JP6035040B2 - Socks manufacturing method - Google Patents

Description

  The present invention relates to a sock manufacturing method in which a predetermined coating layer is provided in a partial region including at least a curved portion in a sock body.

  Conventionally, socks having a coating layer made of a moisturizing material such as silicon rubber on the inner surface that abuts on the heel portion of the foot are known. Patent Document 1 discloses 1 to 100 having a predetermined effect on the human body. An additive resin material obtained by blending an additive material using powder material and / or a fluid agent composed of particles in the range of [μm] in an amount of 0.01 to 20% with respect to the resin material is used as an inner surface of a sock body. By applying to at least the area where the heel of the foot hits and adding various effects in addition to heat retention, the added value and diversity (multifunctionality) of this kind of socks by synergistic effect is enhanced, and Socks are disclosed that eliminate or reduce the growth of odors and the generation of odors due to stuffiness.

  By the way, it is not easy to uniformly provide a resin material on the inner surface of soft clothing such as socks. For this reason, generally, a thin sheet material as disclosed in Patent Document 2 is often applied. However, using such a sheet material has the merit that the layer thickness can be easily uniformed, but has the disadvantage that it is easily peeled off and cannot be easily integrated with the sock body.

  On the other hand, there is also known a method of manufacturing socks that eliminates these disadvantages and makes the layer thickness easy to uniform. Patent Document 3 describes that the inner surface portion of the sock mouth rubber portion is prevented from being scraped off. A sock manufacturing method for manufacturing a sock body in which the inner surface portion is flat in a natural state and has a wrinkle shape with lateral irregularities in a spread state. After the process and the sock manufacturing process, a predetermined anti-slipping agent is applied by screen printing only to a part or all of the contact surface of the inner surface with the foot in the natural state, and applied to the inner surface. A semi-drying process in which the anti-skid agent is dried until it becomes a separable semi-cured state before reaching the normal curing state, and after this semi-drying process, the inner surface is expanded and the anti-slip agent is brought to the normal curing state. And a main drying step for drying. More, for any part coating range in the inner surface portion, hosiery manufacturing method of which is to be coated with a non-slip material easily and uniformly is disclosed.

Utility Model Registration No. 3114911 Japanese Utility Model Publication No. 7-38104 JP 2006-77345 A

  However, the conventional sock manufacturing method including the above-described method for applying an antiskid (coating agent) has the following problems to be solved.

  First, when applying a non-slip agent (coating agent), since a uniform layer thickness has been realized by screen printing, it is necessary to set the sock to be applied in a flat state. Therefore, when it is applied to a portion that comes into contact with a curved surface such as a heel, even if it is actually worn, even if it has a certain degree of elasticity, a part of the coating layer will be greatly extended or the variation in the extension will be increased. In addition, a decrease in uniformity during installation is inevitable. Eventually, the feeling of fitting (fitting) to the skin in the coating layer is not a little damaged, and this leads to problems that some of the coating layers are rapidly deteriorated.

  Secondly, in order to avoid such a problem based on the conventional manufacturing method, if the area of the coating region is reduced or the coating layer is thinned, the influence of the coating layer is reduced, so that improvement can be made. . However, a reduction in the area or thickness of the coating layer means that the original function (performance) of the coating layer such as moisture retention cannot be sufficiently ensured. After all, in the case of the conventional manufacturing method, there is a limit to providing a good coating layer.

  An object of the present invention is to provide a method for manufacturing socks that solves the problems existing in the background art.

