Seamless Athletic Bra With Bonded Foam Cups for High-Impact Support
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Solution Overview
Problem
Conventional high-impact athletic bras often lack comfort while effectively reducing breast momentum during intense activities, particularly for individuals with larger breasts, due to the use of inflexible materials and structures like underwires and rigid cups.
Innovation Solution
An athletic bra design featuring a fabric composition of polyamide and spandex, with foam and double knit layers coupled by polyurethane hot melt adhesive, and a seamless construction that includes bonded edges, to provide support and reduce breast movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If underwires and rigid molded cups are used to support breasts during high impact activities, then breast movement is restricted and support is improved, but comfort deteriorates and the structure becomes rigid and inflexible
Solution Approach 1:
The patent replaces rigid molded cups with a flexible multi-layer cup structure comprising a cup layer and a foam layer. The cup layer is formed from knit fabric with specific stitch patterns that provide structural support while maintaining flexibility. The foam layer provides additional cushioning and support. This flexible construction eliminates the discomfort of rigid structures while maintaining breast support during high impact activities.
Solution Approach 2:
The patent uses composite material construction for the bra cups, combining knit fabric with foam material. The cup layer uses specific knit patterns (such as 1x1 rib knit or interlock knit) combined with foam layers of varying densities. This composite approach provides both the support needed for high impact activities and the comfort of flexible, breathable materials.
2Reliability
If compression is applied to press breasts toward the body to restrict movement, then breast momentum is reduced, but comfort and flexibility are compromised
Solution Approach 1:
The patent applies compression selectively through the multi-layer cup structure and panel construction rather than uniform compression across the entire bra. The cup layers provide localized support where needed, while the panel fabrics and stitching patterns allow for flexibility and breathability in other areas. This localized approach provides movement restriction where necessary while maintaining comfort overall.
Solution Approach 2:
The patent utilizes the elastic properties of spandex-containing fabrics to provide dynamic compression that adapts to movement. The fabric composition (typically 70-80% polyester and 20-30% spandex) allows the material to compress during high impact activities when support is needed, then relax during lower intensity moments, providing comfort and flexibility while maintaining movement restriction when required.
3Reliability
If inflexible materials are used to reduce breast momentum during high impact activities, then support is improved, but comfort and flexibility are reduced
Solution Approach 1:
The patent creates a dynamic support system through the combination of elastic fabrics, multi-layer construction, and strategic stitching. The bra adapts to different movement intensities - providing firm support during high impact activities through the compression and structure of the cup layers, while allowing flexibility and breathability during lower intensity activities. The elastic spandex content allows the material to dynamically respond to body movement and expansion.
Solution Approach 2:
The patent replaces inflexible materials with flexible knit fabrics and foam layers that maintain their supportive function while adapting to body movement. The cup layers use specific knit patterns that provide structural integrity while remaining flexible and breathable. This allows the bra to reduce breast momentum during high impact activities while maintaining flexibility and comfort throughout the range of motion.
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 effectively minimizes breast movement and momentum during high-intensity activities by up to 19% in lateral displacement and 5% in vertical displacement, while maintaining comfort and avoiding the use of rigid structures.
Implementation Method 1
each comprise a first layer and a second layer coupled together by an adhesive, wherein the adhesive is polyurethane hot melt
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An athletic bra comprising an outer shell and an inner layer is provided. The outer shell is configured to lay distal from a wearer when the athletic bra is worn, and the outer shell includes a fabric comprising polyamide and spandex. The inner layer is configured to lay more proximal to the wearer than the outer shell when the athletic bra is worn.