JP6389111B2 - Hat manufacturing method - Google Patents

Description

  The present invention relates to a manufacturing method of a hat configured by joining a plurality of astragalus with a substantially hemispherical crown, and a cap manufactured using the manufacturing method.

  A crown in a cap such as a baseball cap is generally formed in a substantially hemispherical shape by stitching the side edges of a plurality of fabrics cut into a substantially isosceles triangle called “rengue”. The crown formed in a substantially hemispherical shape is attached with a necessary member according to the type of hat, such as a bag or a bottle skin, and then a “molding” operation is performed as a finishing process. The mold insertion is a process of pressing the outer surface of the crown with a hand or the like while the mold (usually heated) formed in a substantially hemispherical shape is inserted inside the crown. With this mold insertion, it is possible to stretch the wrinkles and adjust the shape of the crown, or to adjust the bottle skin etc. to the crown. As a metal mold | die used for a mold case, what is shown, for example in patent documents 1-3 is proposed. However, even if the shape of the cap has been adjusted, it is only a temporary item in a new state, and the shape of the crown will collapse over time after use and washing. There was a problem.

  By the way, the applicant of the present invention is a hat in which a crown is formed in a substantially hemispherical shape by joining together a plurality of lotus roots, and an adhesive core in which at least one lotus root is coated with a hot melt adhesive on one side. It is composed of a ground and a surface layer superimposed on the surface coated with the hot melt adhesive in the adhesive interlining, and is heated while being pressed with a hot press die in a state where the adhesive interlining and the surface are overlapped. There has already been proposed a lotus that is formed by curving a substantially spherical shape (see Patent Document 4). Thereby, it becomes possible to make the whole crown into a beautiful substantially hemispherical shape and to improve the shape retention of the crown. However, since the cap of Patent Document 4 is forcibly formed into a substantially spherical shape, the lotus is after being bent into a substantially spherical shape due to a difference in stress generated between the outer core and the adhesive interlining. There is a problem in that a force for returning to a straight state is generated in the lotus, and the radius of curvature of the lotus actually obtained becomes larger than the desired radius of curvature.

  Further, the present applicant is a hat in which a crown is formed in a substantially hemispherical shape by joining a plurality of lotus pieces together, and the front side lotus forming the front part of the crown is heated while being pressed with a heating press die. Thus, a hat characterized by being formed into a substantially spherical shape has already been proposed (see Patent Document 5). Patent Document 5 also proposes that the front side lotus to be pressed with a hot press die is previously formed into a substantially spherical shape by stitching. This prevents the movement of the front side balance when closing the heating press die, and enables the front side balance to be formed into a desired shape. However, the hat of Patent Document 5 does not change that a stress difference is generated between the surface interlining and the adhesive interlining, and the curvature radius of the actually obtained lotus is slightly larger than the desired curvature radius. There was a problem of ending up.

JP 2003-166113 A JP 2009-041138 A JP 2010-236173 A JP 2012-162828 A JP, 2014-167180, A

  The present invention has been made in order to solve the above-mentioned problems, and even after forming a lotus in a curved shape with a hot press mold, a force that tends to return to a straight state hardly occurs in the lotus and is actually obtained. It is an object of the present invention to provide a method for manufacturing a hat capable of suppressing the curvature radius of a forsythia from becoming larger than a desired curvature radius. It is also an object of the present invention to provide a cap manufactured by this cap manufacturing method.

The above issues
A substantially hemispherical crown is a method of manufacturing a hat configured by connecting a plurality of renges together,
The at least part of the plurality of lotus is composed of a front interlining and a back interlining,
The part of the lotus
A rough bending step of roughly curving the front interlining into a curved surface and roughly curving the back interlining into a curved surface having a smaller radius of curvature than the front interlining.
In a state where the front and back interlinings after the rough bending process are overlapped with each other via an adhesive, the heating press mold has a male surface having a convex curved surface and a concave curved surface. A setting step for setting between the female mold,
The main forming step of integrating the front core and the back interlining and forming them into a curved shape by pressing while heating the front interlining and the back interlining with the heating press mold,
This is solved by providing a method of manufacturing a cap characterized in that the cap is manufactured by going through.

  In this way, in the rough bending process, by straightly curving the back interlining into a curved surface having a smaller radius of curvature than the front interlining, the part of the lotus after the main forming process has a straight state. It is possible to prevent a force from returning to the back.

  The configuration of the present invention may be adopted for all the lotus forming the crown, but in this case, the crown as a whole has a stiff feel and there is a risk that the wearing comfort of the hat may be reduced. For this reason, the configuration of the present invention is preferably applied to only some of the lotus forming the crown. In particular, it is preferable to adopt only for the front range that forms the crown front portion. This is because, from the viewpoint of improving the shape retention and appearance of the crown, the front side balance is most important, and even if the front side balance is somewhat stiff, it does not give the wearer a sense of incongruity. The front side balance is a left front range that covers the wearer's head left front in the crown (forms the crown left front), and a right front range that covers the wearer's head right front in the crown (forms the crown right front). Often composed.

