Flat Knit Bra with Thermal-Molded Support for Larger Cup Sizes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flat knit bras, particularly for larger cup sizes, flatten the breast curve due to lack of structural support from metal underwires, leading to discomfort and unsuitable shape retention during daily wear.
Innovation Solution
A flat knit bra design featuring a band with multiple zones of double-layered knit material, including a center region with thermal molded fibers, and a bridge between cups, combined with power slings and wings, provides enhanced support and shape retention without metal underwires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal underwire is used to provide support and structure, then the bra maintains shape and structure, but wearing comfort is reduced
Solution Approach 1:
The patent removes the metal underwire from the bra structure and replaces it with a knitted bridge component. This extraction of the harmful element (metal underwire) while maintaining the necessary support function through an alternative knitted structure directly resolves the contradiction between structural support and wearing comfort.
Solution Approach 2:
The patent substitutes the mechanical metal underwire system with a knitted bridge system that provides similar structural support through its knitting construction. This replacement of one mechanical support system with another that is more comfortable against the skin resolves the contradiction between support and comfort.
2Ease of operation
If a knitted bra without metal underwire is used to improve comfort, then wearing comfort is improved, but the bra is less suited for larger breast sizes and flattens the breast curve
Solution Approach 1:
The patent divides the bra into multiple functional zones with different knit constructions. The bridge zone provides structural support for larger breasts, while the cup zones provide comfort and shape retention. This segmentation allows different parts of the bra to serve different functions, resolving the contradiction between comfort and support for larger sizes.
Solution Approach 2:
The patent applies different knit constructions to different zones of the bra. The bridge zone has a knit construction optimized for structural support, while the cup zones have constructions optimized for comfort and shape. This local differentiation of material properties allows the bra to simultaneously provide comfort and support for larger breast sizes.
3Productivity
If a flat bed knitted bra is used to achieve zero waste and different material properties, then manufacturing efficiency and material versatility are improved, but the bra flattens the breast curve during daily wear
Solution Approach 1:
The patent uses flat bed knitting to create different material properties in different zones of the bra. The bridge zone has a knit construction that provides structural support and shape retention, while the cup zones have constructions that provide comfort. This local differentiation of material properties through flat bed knitting resolves the contradiction between manufacturing efficiency and shape retention.
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 design offers improved comfort and shape retention for larger breast sizes by distributing support evenly, reducing pressure points, and maintaining a natural breast curve during daily wear.
Implementation Method 1
the centre region of the band comprises a thermal molded fiber
Data Source
Figure 1
Figure 2
Figure 2a
AI summary
The invention is directed to a flat knit bra comprising two cups (1a,1b), two wing zones (5a,5b) and wherein the bra further comprises a band (6) having a first and second end (6a,6b) and a centre region (16), wherein the centre region (16) of the band (6) comprises a thermal molded fiber.