JP5920865B2 - Method for manufacturing shock mitigation hat and apparatus for producing shock mitigation hat with the production method - Google Patents

Description

  The present invention relates to a method for manufacturing an impact mitigation cap for the purpose of protecting the head, an apparatus for producing an impact mitigation cap by the production method, and an impact mitigation cap produced by the production method.

  As an impact relaxation hat, a thing formed by stitching an impact relaxation material such as a substantially triangular synthetic resin with a mesh material in a plurality of circumferential directions is known (for example, see Patent Document 1).

  Also, a normal hat is known that is formed by cutting a mesh material into a substantially triangular shape, arranging the lotus flowers, and sewing adjacent edges together (see, for example, Patent Document 2).

JP 2010-156092 A JP 2008-163524 A

  In the conventional hat, the material is cut into a substantially triangular shape as described above, and a crown is formed by stitching adjacent edges together in a lotus shape. Therefore, it takes a long time to manufacture, and there are problems that a large number of cut ends of the material are produced and the manufacturing cost is high.

  Further, the air permeability of the conventional impact relaxation hat is performed only on the mesh material portion. The shock absorbing material occupying most of the crown was not air permeable, so the air permeability was insufficient.

  Further, a normal hat made by stitching mesh materials is excellent in breathability but does not have impact relaxation properties.

  This invention is made | formed in view of said problem, and makes it a subject to provide the manufacturing method which can manufacture the impact relaxation hat excellent in air permeability at low cost.

  It is another object of the present invention to provide a manufacturing apparatus capable of manufacturing an impact relaxation hat with excellent breathability at low cost.

  It is another object of the present invention to provide an impact mitigation hat that has excellent breathability and low manufacturing costs.

  In order to solve the above-described problems, a method for manufacturing an impact mitigation hat according to the present invention includes a molding step of molding a sheet having air permeability and stretchability in a three-dimensional direction into a crown shape, and the molding step. A thinning and fixing step of pressing and compressing the peripheral portion of the crown-shaped portion in the thickness direction and bonding and fixing, and forming at least a part of the thinned and fixed peripheral portion And a cutting step of cutting out the formed portion.

  The sheet having stretchability in the molding process is formed into a crown shape that conforms to the outer shape of the mold by expanding when the tensile force acts and contracting when the compressive force acts. Next, when the peripheral portion of the portion formed into a crown shape in the thinning and fixing step is thinly consolidated and adhesively fixed, the stretched portion is kept stretched and the shrunken portion is held shrinkage. Next, when the part formed by leaving at least a part of the peripheral edge thinned and fixed in the cutting step is cut off, the impact relaxation cap is completed. Therefore, since an impact relaxation hat with excellent breathability is produced without sewing, cost reduction is achieved. Further, when the shock absorbing hat is used by being attached to the inside of a normal hat, the peripheral edge portion of the crown-shaped portion is thin, so that the hat fits into the sweat. When worn inside a normal hat, the head is protected, and it is possible to avoid a serious situation even if it falls on a bicycle or the like.

  In the above manufacturing method, the forming step may use a convex mold having a substantially hemispherical convex part and a concave mold having an opening into which the substantially hemispherical convex part is fitted.

  A convex substantially hemispherical convex part on which a sheet having elasticity in a three-dimensional direction is placed is inserted into the concave opening, so that the sheet extends or contracts (without wrinkles). The part is covered with a sheet. Therefore, even an inexpensive concave mold in which the concave recess is an opening that does not suppress wrinkles can be formed without wrinkles.

  In the thinning and fixing step, it is preferable to use a heater built-in pressing member provided so as to be movable toward the concave opening.

  Thinning and fixing can be performed simultaneously. Since the sheet is formed in a crown shape and the peripheral portion of the portion formed in the crown shape is thinned and fixed in a state where the portion is constrained by the convex and concave molds, the shape of the portion formed in the crown shape is frozen. .

  The cutting step may use a cutting blade provided so as to be movable toward the concave opening.

  By disposing the cutting blade over the entire circumference of the opening, the molded part and the ear part can be separated at a stretch.