  In the method for manufacturing a hat of the present invention, the part of the lotus may be composed of a single lotus (even a single lotus is cut with a predetermined depth from the apex to the base. Provided, and a method of stitching the opposing sides of the notch together, or by preliminarily bending them, etc.) is a method of arranging a plurality of lotus roots (crowns adjacent to each other). It is preferable that it is composed of a plurality of lotus. Thereby, it is possible to finish the rough bending process only by connecting these plurality of lotus roots.

  Specifically, the part of the lotus is two pieces of lotus connected to each other (for example, the left front lotus and the right front lotus), and the rough curvature of the front core in the rough bending step is represented by the table of the two lotus roots. The side edges of the interlining in the interlining are stitched together, and the rough interlining in the coarse bending step is performed between the side edges of the two lotus backlining in the interlining Are preferably performed by stitching together.

  At this time, the side edges (hereinafter also referred to as “inner side edges”) of the two lotus roots connected to each other in the back interlining are respectively displayed on the front surfaces of the two lotus roots. It forms so that it may overlap with the side edge (inner side edge) of the interlinked side in the interlining, and the side edge (hereinafter referred to as “outward”) It is preferable that the side edges of the two lotus roots are formed on the inner side of the side edges (outer side edges) that are not connected to each other. Even if the inner side edges of the front interlining and the back interlining are formed so as to overlap each other, the back interlining can be formed of a material thicker than the front interlining, or the back interlining can be made more than the front interlining. The curvature radius of the back interlining can be made smaller than the curvature radius of the front interlining by forming it with a harder material. In this regard, if the inner side edges of the front and back interlinings are formed so as to overlap each other, in the setting process, the front interlining and the back interlining are overlapped. When setting the interlining and the back interlining and performing the main forming step, it is possible to prevent relative movement of the periphery of the joint between the front interlining and the back interlining. In addition, by keeping the outer side edge of the back interlining away from the outer side edge of the front interlining, the part of the lotus after finishing the molding process has a force to return to a straight state. It is also possible to make it difficult to occur.

  In the method for manufacturing a hat of the present invention, the front core and the back interlining after finishing the rough bending step may be set as they are in the heating press mold, but the front interlining and the back interlining after finishing the rough bending step are performed. It is preferable to provide a temporary fixing process for temporarily fixing each other before the setting process. This makes it possible to set the front and back interlinings in a heated press mold in a state where they are positioned relative to each other. When the hot press mold is clamped or when performing the main forming step, It is possible to prevent misalignment with the lining interlining. Therefore, it becomes possible to form the partial lotus into a more beautiful curved surface. Although the specific method of temporary fastening is not specifically limited, The method etc. which sew a front core fabric and a back core fabric with a thread | yarn (henceforth "tentative yarn") are illustrated. The temporary holding yarn is removed after the main forming process is completed. The temporary holding yarn is preferably a conspicuous color having a different color from the front and back interlinings.

  In the cap manufacturing method of the present invention, the part of the lotus need not be decorated. However, when the part of the lotus is a front lotus (a front left lotus and a right front lotus), an emblem or the like may be expressed on the outer surface of the lotus by embroidery. However, after the crown is completely hemispherical, it may be difficult to embroider the balance. For this reason, when an embroidery process for embroidering the outer surface of the part of the lotus is provided, the embroidery process is preferably provided before the setting process. However, if the part of the lotus with embroidery is set in a hot press mold and the main forming process is performed, the portion with the embroidery may be crushed. For this reason, in the setting step, it is preferable to provide a thick face material in which a relief portion is formed at a location corresponding to the embroidery, between the hot-press type female die and the surface core of the partial lotus. This makes it possible to perform the main forming step on the part of the lotus without the embroidery portion being crushed.

The above issues are
A substantially hemispherical crown is formed by joining a plurality of renges together,
At least some of the plurality of lotus lotus is composed of a front interlining and a back interlining,
The part of the lotus is
A rough bending step of roughly curving the front interlining into a curved surface and roughly curving the back interlining into a curved surface having a smaller radius of curvature than the front interlining.
In a state where the front and back interlinings after the rough bending process are overlapped with each other via an adhesive, the heating press mold has a male surface having a convex curved surface and a concave curved surface. A setting step for setting between the female mold,
The main forming step of integrating the front core and the back interlining and forming them into a curved shape by pressing while heating the front interlining and the back interlining with the heating press mold,
It is solved by providing a hat characterized by being manufactured by going through.
This hat can be suitably manufactured using the above-described method for manufacturing a hat of the present invention.