  In order to solve the above-described problem, the method of manufacturing a sock according to the present invention, when manufacturing a sock 1s in which a predetermined coating layer 2 is provided in a partial region Ap including at least the curved portion Xr in the sock body 1sm, A coating process in which the base plate 21 is press-fitted into the main body 1 sm to set a partial area Ap in the sock main body 1 sm in a flat state, and a coating agent 2 c using a silicon rubber material 2 cs is applied to the partial area Ap. (S2, S3), a pre-curing step (S4, S5) for curing the coating agent 2c to an intermediate curing state after the completion of the coating step (S2, S3), and an adsorber that can be inserted into the sock body 1sm The mold 11 simulating the curved portion Xr is integrally formed in 52, and the entire mold 11 is formed hollow inside. After forming the small jig 11h... Into the sock body 1sm after the pre-curing step (S4, S5), a partial region on the surface opposite to the surface coated with the coating agent 2c Ap is brought into contact with the mold 11 and, after being brought into contact, suction processing is performed from the mold 11 side for a predetermined set time T2, and at least a partial region Ap of the sock body 1sm is in close contact with the mold 11 After the setting step (S7, S8, S9, S10) to be performed, and the setting step (S7, S8, S9, S10), the coating agent 2c in the partial region Ap in close contact with the mold 11 is cured to form a coating layer. And a curing treatment step (S11, S12).

  According to the sock manufacturing method according to the present invention, the following remarkable effects can be obtained.

  (1) A coating layer 2 is provided in which a sock body 1sm including a coating agent 2c applied to a partial region Ap of the sock body 1sm is cured in a state where the sock body 1sm is in contact with a molding die 11 that is shaped like a curved portion Xr. Therefore, the coating layer 2 has a shape fitted to the shape of the curved portion Xr. Accordingly, it is possible to eliminate problems such as a partial extension of the coating layer 2 at the time of mounting being increased or a variation in the extension being increased, and uniformity at the time of mounting can be ensured. Thereby, while the feeling of fitting (fit feeling) and comfort to the skin in the coating layer 2 can be remarkably enhanced, the stress in the coating layer 2 is made uniform, and the durability (lifetime) can be enhanced.

  (2) Since the coating layer 2 has a shape fitted to the shape of the curved portion Xr, the area of the coating layer 2 and the thickness of the coating layer 2 can be increased as much as necessary. Therefore, the original function (performance) required for the coating layer 2 such as moisture retention can be sufficiently secured.

  (3) When manufacturing the sock 1s, the coating step (S2, S3) for applying the coating agent 2c to the partial region Ap in the sock body 1sm, and after the coating step (S2, S3), A setting step (S7, S8, S9, S10) in which a partial area Ap on the surface opposite to the coated surface is brought into close contact with the molding die 11 shaped like the curved portion Xr, and this setting step (S7, S8, S9, S10), and a curing treatment step (S11, S12) in which the coating layer 2 is provided by curing the coating agent 2c in the partial region Ap in close contact with the mold 11, so that the sock 1s can be easily In addition, it is possible to obtain socks 1 s that can be reliably manufactured and have high quality and high commercial properties.

  (4) Since the silicon rubber material 2cs is used for the coating agent 2c, it can be implemented at a low cost by using a general-purpose material, and the above-described effects of the present invention are sufficiently obtained due to the physical properties of the silicon rubber material 2cs. A good coating layer 2 that can be exhibited can be provided.

  (5) After the completion of the coating step (S2, S3), since the pre-curing step (S4, S5) for curing the coating agent 2c to the intermediate curing state is provided, a material with high fluidity is used as the coating agent 2c. Even if it exists, it can transfer to a setting process (S7, S8, S9, S10) in the state stabilized in shape, and shape homogeneity can be ensured without being influenced by the fluidity | liquidity of the coating agent 2c.

  (6) In the coating process (S2, S3), since the sock body 1sm of the partial area Ap including the curved portion Xr is set in a flat state and the coating agent 2c is applied, the coating agent 2c is applied. It becomes possible, and the high-quality coating layer 2 can be provided easily and quickly, and can be implemented at low cost.

  (7) In the setting step (S7, S8, S9, S10), a suction process is performed from the mold 11 side while the partial area Ap of the sock body 1sm applied with the coating agent 2c is in contact with the mold 11. Since at least a partial region Ap of the sock body 1sm is brought into close contact with the mold 11, the sock body 1sm including the coating agent 2c can be securely brought into close contact with the mold 11 and more uniform. High-coating layer 2 and socks 1s can be obtained.

  (8) Since the suction process is performed only for a predetermined set time T2 after the sock body 1sm is brought into contact with the mold 11, the suction process is performed only for a necessary period in the entire process period of the curing process (S11, S12). In the remaining period, the suction operation can be stopped or directed to another suction process, and energy saving and mass productivity can be improved.

