Foam Bra Cup Rib Structure for Wire-Free Push-Up
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Solution Overview
Problem
Conventional brassieres with metal wires cause discomfort and fail to create a beautiful decollete, while non-wired options lack the push-inward-up effect, and the production of integrated cup designs with seam lines complicates manufacturing.
Innovation Solution
A cup for a brassiere molded from foam textile with varying foam densities and a rib on the sternum-side breast holding face part to create a high-stretch top portion, non-stretch outer periphery, and intermediate stretchability at the upper edge, eliminating the need for wires and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If metal wires are used for shape keeping in brassieres, then the push-inward-up effect is improved, but the wire bites into the skin and gives discomfort to the wearer
Solution Approach 1:
The patent removes the metal wire component entirely from the brassiere design, replacing it with a foam cup structure that provides shape keeping and push-up effects without causing skin discomfort. The foam cup integrates multiple functions (support, shaping, padding) into a single component, eliminating the harmful wire element while maintaining the desired breast-shaping effect.
Solution Approach 2:
The foam cup serves multiple functions simultaneously: it provides shape keeping, push-up effect, sternum protection, and comfort. By consolidating these functions into a single multi-functional component, the patent eliminates the need for separate metal wires while achieving the same or better performance in terms of both shaping and wearer comfort.
2Object-affected harmful factors
If non-wired brassieres are used to avoid discomfort, then wearer comfort is improved, but the push-inward-up effect is insufficient
Solution Approach 1:
The foam cup incorporates a rib structure with varying local densities and hardnesses in different regions. The rib on the sternum-side has specific structural characteristics that provide targeted push-up force, while other areas of the foam cup maintain softer properties for comfort. This local differentiation of material properties enables the non-wired design to achieve effective push-inward-up action.
Solution Approach 2:
The patent uses foam material with varying density and hardness characteristics throughout the cup structure, creating a composite-like construction within a single material system. The rib structure incorporates different foam densities to provide both support and comfort, achieving effective push-up without metal wires.
3Shape
If three panels are sewed together to form integrated cups for creating cleavage, then the cleavage effect is improved, but seam lines appear externally requiring cover cloth attachment
Solution Approach 1:
The patent merges multiple panels into a single integrated foam cup structure without external seam lines. The rib structure is integrated within the foam material itself, eliminating the need for separate cover cloths to conceal seams. This consolidation simplifies the overall construction while maintaining the cleavage effect.
4Ease of operation
If three panels are sewed together to form integrated cups, then the cup structure is improved for push-up effect, but production steps become complicated
Solution Approach 1:
The patent extracts the seam lines and cover cloth requirements from the manufacturing process by using a single-piece foam cup construction. The rib structure is formed directly in the foam molding process, eliminating multiple assembly steps including sewing, aligning panels, and attaching cover cloths, thereby simplifying production while maintaining the push-up effect.
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 provides a comfortable, effective push-up effect for breasts, forming a deep cleavage and beautiful decollete without wires, while simplifying production and reducing costs by eliminating seam lines.
Implementation Method 1
a top-surrounding portion 20a around a top of the cup 20, the top being a most-elevated portion in the cup, is caused to have a foam density higher than a foam density of an outer periphery portion 20b of the cup 20, so as to be a high-stretch portion
Implementation Method 2
each of an outer periphery portion 20b, in the cup 20, of the sternum-side breast holding face part 80, a lower edge portion 24 of the lower breast holding face part 70, and a strap attachment portion 60a of the upper breast holding face part 60 is caused to have a lowest foam density, so as to be a non-stretch portion that is flexible but hardly stretches
Implementation Method 3
a rib 80a is formed on an inner face of the sternum-side breast holding face part 80
Data Source
AI summary
[Object] To provide a cup for a brassiere that is non-wired but can create not only a cleavage in the chest but also a beautiful decollete in the neckline area by pushing up the breasts.[Solution] Provided is a cup 20 for a brassiere 10 obtained by molding a foam textile 1 into a cup shape. The cup 20 includes an upper breast holding face part 60 which covers an upper portion of a breast B and whose underarm-side end portion has a strap 50 attached thereto, a lower breast holding face part 70 which covers a lower portion of the breast B, and a sternum-side breast holding face part 80 which covers a sternum-side portion of the breast B. A rib 80a is formed on the inner face of the sternum-side breast holding face part 80.