  Further, the sheet includes two sheet-like nets that are spaced apart from each other and knitted with multifilaments or spun yarns, and a monofilament having rigidity that connects between the two sheet-like nets. Good.

  The impact applied to the outer sheet net is relieved by the rigid filament, and the impact on the head is weakened. Further, since the shock relaxation hat is formed of two sheet nets, the air permeability is very good.

  The monofilament may be knitted into the two sheet-like nets to connect the two sheet-like nets.

  Since each side of the mesh has rigidity, the mesh is deformed when a force is applied, but when the force is removed, the mesh returns to the original shape. The generation of wrinkles is suppressed even when the film is contracted in the direction and the radial direction and molded and fixed.

  Further, the two sheet-like nets may be a sheet-like net having regular hexagonal meshes composed of two V-shaped sides and two parallel sides.

  Shrinkage in the circumferential direction and radial direction of the sheet when the sheet is formed is facilitated, and the generation of wrinkles is further suppressed.

  An impact mitigation hat manufacturing apparatus according to the present invention, which has been made to solve the above problems, is arranged in a convex shape having a substantially hemispherical convex portion and a convex shape that can be clamped to the convex shape. A concave shape having an opening into which the substantially hemispherical convex portion is inserted, a pressing member with a built-in heater disposed at a peripheral edge portion of the concave shape so as to be movable toward the vicinity of the center of the opening, And a cutting blade disposed at a peripheral edge of the concave opening so as to be movable toward the vicinity of the center.

  Since the pressing member with a built-in heater that can move toward the center of the concave opening is arranged at the periphery of the opening, the sheet is formed into a crown shape with the convex shape and the concave shape formed into a crown shape. The peripheral edge of the portion can be pressed into the outer surface of the convex portion with a pressing member to be thinly consolidated and heat-welded. Therefore, since the sheet expanded and contracted by molding is frozen as it is, the crown state is maintained even if the ear portion is cut out by the cutting blade and taken out from the manufacturing apparatus.

  In order to solve the above-described problems, an impact relaxation hat according to the present invention is manufactured by any one of the above-described manufacturing methods.

  The sheet having stretchability in the molding process is formed into a crown shape that conforms to the outer shape of the mold by expanding when the tensile force acts and contracting when the compressive force acts. Next, when the peripheral portion of the portion formed into a crown shape in the thinning and fixing step is thinly consolidated and adhesively fixed, the stretched portion is kept stretched and the shrunken portion is held shrinkage. Next, when the part formed by leaving at least a part of the peripheral edge thinned and fixed in the cutting step is cut off, the impact relaxation cap is completed. Therefore, since an impact relaxation hat with excellent breathability is produced without sewing, cost reduction is achieved. Further, when the shock absorbing hat is used by being attached to the inside of a normal hat, the peripheral edge portion of the crown-shaped portion is thin, so that the hat fits into the sweat.

It is a schematic sectional drawing of the manufacturing apparatus of the impact relaxation hat which concerns on this invention. It is a principal part cross-sectional schematic diagram which shows the state before starting a formation process. It is a principal part cross-sectional schematic diagram which shows the initial state of a shaping | molding process. It is a principal part cross-section schematic diagram which shows the final state of a formation process. It is a principal part expanded sectional view of FIG. 1 for demonstrating a thinning fixing process. It is a principal part expanded sectional view of FIG. 1 for demonstrating a cutting process. FIG. 2 is a perspective view of an impact relaxation cap manufactured by the manufacturing apparatus of FIG. 1. It is principal part sectional drawing explaining the thinning fixing process of a deformation | transformation aspect. It is sectional drawing of the convex type of a deformation | transformation aspect. It is a top view of the sheet | seat of a deformation | transformation aspect. It is an expansion plane schematic diagram in the circle C1 of FIG. It is an expanded sectional schematic diagram in the circle | round | yen C2 of FIG.

  As shown in FIG. 1, the impact mitigation hat manufacturing apparatus of the present invention includes a convex mold 1 having a hemispherical convex portion 1b fixed to a base 1a and a concave mold 2 having an opening 2a into which the hemispherical convex portion 1b is inserted. I have. The end of the concave mold 2 engages with the shaft 4, and the concave mold 2 moves in the direction of arrow A <b> 1 (in the vertical direction in FIG. 1) by driving means (such as a hydraulic cylinder) (not shown) and stops at a predetermined height. Be able to.

