Brassiere 3D Bonding for Precise Bra Cup Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional methods for manufacturing brassieres with bra cup cores are time-consuming, require skilled labor, and result in discomfort due to seams and misalignment of fabric panels, leading to issues with fabric deformation and misplacement relative to the breast nipples.
Innovation Solution
A 3D bonding technology using adhesive materials, a coating machine, fabric rack, and precise alignment tools to fuse bra cup cores with fabric panels, minimizing the need for additional trimming and reducing misalignment, thereby enhancing comfort and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional stitching method is used to assemble bra cup cores with fabric panels, then the manufacturing process is well-established and reliable, but the process is time-consuming and requires skilled workers
Solution Approach 1:
The patent replaces the traditional mechanical stitching system with a thermal bonding system. A bonding plate with heating elements is pressed against the fabric panel and bra cup core, using heat and pressure to fuse the materials together. This substitution eliminates the need for needles, threads, and skilled stitching operations, thereby significantly reducing assembly time and improving manufacturing efficiency.
Solution Approach 2:
The patent changes the bonding parameters by controlling temperature, pressure, and bonding time. The bonding plate can be adjusted to different temperatures to suit different fabric and foam material combinations. By optimizing these parameters, the process achieves reliable bonding without requiring skilled workers, thus improving productivity while maintaining quality.
2Ease of operation
If traditional stitching method is used, then the assembly process is simple in concept, but the brassieres look cumbersome and joints make wearers feel itchy and uncomfortable
Solution Approach 1:
The patent extracts and eliminates the stitching joints from the final product. By using thermal bonding, the fabric panel and foam layer are fused into a seamless structure with the bra cup core. This removes the visible and tactile stitching elements that cause itchiness and discomfort, while maintaining process simplicity through the bonding plate mechanism.
3Productivity
If fabric panels are molded and fused with bra cup cores using male and female mold heads in one process, then the process is integrated and efficient, but the convex profile of the male mold head must match the concave profile of the bra cup cores completely
Solution Approach 1:
The patent segments the molding and fusing operations into separate steps. First, the fabric panel is molded independently to the desired shape. Then, in a separate fusing step, the molded fabric panel is bonded to the bra cup core using the bonding plate. This segmentation eliminates the need for precise profile matching between mold heads, as each component is formed and then joined independently, maintaining productivity while reducing precision requirements.
4Manufacturing precision
If the depth of molded fabric panels is too shallow, then the vertexes cannot contact and be fused with the vertexes on the bra cup cores, but if the cup depth is too deep, then the excessive fabrics become wrinkled or folded
Solution Approach 1:
The patent applies preliminary action by pre-molding the fabric panel to the exact shape and depth required before the fusing step. The fabric panel is molded in advance with the correct curvature and vertex positioning. During subsequent bonding, the pre-formed fabric panel aligns naturally with the bra cup core vertices, ensuring precise contact without excessive depth that would cause wrinkling. This preliminary shaping eliminates the need for complex real-time adjustments during fusing.
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 3D bonding technology ensures accurate alignment and fusion of bra cup cores with fabric panels, eliminating the need for additional trimming, saving time and material costs, and providing a seamless, comfortable brassiere.
Implementation Method 1
Adhesives will be sprayed on the bonding sides of the bra cup cores
Data Source
AI summary
The present invention belongs to the technical field of undergarments, and discloses a brassiere, which includes a pair of bra cup cores, and one or more body fabric panel attached with the bra cup cores on the front. The brassiere is formed by connecting both sides via side band fabric panel which are warped to a back of the body, and is sealed and fastened via fastening buckles with or without shoulder straps or fabric panel to support, uplift, and control human breasts. The present invention aims at restoring natural and comfortable beauty of the human breasts via the seamless brassiere fused with the bra cup cores with the 3D bonding technology to minimize joining and stitching causing the itch or discomfort for wearers. The 3D bonding technology of the present invention can be used for the shapes, profiles, and peripheries of different types of 3D bra cup core.