  (9) According to a preferred embodiment, provisional adhesive means for temporarily adhering the sock body 1sm of the partial area Ap is provided on the surface of the mold 11, and the coating agent is applied even after the suction processing is canceled after the suction for a set time T <b> 2. If the sock body 1sm including 2c is maintained in a temporarily bonded state on the surface of the mold 11, the temporarily bonded state can be maintained even when the suction process is performed for the set time T2, so that the above-described energy saving and mass productivity can be achieved. Improvements can be reliably activated.

The flowchart for explaining the manufacturing method of the sock which concerns on suitable embodiment of this invention later on, Explanatory drawing of the coating process in the manufacturing method, Explanatory drawing of the setting process and the curing process in the manufacturing method, The perspective view which shows the inner surface of the sock of the reverse state manufactured by the manufacturing method, Appearance perspective view of socks manufactured by the manufacturing method, Appearance side view of socks manufactured by the manufacturing method, Side cross-sectional view omitting a part of socks manufactured by the manufacturing method, Explanatory drawing which shows the other clothing which can be manufactured with the manufacturing method as a reference example,

  Next, preferred embodiments according to the present invention will be given and described in detail with reference to the drawings.

  Initially, the manufacturing method of the sock 1s which concerns on this embodiment is demonstrated with reference to process drawing (flowchart) shown in FIG. 1, referring FIGS.

  First, when manufacturing the sock 1s, a sock body 1sm is prepared (step S1). In this case, the sock body 1 sm is a generally marketed sock knitted with a fiber material. Therefore, the sock body 1sm may be manufactured as a dedicated sock body 1sm by a known manufacturing method, or a commercially available sock may be used as it is as the sock body 1sm.

  On the other hand, for the sock body 1sm, a coating process is performed in which a predetermined coating agent 2c is applied to a partial region Ap including the curved portion Xr on the inner surface 1smi of the sock body 1sm. In this case, silicon rubber material (thermosetting resin) 2cs is used for the coating agent 2c. If such a silicon rubber material 2cs is used, it can be implemented at low cost by using a general-purpose material, and a good coating layer 2 described later can be provided due to the physical properties of the silicon rubber material 2cs. The effects according to the invention can be sufficiently exhibited. The uncured silicone rubber material 2cs has properties as a fluid. Further, the curved portion Xr is a portion corresponding to the heel Hhh (FIG. 7) of the foot Hh. The partial area Ap may be only a part corresponding to this 踵 Hhh, but it is desirable to select a region that extends to a predetermined range around the outside centered on the part corresponding to this 踵 Hhh.

  In the coating process, the prepared sock body 1sm is set on a predetermined application jig (step S2). FIG. 2 illustrates two types of application jigs. (A) shows the screen printing type application jig 31, and (b) shows the roller type application jig 41. Since the coating jig 31 shown in (a) includes the screen printing unit 32, it can perform coating processing by screen printing, and the coating jig 41 shown in (b) includes the roller coating unit 42. A coating process using the roller 43 can be performed. Each of the application jigs 31 and 41 includes a base plate 21 for setting the sock body 1 sm, and the upper surface 21 u of the base plate 21 is formed to be a flat surface. In this case, the base plate 21 can be inserted (press-fit) into the sock body 1sm, and when inserted (press-fit), at least the upper surface 21u of the base plate 21 and the heel Hhh of the sock body 1sm Corresponding parts are placed. The cross-sectional area (vertical surface) of the base plate 21 is selected to be sufficiently larger than the cross-sectional area (vertical surface) inside the sock body 1sm, so that the base plate 21 is inserted inside the sock body 1sm ( When press-fitting, it is considered that the portion corresponding to the heel Hhh that becomes the curved portion Xr is set in a flat state. In (a), 33 indicates a plate frame, 34 indicates a screen, and 35 indicates a squeegee. In (b), 44 indicates a coating agent storage tank, and on the screen 34 and inside the coating agent storage tank 44, silicon is provided. The rubber material 2cs is accommodated.