  Reference numeral 5 denotes a cutting blade portion provided in the concave mold 2 so as to be movable toward the vicinity of the center of the opening 2a and over the entire circumference of the opening 2a. The cutting blade portion 5 includes a cutting blade 5a and a hydraulic cylinder 5b that controls the movement of the cutting blade 5a in the direction of arrow A2 (in the vicinity of the center of the opening 2a).

  On the upper part of the cutting blade part 5, a pressing member 6 is disposed so as to be movable toward the vicinity of the center of the opening 2a and over the entire circumference of the opening 2a. The pressing member 6 includes a pressing portion 6a with a built-in heater and a hydraulic cylinder 6b that controls the movement of the pressing portion 6a in the direction of arrow A3 (in the vicinity of the center of the opening 2a).

  3 is a sheet | seat shape | molded by crown shape. In FIG. 1, the concave mold 2 is driven down to a predetermined position, and the portion above the opening 2a of the sheet 3 is in contact with the outer surface of the hemispherical convex portion 1b.

Next, the manufacturing method of this invention is demonstrated. First, the state of FIG. 1 is restored to the initial state. That is, when the concave mold 2 is lifted by driving means (not shown) and the sheet 3 is returned to the sheet before molding, the state shown in FIG. 2 is obtained.
(Molding step) Next, when the concave mold 2 is gradually lowered, as shown in FIG. 3, the upper surface of the sheet 3 is deformed by being restrained by the inner wall of the opening 2a, and the region of the sheet 3 that has passed through the opening 2a is a hemisphere. The upper outer surface of the shape convex portion 1b is covered. Further, when the concave mold 2 is lowered, the molding progresses to the state shown in FIG. That is, the sheet 3 is formed into a crown shape.

When the sheet is formed into a crown shape, a tensile force is applied to the sheet in the downward direction and a compressive force is applied in the lateral direction (circumferential direction). However, since the sheet 3 is stretchable in the three-dimensional direction, generation of wrinkles and the like is caused. It can suppress and shape | mold in the crown shape similar to the external shape of the convex part 1b.
(Thinning and fixing step) Next, as shown in FIG. 5, the peripheral portion 3a of the portion formed into a crown shape by driving the pressing portion 6a heated to a temperature at which the sheet 3 can be heat-sealed by a hydraulic cylinder 6b. Is thinly consolidated and fused and fixed.
(Cutting step) Next, as shown in FIG. 6, the cutting blade 5a is driven by the hydraulic cylinder 5b to cut the lower part of the fusion-fixed portion. After the cutting, the impact-relieving hat taken out from the manufacturing apparatus holds the crown-shaped body as shown in FIG. In addition, the urethane rubber 1c is embedded in the site | part of the convex part 1b which opposes the cutting blade 5a, and the blade spill of the cutting blade 5a is prevented.

  In the present embodiment, the thinning and fixing step uses the pressing member 6a with a built-in heater as described above. However, pressing may be performed with a pressing member that does not have a built-in heater, and an adhesive may be supplied to the pressing portion. . Alternatively, an adhesive tape may be used instead of supplying the adhesive.

  When the shock absorbing hat shown in FIG. 7 is used while being attached to the inside of a normal hat, it is necessary to store the portion 3a, which is thinly consolidated and fused, in the perspiration of the hat. If the width of 3a is narrow and the fit for sweating is not good, the thinning and fixing step may be repeated by moving the concave mold 2 downward as shown in FIG. The width of the thinly consolidated and fused portion 3a in FIG. 8 is twice or more that in FIG. 7, and the fit to sweat removal is improved.

  In order to manufacture impact mitigation hats having different depths (heights), the lowered position of the concave mold 2 may be changed in the manufacturing apparatus of FIG.

  In order to further change the depth (height), the spacer 1c may be detachably attached to the convex portion 1b as shown in FIG.