  As described above, according to the present invention, even after a lotus is formed into a curved surface with a hot press die, a force that tends to return to a straight state is hardly generated in the lotus, and the curvature radius of the lotus actually obtained is a desired curvature. It is possible to provide a method for manufacturing a hat that can prevent the radius from becoming larger than the radius. It is also possible to provide a cap manufactured by this cap manufacturing method.

It is the perspective view which showed the cap manufactured with the manufacturing method of the cap of this invention. It is the perspective view which showed the state which decomposed | disassembled the hat shown in FIG. 1 into each part. It is the figure which showed the state which looked at the front core of the front left lotus and the front core of the front right lotus from the back side, respectively. It is the figure which showed the state which looked at the back interlining of the front left lotus and the back interlining of the front right lotus from the back side, respectively. It is sectional drawing which showed the state which cut | disconnected the heating press type | mold which finished the setting process by the vertical surface. It is sectional drawing which showed the state which cut | disconnected the hot press type | mold which is performing this formation process by the vertical surface. It is sectional drawing which showed the state which cut | disconnected the heat press type | mold after finishing this shaping | molding process by the vertical surface. It is the figure which showed the state which looked at the press surface of the male type | mold in a heating press type | mold from the direction (vertical lower side) perpendicular | vertical to this press surface. It is the photograph which showed the change of the shape of the front side balance before and after this shaping | molding process.

1. The hat of this invention The suitable embodiment of the hat concerning this invention and its manufacturing method is demonstrated more concretely using drawing. FIG. 1 is a perspective view showing a cap manufactured by the cap manufacturing method of the present invention. FIG. 2 is a perspective view showing a state in which the hat shown in FIG. 1 is disassembled into various parts. FIG. 3 is a view showing a state in which the front core 11a of the left front lotus 11 and the front core 12a of the right front lotus 12 are viewed from the back side. In FIG. 3, the back interlining 11b of the left front range 11 and the back interlining 12b of the right front range 12 are indicated by broken lines, respectively. FIG. 4 is a view showing a state in which the back interlining 11b of the left front range 11 and the back interlining 12b of the right front range 12 are viewed from the back side. In FIG. 4, the front core 11 a of the left front lotus 11 and the front core 12 a of the right front lotus 12 are indicated by broken lines.

  As shown in FIG. 1, the cap according to the present invention includes a substantially hemispherical crown 10. The crown 10 is formed in a substantially hemispherical shape by connecting the side edges of a plurality of renges 11 to 16 having a substantially isosceles triangular shape. The number of the lotus forming the crown 10 is not particularly limited, but in the cap of the present embodiment, the left front lotus 11 that forms the left front portion of the crown 10, the right front lotus 12 that forms the right front portion of the crown 10, and the crown 10, a left lateral range 13 that forms the left side of the crown 10, a right lateral range 14 that forms the right side of the crown 10, a left rear ranger 15 that forms the left rear portion of the crown 10, and a right that forms the right rear portion of the crown 10. The crown 10 is constituted by a total of six lotuses 11 to 16 constituted by the rear lotus 16. In the following description, the front left lotus 11 and the right front lotus 12 that form the front portion of the crown 10 may be collectively referred to as “front side lotus 11, 12”.

  As shown in FIG. 2, the lotus 11, 12, 13, 14, 15, 16 includes a surface material 11a and a lining material 11b, a surface material 12a and a lining material 12b, a surface material 13a and a lining material 13b, a surface material 14a and a lining material 14b, and a surface material 15a and a surface material 15a, respectively. It has a multi-layer structure composed of a lining 15b, a surface 16a and a lining 16b. Among these, the front side surfaces 11a and 12a of the front side balances 11 and 12 are formed of a slightly harder fabric (interlining), and the linings 11b and 12b of the front side balances 11 and 12 are also formed of a slightly higher level of fabric (intermediate). Forming. On the other hand, the outer fabrics 13a, 14a, 15a, 16a and the linings 13b, 14b, 15b, 16b use soft fabrics instead of interlining. In the following description, the outer material 11a and the lining material 11b of the front left lotus 11 and the outer material 12a and the lining material 12b of the front right astragal 12 formed by the interlining material are respectively referred to as the “fronting material 11a”, the “lining material 11b” and the “fronting material”. 12a "and" lining interlining 12b ".

  In the hat of the present embodiment, the front rangers 11 and 12 are formed into a curved shape through a rough bending step, a setting step, and a main forming step, which will be described later, and the force to return to a straight state is generated. 11 and 12 are less likely to occur, and the front side balances 11 and 12 can be held in a beautiful curved shape.

2. Manufacturing method of hat of the present invention The above-described hat of the present embodiment is manufactured by the following method. Among the steps for manufacturing the hat of the present embodiment, for steps not directly related to the front side balances 11 and 12 (cutting of the balances 13 to 16, the band material 20, the bottle skin 30 and the collar 40, sewing or stitching, etc.) A method similar to that of a conventional hat can be employed. For this reason, below, it demonstrates centering on the process regarding the front side balances 11 and 12 among each process which manufactures the cap of this embodiment, and omits description about another process.

