3D Brassiere Front Panel With Foam Compression Support
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Solution Overview
Problem
Conventional brassieres, including sports bras, do not provide adequate support and comfort during exercising, leading to excessive breast movement.
Innovation Solution
A front panel for a brassiere is designed with a three-dimensional shape that conforms to the chest region, incorporating two foam layers with a cavity for additional support, and utilizes compression to minimize breast movement, featuring a peripheral attaching element for secure coupling and optional additional materials like power mesh for enhanced support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional brassieres are used, then the structure is simple, but the support and comfort during exercise is insufficient
Solution Approach 1:
The front panel is divided into multiple functional layers: an inner fabric layer, an outer fabric layer, a first foam layer, and a second foam layer. Each layer serves a specific function - the fabric layers provide structural framework and comfort, while the foam layers provide compression and support. This segmentation allows the brassiere to achieve superior support during exercise while maintaining manufacturability through modular construction.
Solution Approach 2:
The front panel combines different materials with complementary properties: fabric layers for flexibility and comfort, foam layers for compression and support, and optional power mesh material for additional reinforcement. This composite structure enables the brassiere to simultaneously provide adequate support during exercise and maintain wearability, resolving the contradiction between reliability and device complexity.
2Reliability
If the front panel uses compression to minimize breast movement, then the support effectiveness is improved, but the comfort may be reduced
Solution Approach 1:
The foam layers are strategically positioned to provide compression specifically in the breast region, while the fabric layers provide breathable, flexible coverage in other areas. The inner fabric layer contacts the skin to provide comfort, while the outer fabric layer faces outward. This local differentiation allows the brassiere to minimize breast movement through compression where needed while maintaining overall comfort through breathable fabric construction.
Solution Approach 2:
The foam layers are configured with specific density and thickness parameters to achieve optimal compression - enough to minimize breast movement during exercise, but not so much as to cause discomfort or restrict breathing. The power mesh material can be selectively positioned to provide additional support in high-movement areas. By carefully controlling these parameters, the brassiere achieves effective compression while maintaining user comfort.
3Reliability
If additional material is inserted in the cavity for extra support, then the support effectiveness is improved, but the manufacturing complexity increases
Solution Approach 1:
The cavity is pre-formed between the first and second foam layers during the manufacturing process, with the understanding that additional support materials like power mesh will be inserted later. This preliminary preparation simplifies the overall assembly process, as the cavity structure is already in place and only requires filling with optional reinforcement materials rather than requiring complex multi-step construction.
Solution Approach 2:
The additional material in the cavity is designed to be optional and adjustable, allowing the brassiere to provide baseline support through the foam layers alone, or enhanced support by inserting power mesh material into the cavity. This dynamic approach allows the product to adapt to different customer needs without requiring complex manufacturing processes - the cavity is simply filled or left empty based on the specific application requirements.
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 front panel effectively supports the chest region, minimizing breast movement during exercise while providing improved comfort and additional support through compression and customizable materials.
Implementation Method 1
the front panel compresses the breasts, thereby minimising the movement of the breasts, especially when the user exercises
Implementation Method 2
one of the front inner fabric layer or front outer fabric layer comprises a peripheral attaching element that folds over a peripheral edge of the first foam layer and a peripheral edge of the second foam layer and couples/affixes to the other fabric layer
Data Source
AI summary
The present invention relates to a front panel for a brassiere, the front panel comprising an inner fabric layer with a first and second surface, and an outer fabric layer with a first and second surface, a first foam layer coupled to the first surface of the inner fabric layer and a second foam layer coupled to the first surface of the outer fabric layer, wherein the first foam layer and second foam layer are disposed between the first surface of the inner fabric layer and the first surface of the outer fabric layer, and the inner fabric layer and outer fabric layer each having an outer perimeter. The invention also relates to a method of manufacturing the front panel, and a garment comprising the front panel.