  Then, when setting the sock body 1 sm on the base plate 21, the sock body 1 sm is turned over and exposed to the outside so that the inner surface 1 smi becomes the outer surface, and the upper surface of the base plate 21 as shown in FIG. Set to 21u. As a result, the partial area Ap on the inner surface of the sock main body 1 sm is set in a flat state facing the upper surface 21 u of the base plate 21, so that the predetermined coating agent 2 c is used using the application jig 31 or 41. Is applied to a partial area Ap of the sock body 1 sm (step S3). In this way, in the coating process, if the sock body 1sm of the partial region Ap including the curved portion Xr is set in a flat state and the coating agent 2c is applied, it can be performed using existing equipment. There is an advantage that the high-quality coating layer 2 can be provided easily and quickly and can be implemented at low cost.

  On the other hand, when the coating process is completed, a preliminary curing process is performed in which the silicon rubber material 2cs applied to the sock body 1sm is cured to an intermediate cured state. In this case, the sock body 1sm is stored in a heating space set to a heating temperature for curing the silicon rubber material 2cs, and is subjected to a preliminary drying process for drying (heating) for a preset time T1 (step S4). At this time, the set time T1 sets a time for curing the silicon rubber material 2cs to an intermediate cured state. This intermediate cured state is a so-called semi-dry state, and the set time T1 is at least a period of time until the sock body 1sm is detached from the application jig 31 or 41 and set in the molding jig 51 described later. The rubber material 2cs (coating layer 2) is selected considering that the application shape does not change (deform). Then, when the set time T1 has elapsed, the drying process is stopped and the preliminary curing process is terminated (steps S5 and S6). Further, the sock body 1sm is detached from the application jig 31 or 41 (step S7).

  If such a pre-curing step is provided, even if a highly fluid material is used as the coating agent 2c, the coating agent can be transferred to the next setting step in a stable state. The shape homogeneity can be secured without being influenced by the fluidity of 2c.

  Next, a setting step is performed in which a partial region Ap on the surface opposite to the surface on which the coating agent 2c is applied in the sock body 1sm is brought into close contact with the molding die 11 that represents the curved portion Xr. FIG. 3 shows an example of a forming jig 51 having the forming die 11. The mold 11 is integrally formed on the upper surface of the adsorber 52 that can be inserted into the sock body 1sm, and the shape of the mold 11 is shaped like the curved portion Xr, that is, the heel Hhh of the foot Hh. Form. It is desirable that the area of the outer surface of the mold 11 substantially matches the area of the partial region Ap. The adsorber 52 is inserted into the sock body 1sm. Unlike the base plate 21, the cross-sectional area (vertical surface) of the adsorber 52 is the cross-sectional area (vertical surface) inside the sock body 1sm. Select approximately the same or slightly smaller. Further, the molding jig 51 is formed in a hollow interior, and the molding die 11 is integrally formed (continuously formed) by expanding a part of the upper surface of the adsorber 52 upward. As shown in FIG. 3, a large number of small holes 11h are formed. Furthermore, one end side of the adsorber 52 is connected to an intake device 53 such as a vacuum pump.

  Accordingly, in the setting step, as shown in FIG. 3, the forming jig 51 is inserted into the sock body 1sm, and the setting is performed so that the partial region Ap in the sock body 1sm is aligned with the mold 11 ( Step S8). Then, the intake device 53 is operated to intake the inside of the adsorber 52 (step S9). Thereby, the partial area Ap of the sock body 1 sm to which the coating agent 2 c is applied is sucked by the small holes 11 h of the molding die 11, and the partial area Ap is in close contact with the outer surface of the molding die 11. FIG. 3 shows this state, and arrows Fn... Indicate the intake direction. As described above, in the setting process, the suction region is applied from the molding die 11 side while the partial region Ap of the sock main body 1sm coated with the coating agent 2c is in contact with the molding die 11, and at least one of the sock main body 1sm. If the partial area Ap is brought into close contact with the mold 11, the partial area Ap of the sock body 1 sm to which the coating agent 2 c is applied can be reliably brought into close contact with the mold 11, and the homogeneity is higher. The coating layer 2 and further the sock 1s can be obtained.

