Bra Cup Edge Finish Using Folded Outer Layer
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Solution Overview
Problem
Molded bras and bra cups face challenges in defining their perimeter or edge in a robust manner while maintaining aesthetics and comfort, as existing methods like hemming increase thickness and cause discomfort due to stepped transitions.
Innovation Solution
A bra cup design featuring an outer layer folded over the neckline and underarm edges to the concave side without overlapping the inner layer, secured through ultrasonic welding or adhesion to an intermediate foam layer, reducing thickness and improving comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If hemming is used to finish the perimeter or edge of the bra or bra cup, then the edge definition is robust, but the thickness of the bra cup is increased and comfort is reduced
Solution Approach 1:
The outer layer is folded over the edge and attached to the inner layer in a manner that utilizes the third dimension (folding back towards the concave side) to create a robust edge finish without adding significant thickness. The folded portion is positioned to be substantially coplanar with the inner layer, achieving edge stability while minimizing volume increase.
2Stability of the object's composition
If hemming is used to finish the perimeter or edge of the bra or bra cup, then the edge definition is robust, but a stepped transition is created causing discomfort
Solution Approach 1:
The folded outer layer is positioned and attached to create a smooth, substantially coplanar transition with the inner layer at the concave side. This local adjustment eliminates the stepped transition problem while maintaining the robust edge definition at the perimeter, thereby improving comfort without sacrificing edge stability.
3Strength
If the folded-over portion overlaps the innermost layer, then the edge is secured, but reduced comfort is caused due to stepped transition
Solution Approach 1:
The folded outer layer is attached to the inner layer in a way that creates a coplanar surface, effectively copying the smooth contour of the inner layer at the concave side. This eliminates the stepped transition while maintaining the securing function, as the folded portion is firmly attached to provide edge stability without creating discomfort.
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
The solution provides a thinner, more comfortable edge finish that enhances aesthetics and comfort by minimizing thickness and smoothing transitions, addressing the issues of bulkiness and discomfort in traditional hemming methods.
Implementation Method 1
The folded-over portion of the outer layer of material is contiguous with and does not overlap the inner layer of material
Data Source
AI summary
A bra comprising two bra cups is defined. Each bra cup preferably comprises an outermost fabric layer and an innermost fabric layer and at least one intermediate layer intermediate of the outermost fabric layer and the innermost layer. The outermost fabric layer at at least part of at least one of the neckline edge region and underarm edge region of each cup is folded over the intermediate layer and secured at the inner side of the breast cup, preferably joined to the innermost layer through ultrasonic welding. The folded-over portion of the outermost layer is contiguous with and does not overlap the innermost layer. The intermediate layer extends beyond the innermost layer at the neckline edge region and the underarm edge region so that a reduction in thickness is defined at the neckline edge region and the underarm edge region. A method of making the same is also provided.