Brassiere Underwire with Dual Polymer Support
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Solution Overview
Problem
Conventional brassieres with underwires provide less than even pressure, causing discomfort due to the rigid material, and attempts to make them more flexible compromise stabilizing function.
Innovation Solution
A support component for the breast cup made from two regions of different polymer materials, where a harder polypropylene core is surrounded by a softer thermoplastic rubber, providing enhanced support and comfort by conforming to the breast curve and distributing pressure more evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid underwire is used to provide stabilizing function, then support function is improved, but comfort deteriorates due to less than even pressure distribution
Solution Approach 1:
The underwire is constructed with two distinct polymer materials having different hardness levels: a harder first polymer material (Shore A 80-95) in the core region for structural support, and a softer second polymer material (Shore A 60-80) in the outer region for comfort. This local differentiation allows the underwire to provide stabilizing function where needed while reducing pressure discomfort in contact areas.
Solution Approach 2:
The underwire employs a composite structure combining two polymer materials with different mechanical properties. The harder polypropylene core provides rigidity and support, while the softer thermoplastic rubber outer layer distributes pressure more evenly. This composite approach resolves the contradiction between needing rigidity for support and softness for comfort.
2Object-affected harmful factors
If the underwire material is made more flexible to improve comfort, then comfort is improved, but stabilizing function deteriorates
Solution Approach 1:
Different regions of the underwire are assigned different material hardness levels to fulfill different functions: the inner core uses harder material for stabilization while the outer surface uses softer material for comfort. This spatial differentiation of material properties allows both comfort and support to coexist without compromising either.
Solution Approach 2:
The composite polymer structure combines materials of varying flexibility - the softer outer layer enhances comfort while the harder inner core maintains stabilizing function. This multi-material construction avoids the trade-off present in single-material designs.
3Stability of the object's composition
If a single hard polymer material is used for the support component, then stabilizing function is improved, but comfort deteriorates due to uneven pressure distribution
Solution Approach 1:
The support component transitions from uniform hard material to a differentiated structure where the harder first polymer material is concentrated in the core for stability, while the softer second polymer material forms the outer region for even pressure distribution. This local material differentiation resolves the contradiction between stability and comfort.
Solution Approach 2:
By combining two polymer materials with different hardness characteristics in a composite structure, the underwire achieves both stabilizing function (from the harder core) and improved pressure distribution (from the softer outer layer), eliminating the need to choose between these competing requirements.
Data Source
AI summary
A support structure for placement in a lower periphery of a breast cup for a brassiere, the support structure including a support component shaped to follow the curve of at least the underside of a wearer's breast, the support component including a first region formed by a first polymer material and a second region formed by a second polymer material, wherein the first polymer material is harder than the second polymer.