  Next, a curing process is performed. In the curing process, the adsorber 52 in which the sock body 1sm is set is accommodated in a heating space set to a heating temperature for curing the silicon rubber material 2cs, and the drying process is performed (heating) for a preset time T3. It performs (step S10). In FIG. 3, reference numeral 54 denotes a heating device such as a heater. At this time, the suction process is performed only for a preset time T2. The set time T2 is preferably selected to be shorter than the set time T3 for performing the main drying process. That is, if the silicon rubber material 2cs is cured by the main drying process and the shape of the silicon rubber material 2cs (coating layer 2) can be maintained to the shape of the mold 11 even if the suction process is stopped, the suction is performed. Since the process is not necessary, the suction process is stopped at that time (steps S11 and S12). In this way, if the soaking process is performed for a predetermined set time T2 after the sock main body 1sm is brought into contact with the mold 11, the suction process is performed for a necessary period in the entire process period of the curing process, and the rest During this period, the suction operation can be stopped or directed to another suction process, which has the advantage of improving energy saving and mass productivity.

  Incidentally, at this time, temporary adhesion means such as a heat-resistant adhesive tape to which the sock body 1 sm of the partial region Ap is temporarily adhered may be provided on the surface of the mold 11. As a result, the sock body 1sm containing the silicon rubber material 2cs is maintained in a temporarily bonded state on the surface of the mold 11 even after the suction process is canceled after the suction is performed for the set time T2, so the set time T2 is set shorter. it can. As a result, even when the suction process is performed for the set time T2, it is possible to maintain the temporary adhesion state, and there is an advantage that the above-described improvement in energy saving and mass productivity can be surely enabled.

  On the other hand, the set time T3 sets a time for curing the silicon rubber material 2cs to the final cured state. The final cured state is a state in which it is completely dried. When the set time T3 has elapsed, the drying process is stopped and the curing process is terminated (steps S13 and S14). Thereby, the sock 1s which has the coating layer 2 which hardened the silicon rubber raw material 2cs can be obtained. The obtained sock 1s is detached from the forming jig 51 (step S15). FIG. 4 shows the sock 1 s that has been removed from the forming jig 51 after the curing process has been completed. Further, the sock 1s in the reversed state is returned to the original state (normal state) (step S16). Thereby, the sock 1s shown in FIG. 5 can be obtained.

  Thus, according to the method for manufacturing the sock 1s according to the present embodiment, at least the coating process (S2, S3) for applying the coating agent 2c to the partial region Ap in the sock body 1sm, and the coating process (S2, S2). After the completion of S3), a setting step (S7, S8, S9, S10) in which a partial region Ap on the surface opposite to the surface to which the coating agent 2c has been applied is brought into close contact with the molding die 11 that represents the curved portion Xr; After this setting step (S7, S8, S9, S10), a curing treatment step (S11, S12) for providing the coating layer 2 by curing the coating agent 2c in the partial region Ap in close contact with the mold 11; Since it is provided, the sock 1s can be manufactured easily and reliably, and the sock 1s with high quality and high merchantability can be obtained.

  Next, the usage method and operation of the sock 1s manufactured by the manufacturing method according to the present embodiment will be described with reference to FIGS.

  In order to use the sock 1s, it can be put on the foot Hh in the same manner as a general sock. At this time, as shown in FIG. 6, the coating layer 2 is held in a shape that substantially matches the heel Hhh of the foot Hh. Therefore, when the sock 1 is worn, as shown in FIG. 2 abuts on the surface of the heel Hhh in an almost intact shape.

  That is, the final curing is achieved by bringing the sock body 1sm including the coating agent 2c applied to a partial region Ap of the sock body 1sm and cured to an intermediate cured state into contact with the mold 11 that is shaped like the curved portion Xr. Since the coating layer 2 is cured to the state, the coating layer 2 has a shape that fits the shape of the curved portion Xr to be attached.

