Grooved Support Sport Bra Design
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Solution Overview
Problem
Conventional sport bras with underwires cause discomfort, chafing, and restrict motion due to their weight and bulkiness, which are not ideal for high-intensity activities.
Innovation Solution
A sport bra design featuring support grooves pressed into compressible material that partially surround the breasts, extending from the sternum to the underarm area, providing support without the need for underwires, constructed from multiple layers of materials including compressible foam and spandex for flexibility and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional underwires are used for support, then breast support and separation are improved, but comfort deteriorates due to pressing into flesh and causing chafing
Solution Approach 1:
The patent removes the underwire component entirely from the bra structure. Instead of using traditional metal or plastic underwires, the invention employs grooves pressed into foam material that provide support through compression and structural integration with the cup material, eliminating the harmful pressing and chafing effects while maintaining support functionality.
Solution Approach 2:
The patent uses composite construction combining foam material with grooves pressed into it. The grooves create structural reinforcement within the foam cups themselves, providing support through the integrated foam-groove composite structure rather than through separate underwire components, thus eliminating discomfort while maintaining support.
2Strength
If underwires are included in the bra, then support structure is improved, but weight increases which is detrimental for high-intensity activities
Solution Approach 1:
The patent eliminates the underwire component which adds significant weight to the garment. The support structure is reimagined using grooves pressed into lightweight foam material, providing necessary structural support without the weight penalty of metal or plastic underwires, making the garment suitable for high-intensity athletic activities.
3Strength
If bulky underwires are used, then structural support is improved, but range of motion is restricted
Solution Approach 1:
The patent removes bulky underwire structures that restrict movement. Instead, grooves are pressed directly into the foam cups to provide structural support, creating a streamlined design that moves with the body during athletic activities without restricting range of motion.
Solution Approach 2:
The patent uses foam material with pressed grooves that provides structural support while maintaining flexibility. The foam-groove construction allows the material to conform and move with the body during athletic activities, unlike rigid underwires that restrict motion.
4Ease of manufacture
If cut-and-sew construction techniques are used with underwires, then garment assembly is achieved, but manufacturing complexity and labor intensity increase
Solution Approach 1:
The patent combines the support structure and cup material into a single integrated foam component with grooves pressed into it. This eliminates the need for separate underwire pieces and multiple stitching operations, simplifying manufacturing to primarily molding and pressing operations while maintaining structural support functionality.
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 sport bra offers effective support and motion control during athletic activities while minimizing discomfort and weight, allowing for a full range of motion without the drawbacks of traditional underwire designs.
Implementation Method 1
The support grooves may be pressed into a layer of compressible material such that the support grooves extend from a central region along the wearer's sternum, curve underneath the breasts and extend upwardly towards the underarm region.
Data Source
Figure 1
Figure 2~3A
Figure 3B~4
AI summary
Sport bras having one or more support grooves for lifting, separating, shaping a supporting a wearer's breasts and methods for fabricating these sport bra are described. The support grooves may be pressed into a layer of compressible material such that the support grooves extend from a central region along the wearer's sternum, curve underneath the breasts and extend upwardly towards the underarm region.