Molded Composite Bra Cups with Dual-Layer Foam
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Solution Overview
Problem
Traditional bra cups made from low density and low hardness polyurethane foams fail to meet consumer requirements for machine washability, dimensional stability, and color fastness, making them commercially unviable despite their desirable attributes of being lightweight and soft.
Innovation Solution
A molded composite article comprising two polyurethane foam laminates with specific density and hardness ranges, bonded together with an adhesive, which undergoes thermoforming to achieve less than 3% shrinkage and no delamination after multiple wash cycles, while maintaining softness and lightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If low density and low hardness polyurethane foam is used to make bra cups, then the bra becomes softer and lighter, but the machine washability and dimensional stability deteriorate
Solution Approach 1:
The patent applies composite materials by combining low density/low hardness foam (for softness) with high density/high hardness foam (for structural stability). The soft foam layer provides comfort and soft hand-feel, while the rigid foam layer maintains dimensional stability during machine washing and prevents deformation. This composite structure resolves the contradiction between softness and washability.
Solution Approach 2:
The bra cup is segmented into multiple functional layers: a soft foam layer for comfort, a rigid foam layer for structural support, and a fabric layer for breathability and aesthetics. Each layer performs its specific function, allowing the overall product to achieve both softness and machine washability simultaneously.
2Weight of moving object
If low density and low hardness polyurethane foam is used to make bra cups, then the bra becomes lighter, but the dimensional stability to wash deteriorates
Solution Approach 1:
The patent uses composite materials combining lightweight soft foam with rigid high-density foam. The soft foam provides lightness and comfort, while the rigid foam layer maintains dimensional stability during washing cycles, preventing shrinkage and deformation. This resolves the contradiction between weight and dimensional stability.
3Ease of manufacture
If traditional single-layer foam structure is used, then the manufacturing process is simple, but the wash durability deteriorates
Solution Approach 1:
The patent employs composite materials with multiple foam layers bonded together. The soft foam layer provides comfort while the rigid foam layer ensures wash durability. The composite structure maintains relatively simple manufacturing processes while dramatically improving wash durability through the synergistic combination of different foam properties.
4Ease of operation
If low density foam is used, then the bra becomes softer, but the color fastness to heat and light deteriorates
Solution Approach 1:
The patent uses composite materials where the rigid high-density foam layer provides thermal stability and resistance to degradation from heat and light exposure. This layer protects the soft foam layer and fabric components, maintaining color fastness while the soft foam layer provides the desired softness and comfort.
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 successfully meets the required testing standards for machine washability, dimensional stability, and color fastness, ensuring the bra cups remain soft, lightweight, and durable, overcoming previous commercial viability issues.
Implementation Method 1
an adhesive bonding the first and second laminates together
Implementation Method 2
which undergoes thermoforming to achieve less than 3% shrinkage
Data Source
AI summary
Disclosed herein is a molded article made from two different polyurethane foam laminate materials, which displays both softness and resilience to machine washing. Also disclosed herein is a method of making said foam article.