  Therefore, even if the coating layer 2 is extended due to the size of the foot Hh, the coating layer 2 comes into contact with the surface of the heel Hhh with a substantially uniform pressure. As a result, problems such as an increase in the extension of the coating layer 2 and an increase in the variation of the extension at the time of mounting are eliminated. As described above, according to the sock 1s obtained by the manufacturing method according to the present embodiment, uniformity during wearing can be ensured, and thus the feeling of wearing (fitting) and comfort on the skin in the coating layer 2 are greatly enhanced. In addition, the stress in the coating layer 2 can be made uniform, and durability (life) can be improved. In addition, since the coating layer 2 has a shape that fits the shape of the curved portion Xr to be mounted, the area of the coating layer 2 and the thickness of the coating layer 2 can be increased as much as necessary. Thereby, the original function (performance) calculated | required by the coating layer 2 of moisture retention etc. can fully be ensured.

  Next, another garment 1 that can be manufactured by the manufacturing method according to the present invention will be described as a reference example with reference to FIGS.

  FIG. 8A shows a case where the garment 1 is applied to a supporter 15 attached to the arm Ha. In this case, since the part corresponding to the elbow Hae in the supporter 15 is the curved part Xr, the coating layer 2 similar to the above-described sock 1s is provided in the partial region Ap including the curved part Xr. Even in the case of such a supporter 15, since the coating layer 2 abuts on a part of the human body, it can be carried out in the same manner as in the case of the sock 1s described above, and the same effect can be obtained.

  Moreover, FIG.8 (b) shows the case where it applies to the brassiere 16 with which the garment 1 is mounted | worn with the breast Hd. In this case, the portion corresponding to the cup portion 16c... In the brassiere 16 becomes the curved portion Xr. Therefore, the coating layer 2 similar to the above-described sock 1s is provided in the partial region Ap including the curved portion Xr. Even in the case of such a brassiere 16, since the coating layer 2 contacts a part of the human body, it can be carried out in the same manner as in the case of the sock 1s described above, and the same effect can be obtained.

  Further, FIG. 8C shows a case where the garment 1 is applied to a garment 17 having a shoulder pad 18. In this case, since the part corresponding to the shoulder pad 18 becomes the curved part Xr, the coating layer 2 similar to the above-described sock 1s is provided in the partial region Ap including the curved part Xr. Even in the case of such a garment 17, since the coating layer 2 is in contact with a part of the human body, it can be performed in the same manner as in the case of the above-described sock 1s, and the same effect can be obtained.

  As mentioned above, although preferred embodiment was described in detail, this invention is not limited to such embodiment, It does not deviate from the summary of this invention in a detailed structure, a shape, a raw material, quantity, a numerical value, etc. It can be changed, added, or deleted arbitrarily.

  For example, in the coating process, the screen printing type application jig 31 and the roller type application jig 41 are shown as the application jigs, but other brush application methods and spray application methods are not excluded.

  The sock manufacturing method according to the present invention can be applied to the illustrated socks, arm supporters, leg supporters, and the like.

  1s: socks, 1sm: sock body, 2: coating layer, 2c: coating agent, 2cs: silicone rubber material, 11: molding die, 11h ...: many small holes, 21: base plate, 51: molding jig, 52: Adsorber, Xr: Curved part, Ap: Partial region, (S2, S3): Coating process, (S4, S5): Pre-curing process, (S7, S8, S9, S10): Setting process, (S11 , S12): Curing process

Claims (1)

  In a sock manufacturing method for manufacturing a sock in which a predetermined coating layer is provided in a partial region including at least a curved portion in the sock body, a base plate is press-fitted into the sock body to thereby press the one in the sock body. A coating process in which a partial area is set in a flat state and a coating agent using a silicon rubber material is applied to the partial area; and a pre-curing process in which the coating agent is cured to an intermediate curing state after the coating process is completed; A molding die that is shaped like the curved portion is integrally formed in an adsorber that can be inserted into the sock body, and the whole is formed hollow inside, and a plurality of small holes are formed in the molding die. After the forming jig is inserted into the sock body after the pre-curing step, the partial area on the surface opposite to the surface on which the coating agent is applied. Is set in contact with the mold, and after the contact, a suction process is performed from the mold side for a predetermined set time, and at least the partial region of the sock body is in close contact with the mold. And a curing treatment step of providing the coating layer by curing the coating agent in the partial region in close contact with the mold after the setting step. .

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