Thermomoulded Bra Cup Laminate for Seamless Moisture Management
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Solution Overview
Problem
Existing bra cups made from certain fabrics and materials are unsuitable for seamless thermomoulding due to issues like fabric selection, heat setting, stretchability, and resilience, leading to defects such as melting, deformation, and uneven thickness, which results in unusable cups, and existing reusable pads are bulky, uncomfortable, and ineffective in managing bodily fluids.
Innovation Solution
A laminated assembly of a fluid wicking fabric, a fluid trapping core element, and a moisture barrier component, thermomoulded into a 3D shape, with optional bra cup scaffold for support, ensuring seamless and effective moisture management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reusable pads and liners are used to manage bodily fluids, then fluid protection is improved, but comfort and wearability deteriorate due to bulkiness and movement
Solution Approach 1:
The invention merges the fluid protection function directly into the bra cup structure by integrating a fluid-resistant layer within the moulded cup assembly. This eliminates the need for separate reusable pads and liners, providing fluid protection while maintaining comfort and wearability through seamless integration.
Solution Approach 2:
The fluid-resistant layer is nested within the multi-layer construction of the moulded bra cup, positioned between the outer fabric layer and the inner moisture management layer. This nested structure provides fluid protection without adding external bulk, allowing the bra to maintain a sleek, comfortable fit.
2Ease of manufacture
If traditional bullet or bubble moulding is used to make seamless bra cups, then seamless construction is improved, but manufacturing precision deteriorates due to fabric defects like melting, deformation, and uneven thickness
Solution Approach 1:
The invention changes the material parameters by using heat-set stable fabrics that are specifically selected for their resistance to heat and pressure during the moulding process. These fabrics maintain their dimensional stability and physical properties under moulding conditions, preventing defects like melting, deformation, and uneven thickness while still enabling seamless construction.
Solution Approach 2:
The invention uses composite material structures with multiple layers including fluid-resistant layers, moisture management layers, and heat-set stable fabrics. This composite construction provides the necessary thermal and mechanical stability during moulding while maintaining manufacturing precision and preventing fabric defects.
3Manufacturing precision
If heat-set stable fabrics are selected for thermomoulding, then manufacturing precision is improved, but adaptability deteriorates due to limited fabric selection
Solution Approach 1:
The invention creates a universal solution by developing a multi-layer composite structure where different fabric types can be integrated. The system accommodates various fabric selections including natural fibres, synthetic fibres, and blends, allowing the same moulding process to work with diverse materials while maintaining heat set stability and manufacturing precision.
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 seamless, comfortable, and effective moisture management for bodily fluids, maintaining shape and functionality through multiple wash cycles, while being biodegradable and compostable.
Implementation Method 1
a fluid wicking fabric component for wicking bodily fluid from a wearer's skin
Implementation Method 2
it is possible to make seamless bra cups by compression moulding and/or thermo moulding, for example, which softens a polyester fabric by heating and/or applying pressure forces when placed over a shaped mould
Implementation Method 3
softens a polyester fabric by heating and/or applying pressure forces
Implementation Method 4
make seamless bra cups by compression moulding and/or thermo moulding, for example, which softens a polyester fabric by heating and/or applying pressure forces
Data Source
AI summary
A moisture management moulded bra cup and bra containing same for wicking bodily fluid away from a wearer's skin.