In the hat of the present embodiment, the front side balances 11 and 12 are
(1) a rough bending step of rough bending the front interlinings 11a and 12a and the back interlinings 11b and 12b;
(2) an embroidery process for embroidering the outer surfaces of the front cores 11a and 12a after the rough bending process;
(3) a temporary fastening step of temporarily fastening the front interlinings 11a, 12a after the embroidery process and the back interlinings 11b, 12b after the rough bending process;
(4) A setting step of setting the front interlining 11a, 12a and the back interlining 11b, 12b, which have finished the temporary fixing step, on the heating press die 50 in a state where they are overlapped with each other via an adhesive;
(5) The main forming step of pressing the front interlinings 11a and 12a and the back interlinings 11b and 12b with the heating press mold 50 after finishing the setting step;
It is manufactured by going through.

  The kind of cloth used for the surface interlining 11a, 12a is not particularly limited as long as it can perform a rough bending process and the like to be described later, and various kinds of cloth made of synthetic fibers or natural fibers, and resin sheets, etc. Can be used. In the manufacturing method of the present embodiment, the surface interlinings 11a and 12a are formed on the back surface of a fabric (number of driven 31 (vertical) × 33 (horizontal)) woven from a yarn made of polyester fibers (count 10 / −). A cloth in which a resin sheet blended with ethylene vinyl acetate (EVA) and polyethylene is laminated is used.

Moreover, the kind of cloth used for the lining materials 11b and 12b is not particularly limited as long as it can perform a rough bending process and the like to be described later, and various kinds of cloth made of synthetic fibers or natural fibers, and resin therefor. A cloth in which a sheet or the like is laminated can be used. In the manufacturing method of the present embodiment, the linings 11b and 12b are made of a fabric (weighing 370 g / m ² ) woven from yarn made of polyester fibers (warp yarn count 10/2, weft yarn count 10/2), The number of driving 25 (vertical) x 25 (horizontal)) is used. As will be described later, an adhesive is applied to the surfaces to be bonded to the outer surfaces of the lining fabrics 11b and 12b (front lining fabrics 11a and 12a).

2.1 Coarse-curving step The coarse-curving step is a step of roughly curving the front cores 11a and 12a into a curved surface and rough-curving the back cores 11b and 12b into a curved surface having a smaller radius of curvature than the front core. is there. As already described, the specific method of the rough bending process is not particularly limited. In the manufacturing method of the present embodiment, the inner core A ₁ A ₃ in the outer core 11a and the inner edge B ₁ B _{3 in the} outer core 12a shown in FIG. The bases 11a and 12a are roughly curved into a curved shape, and the inner side edge C ₁ C ₂ in the back interlining 11b and the inner side edge D ₁ D ₂ in the back interlining 12b shown in FIG. 4 are stitched together. As a result, the interlinings 11b and 12b are roughly curved into a curved shape. That is, since the inner side edges A ₁ A ₃ , B ₁ B ₃ , C ₁ C ₂ , and D ₁ D ₂ are all convex curves, the front interlinings 11a and 12a and the back interlining 11b , 12b, even if they are cut into a flat shape, by stitching the inner side edges A ₁ A ₃ , B ₁ B ₃ , C ₁ C ₂ , D ₁ D ₂ as described above As shown in FIG. 2, the stitched outer core 11a and the outer core 12a, and the stitched inner core 11b and the inner core 12b are both three-dimensionally curved into a curved surface (substantially spherical). Coarse curve).

In the rough bending process, the method of making the curvature radii of the back interlinings 11b and 12b smaller than the curvature radii of the front interlinings 11a and 12a is not particularly limited. For example, the curves of the inner side edges C ₁ C ₂ , D ₁ D ₂ of the back interlinings 11b, 12b in FIG. 4 are the same as the inner side edges A ₁ A ₃ , B ₁ B ₃ of the front cores 11a, 12a. If it is tighter than the curve, the curvature radii of the back cores 11b and 12b after stitching can be made smaller than the curvature radii of the front cores 11a and 12a after stitching. However, in this case, when the heating press die 50 to be described later is clamped or when the main forming step is performed, the periphery of the joint between the front core 11a and the front core 12a, the back core 11b, and the back core. There is a possibility that it becomes difficult to finish the front side balances 11 and 12 in a beautiful curved shape because the joints around the joint with 12b move relatively. For this reason, in the manufacturing method of this embodiment, as shown in FIG. 4, the inner side edge C ₁ C ₂ of the back interlining 11b is set to the section A in the inner side edge A ₁ A ₃ of the front interlining 11a. ₁ A ₂ and the same curve overlapping with each other, the inner side edge D ₁ D ₂ of the back interlining 12b, the section B ₁ B ₂ in the inner side edge B ₁ B ₃ of the front interlining 12a, They are formed with the same curves that overlap each other. Since the linings 11b and 12b are made of a thicker and harder cloth than the front linings 11a and 12a, they are made to coincide with the inner side edges C ₁ C ₂ and D ₁ D ₂ of the linings 11b and 12b. However, the curvature radii of the back interlinings 11b and 12b are smaller than the curvature radii of the front interlinings 11a and 12a.

