Breast Cup Gel Pad Assembly for Natural Appearance
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Solution Overview
Problem
Conventional bras with foam pads for enhancing breast size often result in an unnatural feel and appearance due to the way they touch and look under clothing.
Innovation Solution
A breast cup assembly featuring an outer and inner fabric layer with a gel pad positioned between flexible films, providing a natural feel and enhanced appearance by using a polyurethane gel that cures to a solid state, integrated into a brassiere design with specific manufacturing steps involving molding, film application, and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If foam pads are used to enhance breast size, then the apparent breast size is increased, but the natural look and feel is compromised
Solution Approach 1:
The patent changes the material parameter from foam to gel, specifically using a polyurethane gel that can be injected and cured to form a soft, flexible pad. This material parameter change maintains the volume enhancement while improving the tactile properties to provide a more natural feel that conforms to the breast shape.
Solution Approach 2:
The patent uses a composite structure combining flexible films (outer and inner layers) with gel material. The flexible films provide structural integrity and shape while the gel provides the natural feel and conformability. This composite approach resolves the contradiction by combining the volume-providing capability with the natural-feel property.
2Volume of moving object
If foam pads are used to enhance breast size, then the apparent breast size is increased, but the appearance under clothing becomes unnatural
Solution Approach 1:
The patent changes the material parameter from foam to gel, which allows the material to be molded into shapes that better replicate natural breast contours. The gel can be injected and cured to form smooth, natural-looking surfaces that enhance breast size while maintaining realistic appearance under clothing.
Solution Approach 2:
The patent uses flexible films as outer and inner layers that can conform to the breast shape and provide a smooth, natural appearance. These thin films are flexible enough to move with the body while maintaining a natural silhouette under clothing, resolving the appearance issue while preserving volume enhancement.
3Ease of operation
If gel material is injected between flexible films, then the natural feel and appearance are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies the flexible films to the breast cup structure beforehand, creating a prepared cavity or space between the layers. This preliminary action of applying films and creating the gel-receiving space simplifies the subsequent gel injection process, making the manufacturing more manageable despite the added complexity of using gel material.
Solution Approach 2:
The patent uses gel injection, which is a hydraulic process, to form the pad material within the flexible film structure. This method allows for precise placement and shaping of the gel material without requiring complex mechanical assembly, reducing manufacturing complexity while achieving the desired natural feel and appearance.
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 enhances the appearance of the bust while maintaining a natural look and feel, with the gel pad overlaying a significant area of the breast cup for optimal comfort and aesthetics.
Implementation Method 1
a gel pad positioned in the cavity formed between the inner and outer flexible films
Data Source
AI summary
There is provided a breast cup assembly comprising an outer panel comprising an outer fabric layer, an inner panel comprising an inner fabric layer, an inner flexible film applied over the convex surface of the inner panel, an outer flexible film applied to the inner flexible film such that the inner and outer flexible films are sealed substantially proximal to a periphery of the inner panel forming a cavity between the inner and outer flexible films, and a gel pad positioned in the cavity formed between the inner and outer flexible films. A method of producing such a breast cup assembly is also provided.