Molded cup and manufacturing method thereof

Abstract

A molded cup includes a first fabric layer, a cup core, and a second fabric layer. The first fabric layer and the second fabric layer are respectively provided on an outer surface and an inner surface of the cup core, and the cup core is filled with fluff. The cup core includes an upper layer, an intermediate layer, and a lower layer, the fluff is filled between the upper layer and the lower layer, and the upper layer and the lower layer of the cup core are manufactured by molding of a foam material. The molded cup enables breasts to breathe smoothly without being pressed, and can provide good support and protection effects and maintain comfort for the breasts.

1 . A molded cup, comprising:
 a first fabric layer;   a cup core; and   a second fabric layer,   wherein the first fabric layer and the second fabric layer are respectively provided on an outer surface and an inner surface of the cup core, and the cup core is filled with fluff.   
     
     
         2 . The molded cup according to  claim 1 , wherein the cup core includes an upper layer, an intermediate layer, and a lower layer, the fluff is filled between the upper layer and the lower layer, and the upper layer and the lower layer of the cup core are manufactured by molding of a foam material. 
     
     
         3 . The molded cup according to  claim 1 , wherein the cup core is provided with a plurality of holes at least in a central region thereof, and two adjacent holes in a transverse direction and two adjacent holes in a longitudinal direction enclose a diamond shape. 
     
     
         4 . The molded cup according to  claim 3 , wherein angles of an upper angle and a lower angle of the diamond that is enclosed are smaller than angles of a left angle and a right angle of the diamond. 
     
     
         5 . The molded cup according to  claim 2 , wherein the fluff is filled in a central region between the upper layer and the lower layer, peripheral regions of the upper layer and the lower layer are attached to each other, and
 wherein the upper layer and the lower layer of the cup core are provided with a plurality of holes, regions provided with the holes extend to the peripheral regions of the upper layer and the lower layer, and the holes located in the peripheral regions of the upper layer and the lower layer are through-connecting.   
     
     
         6 . A manufacturing method of the molded cup according to  claim 1 , wherein the molded cup includes a first fabric layer, a cup core, and a second fabric layer, the manufacturing method comprising the following steps:
 S 1 . preparing a cup core using a die, and filling the cup core with fluff;   S 2 . covering the first fabric layer and the second fabric layer on an outer surface and an inner surface of the cup core respectively, and forming a semi-manufactured cup by low-temperature 3D fitting; and   S 3 . tailoring the semi-manufactured cup to obtain a bra cup.   
     
     
         7 . The manufacturing method of the molded cup according to  claim 6 , wherein in step S 1 , the cup core includes an upper layer, an intermediate layer, and a lower layer, the fluff is filled in the intermediate layer of the cup core, and the upper layer and the lower layer of the cup core are formed by low-temperature molding of a foam material injected into the die. 
     
     
         8 . The manufacturing method of the molded cup according to  claim 7 , wherein the die includes a male die and a female die, in step S 1 , a manufacturing process of the cup core includes:
 injecting a first layer of foam material into the female die, then adding fluff on the first layer of foam material,   continuing to inject a second layer of foam material over the fluff,   folding the male die and the female die, and   obtaining a cup core by low-temperature fitting;   
       in which the first layer of foam material forms the upper layer of the cup core, and the second layer of foam material forms the lower layer of the cup core. 
     
     
         9 . The manufacturing method of the molded cup according to  claim 6 , wherein step S 1 - 2  is also included between step S 1  and step S 2 , including the steps of: punching holes on the obtained cup core, and the holes being arranged throughout the cup core; and
 in step S 2 , firstly bonding the cup core to the first fabric layer and second fabric layer by an adhesive, and then obtaining a semi-manufactured cup by low-temperature molding fitting. 
 
     
     
         10 . A manufacturing method of the molded cup according to  claim 1 , wherein the molded cup comprises a first fabric layer and a second fabric layer, the manufacturing method comprising the following steps:
 S 1 . selecting a mold including a female die and a male die, and obtaining a corresponding cup shape by designing shapes of the female die and the male die;   S 2 . placing the first fabric layer on the female die, sequentially adding the first layer of foam material, the fluff and the second layer of foam material on the first fabric layer, then placing the second fabric layer on the second layer of foam material, folding the male die and the female die, and obtaining a semi-manufactured cup by low-temperature molding; and   S 3 . tailoring the semi-manufactured cup to obtain a bra cup.