Variable Cross-Section Under-Support for Bra Comfort
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Solution Overview
Problem
Conventional bra underwires provide inadequate support and comfort for women with breast implants, leading to discomfort, pain, and potential health issues due to inconsistent stiffness, restricted lymph flow, and manufacturing complexities.
Innovation Solution
A novel under-support design featuring a curved shape with a concave and convex edge and multiple openings, made from a flexible polypthalamide material, integrated into a molded foam cup using injection and thermocompression molding processes, which distributes weight and provides stable support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional underwires are made with consistent stiffness, then manufacturing is simplified, but support adaptability to various breast shapes and sizes is reduced
Solution Approach 1:
The underwire is designed with variable cross-sectional dimensions along its length, creating zones of different stiffness. The first portion has a larger cross-section for greater stiffness to support heavier breast tissue areas, while the second portion has a smaller cross-section for flexibility to adapt to lighter areas. This dynamic variation in structural properties allows the single underwire to adapt to various breast shapes and sizes while maintaining consistent manufacturing processes.
2Ease of operation
If underwires are made more flexible to conform to body shape, then comfort is improved, but support capability is compromised
Solution Approach 1:
The underwire incorporates local quality variations through its non-uniform cross-sectional design. The first portion features a larger cross-section with increased moment of inertia to provide strong support capability where needed, while the second portion has a reduced cross-section that allows flexibility and comfort. This localized differentiation of structural properties enables the underwire to simultaneously achieve both support strength and comfort conformability in different regions.
3Strength
If underwires exert extreme pressure to provide support, then support effectiveness is improved, but harmful effects on breast tissue and implants occur
Solution Approach 1:
The underwire design utilizes parameter changes in its cross-sectional dimensions to optimize the pressure distribution. By varying the cross-sectional area and moment of inertia along its length, the underwire achieves adequate support effectiveness in regions requiring it while reducing pressure in sensitive areas. This parametric variation allows the underwire to provide necessary support without exerting extreme pressure that could cause tissue damage or implant indentation.
4Reliability
If conventional bras use multiple separate components for under-support, then support functionality is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention merges multiple under-support functions into a single integrated underwire structure. Instead of using separate components for support, cushioning, and shaping, the design combines these functions into one non-uniform underwire with variable cross-section. This consolidation maintains the reliability and functionality of multi-component systems while reducing device complexity, manufacturing steps, and assembly requirements.
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 enhances comfort and support by distributing breast tissue weight, reducing pressure points, improving lymphatic circulation, and simplifying manufacturing with a single-component under-support that integrates seamlessly into the foam cup, reducing the risk of deformation and movement.
Implementation Method 1
melt the polypthalamide material and inject the molten polypthalamide material into the mold; after the liquid material has cooled to form a solid foam
Implementation Method 2
compressing the under-support between a first solid foam and a second solid foam at an elevated temperature (e.g., about 200 degrees Celsius) for a period of time (e.g., about one minute, about two minutes, about three minutes or more), and then allowing the molded bra cup to cool
Data Source
AI summary
The present disclosure provides for an under-support, which includes curved end portions and a support portion extending between the curved end portion. The support portion includes a plurality of openings. The present disclosure further provides for the under-support embedded in a foam cup. When the disclosed under-support is embedded in a foam cup, the foam extends through the openings in the support portion.