Table interlining 11a, the center portion of the stapling portion of 12a (a r _a.) The radius of curvature at the (most recessed portion when viewed from the back side) back for interlining 11b, the center portion of the suture portion 12b (from the back side The ratio r _b / r _a of the radius of curvature (referred to as r _b ) at the most depressed portion when viewed is not particularly limited as long as it is less than 1. However, when the ratio _r b / _{r a} too small, in the molding step described later, back interlining 11b, 12b not only becomes difficult along Table interlining 11a, 12a, after the molding step, Urashin There is also a possibility that the force by which the ground 11b, 12b pulls the front cores 11a, 12a inward becomes too strong. For this reason, the ratio r _b / r _a is preferably 0.6 or more. The ratio r _b / r _a is more preferably 0.7 or more, and further preferably 0.8 or more. On the other hand, if the ratio r _b / r _a is too large, there is a possibility that the force to return to the straight state that can be manifested in the front side balances 11 and 12 that have finished the molding process cannot be suppressed. For this reason, the ratio r _b / r _a is preferably 0.99 or less. The ratio r _b / r _a is more preferably 0.97 or less, and further preferably 0.95 or less.

Further, in the manufacturing method of the present embodiment, as shown in FIG. 4, the outer side edge C ₃ C ₄ of the back interlining 11b is wider than the outer side edge A ₄ A ₅ of the front interlining 11a. ₁ only ahead inwardly declined to outer side edges _D 3 _{D 4} of the back interlining 12b, inwardly by a width _{W 1} than the outer side edge _B 4 _{B 5} of Table interlining 12a. Outer side edges C ₃ C ₄ and D ₃ D ₄ of the linings 11b and 12b are respectively outer side edges A ₄ A ₅ and B ₄ B _{5 of the} front cores 11a and 12a in the main forming process described later. It is fixed at a location that substantially matches. For this reason, the force which is going to bend inward can be added with respect to the front core fabrics 11a and 12a from the back fabrics 11b and 12b after finishing this forming process. Therefore, it is possible to form the front side balances 11 and 12 in a more beautiful curved shape. The width W ₁ that keeps the outer side edges C ₃ C ₄ and D ₃ D ₄ of the linings 11b and 12b varies depending on the thickness and width of the linings 11b and 12b, and is not particularly limited. However, too narrow a width W _1, the above effect may become difficult to achieved. Therefore, the width _{W 1} is preferably an 0.3mm or more. Width _{W 1} is more preferably a 0.5mm or more, more preferably to 1mm or more. On the other hand, an excessively large width _{W 1,} the back interlining 11b, Table interlining 11a from 12b, the table interlining 11a applied to 12a, there is a risk that the force to bend the 12a inside becomes too large. Therefore, the width _{W 1} is usually a 5mm or less. Width _{W 1} is preferable to be 3mm or less, and more preferably 2mm or less. In the production method of the present embodiment, the width W ₁ is set to about 1 mm.

Incidentally, in the manufacturing method of this embodiment, the back interlining 11b, the lower edge _{C 2 C 3, D 2 D} 3 Table interlining 11a of 12b, under 12a edge _A 3 _{A 4,} than B 3 _{B 4} only the width W ₂ is ahead on the inside. The specific value of the width W _2, is not particularly limited, in the manufacturing method of this embodiment, is set to 10-15 mm.

2.2 Embroidery process The embroidery process is a process in which embroidery 17 (see FIG. 2) is applied to the outer surfaces of the front cores 11a and 12a after the rough bending process. The embroidery 17 is provided for the purpose of providing an emblem on the hat or representing a decorative pattern on the hat, and is provided in a form representing characters or figures according to the purpose. The place where the embroidery 17 is provided varies depending on its purpose and is not particularly limited. However, in the hat according to the present embodiment, the embroidery 17 is provided at a substantially central portion of the boundary between the front core 11a and the front core 12a. The embroidery 17 functions as a hat emblem. Since the method of applying the embroidery 17 can be the same as that of the conventional embroidery, the detailed description is omitted.

