52 is a perforated sponge core that can be added, and the inner layer 51 is a large-pore perforated sponge bonded to the fabric. The size and shape of the porous flexible fabric panel assembly 5 are determined by the shape of the bra cup surface and the process requirements.

[0072] The concave mold 3 is fixedly installed on the hot press platform and has a concave cavity that matches the shape of the target product. It is used to support and shape the porous flexible cut piece material group 5.

[0073] The punch 4 is located above the die 3 and is connected to the curved pressure plate 2 through the spring mechanism 1. It applies pressure during the downward movement to complete the final shaping.

[0074] This invention enables one-time hot-press molding of bra cups. Simultaneously, the resulting perforated flexible fabric bra cup has a smooth and flat appearance, with clear, rounded holes and a complete shape, truly achieving "visible breathability." The prepared product combines high breathability with excellent structural integrity, significantly improving wearing comfort, such as... Figure 7 As shown.

[0075] This invention organically combines a spring mechanism 1 with a curved pressure plate 2, and works in conjunction with a concave mold 3 and a convex mold 4 to construct a complete flexible hot pressing molding system. This system not only solves the problems of collapse and wrinkling that exist in traditional molds when processing porous materials, but also achieves technological breakthroughs in controllable pressure, stable molding, and excellent appearance. It is particularly suitable for one-time hot pressing molding of medium-thick cup-shaped, highly breathable covers.

[0076] It should be noted that all terms used in this utility model to indicate direction and position, such as "up", "down", "left", "right", "front", "back", "vertical", "horizontal", "inner", "outer", "top", "lower", "tail end", "head end", "center", etc., are only used to explain the relative positional relationship and connection between the components in a specific state, and are only for the convenience of describing this utility model, and are not required to require this utility model to be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0077] While the present invention has been disclosed above, it is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the present invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A highly breathable perforated cup forming elastic mechanism, used in conjunction with a hot press mold, wherein the hot press mold includes a concave mold (3) and a convex mold (4), characterized in that, The elastic mechanism includes a spring mechanism (1) and a curved pressure plate (2). The curved pressure plate (2) is located between the die (3) and the punch (4). The spring mechanism (1) connects the curved pressure plate (2) and the punch (4). The punch (4) passes through the curved pressure plate (2) to hot press the porous flexible cut piece material group (5), which can prevent the hole structure of the porous flexible cut piece material group (5) from collapsing and wrinkling.

2. The elastic mechanism according to claim 1, characterized in that, The spring mechanism (1) includes an extension plate (11) and a spring assembly (12). The extension plate (11) is fixedly connected to the punch (4), and the spring assembly (12) connects the extension plate (11) and the curved pressure plate (2).

3. The elastic mechanism according to claim 2, characterized in that, The spring assembly (12) includes a spring and an adjustable bolt.

4. The elastic mechanism according to claim 3, characterized in that, The curved pressure plate (2) is provided with a through hole (21), and the adjustable bolt can move through the curved pressure plate (2) along the through hole (21).

5. The elastic mechanism according to claim 1, characterized in that, The curved pressure plate (2) is provided with a hollow area that matches the outline of the cup to be formed, and the punch (4) closes with the die (3) through the hollow area.

6. The elastic mechanism according to claim 1, characterized in that, The lower surface of the curved pressure plate (2) is provided with an inner edge (22), which cooperates with the die (3) to guide the pressure distribution and prevent excessive extrusion.

7. The elastic mechanism according to claim 6, characterized in that, The shape of the inner edge (22) of the pressure plate is consistent with the outer curved surface of the die (3), and extends outward into a curved ring.

8. The elastic mechanism according to claim 1, characterized in that, The porous flexible cut piece material group (5) is a multi-layer porous material.

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