Bra Cup Composite Layer Corrugation Molding

Solution Overview

Problem

Current methods for creating corrugations on bra cups are inefficient, material-intensive, and fail to achieve a three-dimensional effect, with printing and bonding processes being complex and wasteful, and unable to accurately position three-dimensional corrugations.

Innovation Solution

A bra cup manufactured using a composite layer material comprising an outer elastic fabric layer, an inner elastic fabric layer, and an intermediate foaming layer, where the foaming layer's protrusions mate with the fabric layers' corrugations to form sustainable three-dimensional corrugations through compression molding, enhancing structural integrity and comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If tattoos or bonding are used to add corrugations on the cup, then aesthetic effect is improved, but manufacturing complexity increases and manufacturing efficiency decreases

Engineering Contradiction:

Improvecorrugation aesthetic effectVSAvoidmanufacturing process complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The corrugation patterns are pre-formed on the fabric layers before assembly. The outer fabric layer is provided with first protruding or concave corrugations, and the intermediate foaming layer is provided with second protruding or concave corrugations that mate with the first corrugations. This preliminary formation of corrugations on individual layers eliminates the need for post-assembly tattooing or bonding processes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses a composite structure consisting of an outer fabric layer, an intermediate foaming layer, and an inner fabric layer. The corrugations are formed by the interaction between the intermediate foaming layer and the outer fabric layer, where the second corrugations of the foaming layer mate with the first corrugations of the fabric layer to form the final outer corrugations of the cup.

Inventive Principle:

Principle #40Composite materials

2Shape

If tattoos or bonding are used to add corrugations on the cup, then aesthetic effect is improved, but material waste increases

Engineering Contradiction:

Improvecorrugation aesthetic effectVSAvoidmaterial waste

Core Design Contradiction:

ShapeVSLoss of substance

Solution Approach 1:

The corrugation patterns are pre-formed on the fabric layers before assembly. The outer fabric layer is provided with first protruding or concave corrugations, and the intermediate foaming layer is provided with second protruding or concave corrugations that mate with the first corrugations. This preliminary formation of corrugations on individual layers eliminates the need for post-assembly tattooing or bonding processes.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If printing is used to create corrugations, then manufacturing process is simplified, but three-dimensional effect is lost and positioning precision decreases

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidcorrugation positioning precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention uses a composite structure consisting of an outer fabric layer, an intermediate foaming layer, and an inner fabric layer. The corrugations are formed by the interaction between the intermediate foaming layer and the outer fabric layer, where the second corrugations of the foaming layer mate with the first corrugations of the fabric layer to form the final outer corrugations of the cup.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The corrugation patterns are pre-formed on the fabric layers before assembly. The outer fabric layer is provided with first protruding or concave corrugations, and the intermediate foaming layer is provided with second protruding or concave corrugations that mate with the first corrugations. This preliminary formation of corrugations on individual layers eliminates the need for post-assembly tattooing or bonding processes.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If printing is used to create corrugations, then manufacturing process is simplified, but three-dimensional effect is lost

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidthree-dimensional corrugation effect

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The invention uses a composite structure consisting of an outer fabric layer, an intermediate foaming layer, and an inner fabric layer. The corrugations are formed by the interaction between the intermediate foaming layer and the outer fabric layer, where the second corrugations of the foaming layer mate with the first corrugations of the fabric layer to form the final outer corrugations of the cup.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention transitions from two-dimensional printed patterns to three-dimensional physical corrugations by utilizing the intermediate foaming layer to provide actual protruding or concave structures. The second protruding or concave corrugations of the foaming layer mate with the first protruding or concave corrugations of the fabric layer, creating genuine three-dimensional outer corrugations that maintain aesthetic effect while simplifying manufacturing.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method allows for efficient production of sustainable three-dimensional corrugations on bra cups, improving wear comfort and reducing material waste, while enabling accurate positioning and structural support.

Implementation Method 1

bonding an outer fabric layer on the first surface of the intermediate foaming layer; and subjecting the bonded outer fabric layer, intermediate foaming layer and inner fabric layer to hot compression molding between the first mold and the second mold

Methodology Applied

Scientific EffectHot compression molding:

Implementation Method 2

the outer fabric layer has first protruding or concave corrugations; and the first surface of the intermediate foaming layer has second protruding or concave corrugations, the second protruding or concave corrugations mating with the first protruding or concave corrugations to form the outer corrugations of the cup

Methodology Applied

Scientific EffectCompression molding: Compression

Data Source

PatentUS10485271B2Bra cup and manufacturing method thereof

Publication Date: 2019.11.26 KAIPING U LIKE UNDERGARMENT ACCESSORIES CO LTD

AI summary

The present invention relates to the field of undergarments, bras, or swimsuit accessories, and is directed to providing a bra cup having sustainable three-dimensional corrugations and a manufacturing method thereof with simple processes. The bra cup is formed by compression molding with a composite layer material and has a protruding outer side face and a concave inner side face. The outer side face has outer corrugations of the cup that are formed by compression molding. The composite layer material comprises at least: an outer fabric layer; an inner fabric layer; and an intermediate foaming layer. The intermediate foaming layer has a first surface bonding to the outer fabric layer and a second surface bonding to the inner fabric layer, the first surface having second protruding or concave corrugations, the second protruding or concave corrugations mating with the first protruding or concave corrugations to form the outer corrugations of the cup.