2.3 Temporary Fastening Process The temporary fastening process is a process in which the front cores 11a and 12a that have finished the embroidery process and the back cores 11b and 12b that have finished the rough bending process are stacked and temporarily fastened together. As a result, it becomes possible to set the front interlinings 11a, 12a and the back interlinings 11b, 12b in the hot press mold in a state where they are positioned with respect to each other. The specific method of temporary fastening is not particularly limited, but in the manufacturing method of the present embodiment, the vicinity of the center of the front cores 11a, 12a and the back cores 11b, 12b is temporarily fixed (not shown). Sewing locally. In the manufacturing method of this embodiment, the front interlinings 11a and 12a and the back interlinings 11b and 12b are all dark blue or black dark, and therefore the temporary fixing yarn is white (light color). Thereby, it is possible to make the temporary retention yarn stand out and to easily remove the temporary retention yarn after the main forming step is completed. It is also possible to prevent forgetting to remove the temporary yarn.

2.4 Set Process FIG. 5 is a cross-sectional view showing a state where the hot press die 50 after the set process is cut along a vertical plane. As shown in FIG. 5, the setting step includes a convex curved press surface 51a in the heating press die 50 in a state where the front cores 11a and 12a and the back cores 11b and 12b are overlapped with each other via an adhesive. And a female mold 52 having a concave curved press surface 52a. When FIG. 5 is seen, it turns out that the curvature radius of back interlining 11b, 12b is smaller than the curvature radius of front interlining 11a, 12a.

  If the adhesive is interposed between the front interlinings 11a and 12a and the back interlinings 11b and 12b, the manner in which the adhesive is provided is not particularly limited. The adhesive may be applied to the back surfaces of the front cores 11a and 12a, but is usually applied to the surfaces of the back cores 11b and 12b. In the manufacturing method of the present embodiment, an adhesive is applied in the form of dots on the surfaces of the linings 11b and 12b (so-called “dot glue”). Thus, it is possible to make it difficult for wrinkles to be formed on the front side balances 11 and 12 after the main forming step is applied by applying the adhesive in a dot shape. The type of the adhesive to be used is not particularly limited as long as it is melted in the main forming process described later and cured after the main forming process. Examples of such an adhesive include a hot-melt adhesive made of a thermoplastic resin such as ethylene vinyl acetate (EVA).

  The heating press mold 50 may be arranged such that the male mold 51 and the female mold 52 face each other in a non-vertical direction (such as a horizontal direction). However, the heating press mold 50 according to this embodiment is a male mold. 51 and the female mold 52 are arranged so as to face each other in the vertical direction. As a result, the setting process can be performed without providing a separate mechanism for supporting the front interlinings 11a and 12a and the back interlinings 11b and 12b, and the mechanism of the heating press die 50 can be simplified and saved. It can be a space. In this case, there is no particular limitation as to which is the upper die (the die arranged on the vertical upper side) and which is the lower die (arranged on the vertical lower side), but in the heating press die 50 of this embodiment, the male The mold 51 is an upper mold and the female mold 52 is a lower mold.

  Moreover, in the manufacturing method of this embodiment, as shown in FIG. 5, the press surface 51a of the male mold 51 and the press surface 52a of the female mold 52 are respectively thick (the thickness when not compressed is about 1 to 20 mm). The face materials 53 and 54 are covered. For this reason, the press surfaces 51a and 52a heated in the main forming process to be described later do not directly contact the backing interlinings 11b and 12b and the front interlinings 11a and 12a, and the backing interlinings 11b and 12b and The surface interlinings 11a and 12a are made less painful by heat. The materials of the face materials 53 and 54 are not particularly limited, but as will be described later, the heating of the back cores 11b and 12b and the front cores 11a and 12a in the main forming step is sprayed from the press surface 51a or the press surface 52a. In the case of using pressurized steam, a non-woven fabric or the like is preferably air permeable. Thereby, it becomes possible to diffuse the pressurized steam sprayed from the press surfaces 51a, 52a in the main forming step between the press surface 51a and the press surface 52a, and the back interlinings 11b, 12b and the front interlinings 11a, It becomes possible to heat the wide range in 12a uniformly. Further, if the face materials 53 and 54 are made of a material having cushioning properties such as a nonwoven fabric, when the heating press die 50 is clamped, the backing interlinings 11b and 12b and the front interlinings 11a and 12a are within a narrow gap. It is possible to prevent wrinkles from being formed on the front side balances 11 and 12 so as not to be pinched.

  By the way, in the manufacturing method of this embodiment, as shown in FIG. 5, as the face material 54 on the side where the front cores 11a and 12a are arranged, an opening 54a (a relief part) is provided at the center. Something is used. In the manufacturing method of the present embodiment, as described above, the embroidery 17 is applied to the center portions of the front cores 11a and 12a. When the face material 54 hits the embroidery 17, the embroidery 17 is applied in the main forming process described later. There is a risk of crushing. In this regard, by providing an opening 54a as a relief portion at a location overlapping the embroidery 17 in the face material 54, the main molding process can be performed without the embroidery 17 being crushed. The opening shape of the opening 54a is not particularly limited as long as the embroidery 17 can be inserted. Further, the escape portion of the embroidery 17 does not need to be the opening 54a penetrating the face material 54 on the front and back sides, and the recesses (the front cores 11a and 12a on the face material 54 are disposed) that do not penetrate the face material 54 on the front and back sides. It is good also as the recessed part provided in the side.