  The sheet 3 may be a urethane sheet, a foamed resin sheet, or the like, but the two sheet-like nets that are knitted with multifilaments or spun yarns and spaced apart from each other are connected to the two sheet-like nets. And a monofilament material that is knitted into the two sheet-like nets and connects the two sheet-like nets.

  It is possible to produce an impact relaxation hat with better moldability, further suppression of wrinkles, better air permeability, and excellent impact relaxation properties.

  As shown in FIGS. 10 to 12, the three-dimensional knitted material is a sheet-like net 11 </ b> A in which a hexagonal mesh composed of two V-shaped sides 11 </ b> Aa and two parallel sides 11 </ b> Ab knitted with a multifilament or spun yarn 14 </ b> A is regularly connected. And a sheet-like net 12A in which hexagonal meshes consisting of two V-shaped sides 12Aa and two parallel sides 12Ab knitted with multifilaments or spun yarns 14A are regularly arranged, are arranged in two sheets. The nets 11A and 12A are connected by a plurality of monofilaments 13A having rigidity.

  As the three-dimensional knitted material, for example, Unitika cubic eye (registered trademark) can be used. In the case of cubic eye (registered trademark), 14A is a twisted yarn of a plurality of polyester filaments, and 3A is a nylon monofilament.

  Since the monofilament 13A connects the V-shaped side 11Aa and the parallel side 11Ab of the sheet-like net 11A and the opposite sides entangled with the V-shaped side 12Aa and the parallel side 12Ab of the sheet-like net 12A, the sides 11Aa and 11Ab 12Aa and 12Ab are also rigid. Therefore, when the force is applied, the mesh is deformed, but when the force is removed, the mesh has a characteristic of returning to the original rectangular mesh (viewed from the side). However, in a state where the sheet is formed in a crown shape with a convex shape and a concave shape, the peripheral portion of the crown-shaped portion is pressed against the outer surface of the convex portion with a pressing member to be thinly consolidated and heat-welded. It cannot return to the rectangular mesh, and the deformed shape is frozen.

1 ... convex 1b ... convex 2 ... concave 2a ... opening 3 ... ······························································ Pressing members 11A, 12A ... Monofilament 14A ... Multifilament or spun yarn

Claims (6)

A molding step of molding a sheet having air permeability and stretchability in a three-dimensional direction into a crown shape;
A thinning and fixing step of pressing and compressing the peripheral edge of the portion formed into a crown shape in the molding step in the thickness direction and bonding and fixing;
And a cutting step of cutting out a molded part leaving at least a part of the peripheral edge part that is thinned and fixed.   2. The method for manufacturing an impact relaxation hat according to claim 1, wherein the forming step uses a convex mold having a substantially hemispherical convex part and a concave mold having an opening into which the substantially hemispherical convex part is fitted.   The method of manufacturing an impact mitigation cap according to claim 2, wherein the thinning and fixing step uses a pressing member with a built-in heater movably provided toward the concave opening.   The method of manufacturing an impact mitigation hat according to claim 2 or 3, wherein the cutting step uses a cutting blade provided so as to be movable toward the concave opening.   The sheet includes two sheet-like nets that are knitted with multifilaments or spun yarns and spaced apart from each other, and a monofilament that has rigidity to connect between the two sheet-like nets, The two sheet-like nets are woven into the two sheet-like nets to connect the two sheet-like nets, and the two sheet-like nets are hexagonal meshes composed of two V-shaped sides and two parallel sides. The method for producing an impact relaxation hat according to any one of claims 1 to 4, wherein the mesh is a regular sheet-like net. It is an apparatus which manufactures an impact relaxation hat with the manufacturing method of any one of Claims 1-4,
A convex shape having a substantially hemispherical convex portion;
A concave mold provided with an opening into which the substantially hemispherical convex portion is inserted and disposed in the convex mold so as to be clamped to the convex mold;
A pressing member with a built-in heater disposed at the peripheral edge of the concave opening so as to be movable toward the vicinity of the center of the opening;
An apparatus for manufacturing an impact mitigation hat, comprising: a cutting blade disposed on a peripheral edge of the concave opening so as to be movable toward the vicinity of the center of the opening.

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