Breast Cup Assembly Uniform Density Foam Core
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Solution Overview
Problem
Conventional bra cups have varying hardness due to density differences across the cup, and precise positioning of foam pads during manufacturing is challenging, leading to undesirable results in comfort and aesthetics.
Innovation Solution
A breast cup assembly with a molded core assembly featuring a core foam layer of varying thickness but constant density, laminated with a core fabric layer, and integrated with thermoplastic polyurethane (TPU) film between the core and inner fabric layers, allowing for precise shaping and uniform density across the cup regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If foam material of uniform thickness is molded to form bra cup, then the cup shape is formed, but the density varies across the cup region causing varying hardness
Solution Approach 1:
The foam layer is designed with locally varying thickness rather than uniform thickness. The thickness varies from a first thickness at the central portion to a second thickness at the periphery, creating different densities in different regions to achieve uniform hardness across the cup while maintaining the desired 3D shape.
Solution Approach 2:
The thickness parameter of the foam layer is changed across different regions of the cup. By controlling the thickness gradient from center to periphery, the density distribution is optimized to ensure uniform hardness throughout the cup structure.
2Ease of operation
If additional foam pads are provided within the cup, then comfort is improved, but precise positioning during manufacture becomes difficult
Solution Approach 1:
The foam layer is merged with the fabric layer into a single integrated structure. The foam layer is laminated to the fabric layer and shaped into the desired 3D cup form, eliminating the need for separate foam pads and their associated positioning challenges during manufacturing.
Solution Approach 2:
A composite structure is created by laminating the foam layer with the fabric layer. This composite construction integrates the cushioning function directly into the cup structure, providing comfort while simplifying manufacturing by eliminating separate padding components.
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 ensures consistent hardness and improved comfort and aesthetics by maintaining uniform density across the cup regions, eliminating the need for additional foam pads and simplifying the manufacturing process.
Implementation Method 1
a thermoplastic polyurethane (TPU) film disposed between the molded core assembly and the inner fabric layer, the TPU film being adapted to affix the core assembly to the inner fabric layer
Implementation Method 2
The molded core assembly is shaped into 3D shape by molding
Data Source
AI summary
A breast cup assembly including an outer fabric layer, an inner fabric layer, and a molded core assembly having two cup regions and disposed between the outer and inner fabric layers, the core assembly including an inner core foam layer laminated with an outer core fabric layer. Each of the inner and outer fabric layers may have a range greater than the extent of the core assembly, and the inner core foam layer at each of the two cup regions of the core assembly has varying thickness but substantially the same density across the cup region.