  Moreover, it is also preferable to cover the surface of the face material 54 on the side on which the face cores 11a and 12a are placed with a wire mesh. Thereby, it becomes possible to prevent the outer surface of the outer cores 11a and 12a after the main forming process is finished. When the setting step is finished, the hot press die 50 is clamped and a main forming step described later is performed.

[Main molding process]
FIG. 6 is a cross-sectional view showing a state in which the hot press die 50 performing the main forming process is cut along a vertical plane. As shown in FIG. 6, the main forming step is performed by pressing the front cores 11 a and 12 a and the back cores 11 b and 12 b of the front side balances 11 and 12 while heating them with a press die 50. 12a and the backing interlinings 11b and 12b are integrated and formed into a substantially spherical shape.

  Heating of the front cores 11a, 12a and the back cores 11b, 12b in the main forming process is performed by directly moving the male mold 51 and the female mold 52 with a heat source (such as a heater or a burner) accommodated in the male mold 51 or the female mold 52. However, in the manufacturing method of the present embodiment, it is performed by pressurized steam blown from the male mold 51. That is, as shown in FIG. 6, the press surface 51a of the male die 51 is provided with a plurality of steam spray holes 51b having a diameter of about 1 cm, and the front range 11 by pressurized steam sprayed from these steam spray holes 51b. , 12 are heated. The pressurized steam sprayed from the steam spray holes 51b diffuses between the press surface 51a of the male mold 51 and the press surface 52a of the female mold 52, and then a plurality of steam provided on the press surface 52a of the female mold 52. It comes out of the hole 52b. The steam spray holes 51b and the steam vent holes 52b are respectively provided in a total of 49 pieces (see FIG. 8) in seven rows and seven columns at the center and the periphery of the press surface 51a and the press surface 52a, respectively. FIG. 8 is a view showing a state in which the press surface 51a of the male die 51 in the heating press die 50 is viewed from the vertical direction (vertical lower side).

  The temperature of the pressurized steam sprayed from the steam spray holes 51b is not particularly limited, but if it is too low, it may be difficult to impart high shape retention to the front side lotions 11 and 12. For this reason, the temperature of the pressurized steam is usually 80 ° C. or higher. The temperature of the pressurized steam is preferably 90 ° C. or higher, and preferably 100 ° C. or higher. On the other hand, if the temperature of the pressurized steam sprayed from the steam spray hole 51b is too high, the front side balances 11 and 12 may be burnt. For this reason, the temperature of the pressurized steam is usually 150 ° C. or lower. The temperature of the pressurized steam is preferably 130 ° C. or lower, and more preferably 120 ° C. or lower. In the manufacturing method of this embodiment, the temperature of the pressurized steam is about 110 ° C.

  Moreover, the time (heating time) which sprays pressurized steam from the steam spraying hole 51b varies depending on the thickness of the dough forming the front side lotions 11 and 12 for performing the main forming step, and is not particularly limited. However, if the heating time is too short, it may be difficult to form and maintain the front side balances 11 and 12 in a desired shape. For this reason, the heating time is usually 5 seconds or more. The heating time is preferably 10 seconds or more, and more preferably 15 seconds or more. On the other hand, if the heating time is excessively long, it may be difficult to form and maintain the front side balances 11 and 12 in a desired shape in the main forming step. In addition, the productivity of the hat may be reduced. Further, depending on the temperature of the pressurized steam, the front side lotions 11 and 12 may be burnt. For this reason, the heating time is usually 120 seconds or less. The heating time is preferably 60 seconds or shorter, and more preferably 40 seconds or shorter. In the manufacturing method of this embodiment, the thickness of the dough forming the front side balances 11 and 12 is about 2 mm, and the heating time in the main forming step is 20 seconds. However, after the heating time is over, a vacuum time of 20 seconds for removing the steam remaining between the press surface 51a and the press surface 52a from the steam vent 52b is provided.

  FIG. 9 is a photograph showing a change in the shape of the front side balances 11 and 12 before and after the main forming step. As shown in the lower side of FIG. 9, the front side balances 11 and 12 after the completion of the main molding process have a substantially spherical shape with a smaller radius of curvature and a natural appearance than before the main molding process (the upper side of the same figure). It has become. When the main forming step is completed, the front crowns 11 and 12 are cooled. The front crowns 11 and 12 may be actively cooled, but natural cooling is usually sufficient.

[Others]
When the main molding process is completed, a crown molding process is subsequently performed. As shown in FIG. 2, the crown forming process is a process of obtaining the substantially hemispherical crown 10 by connecting the other renges 13 to 16 to the front side balances 11 and 12 that have completed the main forming process. The other renges 13 to 16 may be connected to each other in advance before being connected to the front side forks 11 and 12, or the front side forks 11 and 12 are connected to the front side forks 13 and 14, and further connected to the front side forks 15 and 16. You may make it match. The method of connecting the lotus 11 to 16 is usually performed by stitching each fabric using a sewing machine or the like. At this time, the band material 20 (see FIG. 2) is usually sewn to the boundary between the lotus 11-16. Necessary members such as a bottle skin 30 (see FIG. 2) and a collar 40 (see FIG. 2) such as a bottle skin 30 (see FIG. 2) are attached to the crown 10 which has become substantially hemispherical after the crown forming process. A mesh fabric (not shown) formed in a hemispherical shape can be attached to the inside of the crown 10.

  When the crown molding process is completed, a mold insertion process is subsequently performed. The mold insertion process is a process in which the crown 10 that has undergone the crown formation process is molded and the wrinkles of the crown 10 are extended. The mold is inserted by pressing the outer surface of the crown 10 with a hand or the like while the mold (usually heated) formed in a substantially hemispherical shape is inserted inside the crown 10. By this mold insertion process, it is possible to stretch the wrinkles to adjust the shape of the crown 10 or to adjust the bottle skin or the like to the crown 10. As the mold used in the mold insertion process, various types conventionally used can be used. When the mold insertion process is completed, the manufacturing method of the cap of this embodiment is completed.

[Usage]
The cap manufacturing method of the present invention can be used to manufacture various caps having a substantially hemispherical crown. Caps with a substantially hemispherical crown include caps with a heel (front heel) on the lower edge of the front of the crown, such as a baseball cap, and a prim on the lower rim of the crown. A hat-type thing provided with is illustrated. The cap manufacturing method of the present invention is capable of improving the shape retention of the crown, so that it is likely that the crown will be deformed due to wearing or washing, such as a sports cap such as a baseball cap, a school cap, It is particularly suitable for manufacturing hats that are frequently worn and washed, such as work caps.

10 Crown 11 Front left astragalus (frontal astragalus)
11a Outer interlining (outer surface)
11b Lining (lining)
12 Right front astragalus (frontal astragalus)
12a Outer surface 12b Lining 13 Left side lotus 13a Outer surface 13b Lining 14 Right side lotus 14a Outer surface 14b Lining 15 Left rear lotus 15a Outer surface 15b Lining 16 Right rear lotus 16a Outer surface 16b Lining 20 Band material 30 Bottle skin 40 Mold 50 Die 51a Press surface 51b Steam spray hole 52 Female mold 52a Press surface 52b Steam vent 53 Face material 54 Face material 54a Opening (relief part)

Claims (5)

A substantially hemispherical crown is a method of manufacturing a hat configured by connecting a plurality of renges together,
The at least part of the plurality of lotus is composed of a front interlining and a back interlining,
The part of the lotus
A rough bending step of roughly curving the front interlining into a curved surface and roughly curving the back interlining into a curved surface having a smaller radius of curvature than the front interlining.
An adhesive application step of applying a hot melt type adhesive to the back surface of the front interlining or the surface of the back interlining;
Temporary fastening step of temporarily fastening each other with a temporary thread around the center portion of the front and back interlinings after the rough bending step;
Table interlining and back interlining finishing the temporary fixing step, with the non-central portion of the back interlining is lifted from the table interlining, male and concave curved surface having a convex curved press surface in pressurized hot press type A setting step of setting between a female mold having a shaped press surface;
By pressing the front and back interlinings after the setting process with a hot press mold, the hot melt adhesive is used to integrate the front and back interlinings and to form a curved surface. The main molding process;
The manufacturing method of the cap characterized by manufacturing by going through.
The part of the lotus is two lotus connected to each other,
While performing the rough curve of the surface core in the rough curve step by stitching together the side edges of the two lotus surface cores to be joined together,
The manufacturing method of the cap of Claim 1 which performs the rough curve of the backing interlining in the coarse bending process by stitching together the side edges on the side of the interlining of the two lotus roots.
The side edges of the two lotus roots connected to each other in the back interlining are formed so as to overlap with the side edges of the two lotus roots connected to each other in the front core.
The side edges of the two lotus roots that are not joined to each other are formed inwardly of the side edges of the two lotus root that are not joined to each other. The manufacturing method of the cap of Claim 2.
The method of manufacturing a cap according to claim 2 or 3, wherein the partial lotus is a left front lotus forming a crown left front portion and a right front lotus forming a crown right front portion.
An embroidery process for embroidering the outer surface of the part of the lotus is provided before the setting process,
In the setting step, any one of claims 1-4 provided between the table interlining of the embroidery part said the female thick surface material heated press mold relief portion is formed at a position corresponding to the astragalus The manufacturing method of the described cap.

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