JPH08302517A - Production of protective headgear made of felt - Google Patents

Abstract

PURPOSE: To provide a lightweight and air-permeable protective headgear improved in the protective performance against obstacles. CONSTITUTION: A rigid felt 3 comprising internally solid regular fibers mixed with lower-melting fibers is sandwichingly laminated with flexible felts 1, 2 each comprising hollow fibers of nearly equal melting point to the regular fibers and of lower melting point in a mutually entangled fashion into a laminated felt. There are provided a hemispherical convex male mold and a female mold having a hemispherical concave engageable with the convex of the male mold. The laminated felt is then heated to a temperature enough to melt the lower melting point fibers and put in between the male and female molds with the flexible felt 1 faced on the male mold and then sandwichingly pressed by the male and female molds to deform the cross-section of the laminated felt into half-arc shape.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a felt protective cap that can withstand a predetermined impact.

[0002]

2. Description of the Related Art As a protective hat that can withstand a large impact, F
There was a helmet formed of a hard plastic material such as RP. Further, there were work hats, baseball hats, etc. formed of cloth materials as protective hats that withstand small impacts.

[0003]

The above-mentioned helmet is heavy and poor in breathability, and is not suitable for light work, exercise, etc., which requires agile movement. Further, there is a drawback that the design cannot be uniform because it is not possible to obtain a variety of shapes. Further, the cloth hat cannot be increased in rigidity or strength, and has a drawback that the protective function is deteriorated. It is an object of the present invention to obtain a novel method of manufacturing a protective hat made of felt, which eliminates the above drawbacks.

[0004]

The present invention is configured as follows to achieve the above object. That is, a hard felt formed by mixing regular fibers having a solid interior and low-melting-point fibers having a lower melting point than the regular fibers, a hollow fiber having a melting point substantially the same as that of the regular fibers and a hollow inside and hollow fibers Also provided with a soft felt formed by mixing low melting point fibers having a low melting point, and by laminating the hard felt and the soft felt and entwining the fibers of both to provide a laminated felt, a male having a hemispherical convex portion A mold and a female mold having a hemispherical concave portion to which the convex portion of the male mold is fitted, the laminated felt is heated to a temperature at which the low-melting fiber melts, and the heated laminated felt is placed on the soft felt side thereof. Is disposed between the male mold and the female mold toward the male mold, and the heated laminated felt is clamped by the male mold and the female mold to be deformed into a semi-circular cross section. In this case, it is preferable that the hollow fiber is a hollow polymer fiber in which the shrinkage rate on one half circumference side and the shrinkage rate on the other half circumference side are different from each other. Further, a hard felt formed by mixing regular fibers having a solid interior and low-melting-point fibers having a lower melting point than the regular fibers, hollow fibers having a melting point substantially the same as that of the regular fibers and hollow inside and hollow fibers And a hollow polymer having a melting point that is substantially the same as that of the regular fiber and has different shrinkage rates on one half-circumferential side and the other half-circumferential side that are different from each other. A second soft felt made by mixing fibers and low-melting-point fibers having a lower melting point than the hollow polymer fiber is provided, and the first soft felt and the second soft fiber are sequentially laminated on the hard felt, and these three members are combined. The fibers are entangled with each other to provide a laminated felt, and a male die having a hemispherical convex portion and a female die having a hemispherical concave portion for fitting the male convex portion are provided. The low-melting-point fiber is heated to a temperature at which it melts, and the heated laminated felt is placed between the male mold and the female mold with the second soft felt layer facing the male mold. The heated laminated felt is sandwiched and deformed into a semi-circular cross section.

[0005]

Embodiments of the present invention will be described below with reference to the drawings. First, as shown in FIGS. 1 and 2, the regular fiber 3
And the low melting point fiber 4 are entangled with each other to form the hard felt 2. That is, the melting point of the regular fiber 3 is about 23.
A regular polyester at 0 ° C. has a single structure with a solid interior and is crimped mechanically to form a crimp. The low melting point fiber 4 has a double structure of a core portion 4a and a sheath portion 4b. In addition, the core 4a is made of regular polyester having a melting point of about 230 ° C. like the regular fiber 3 and the sheath 4b is made of a low melting point polyester having a melting point of about 110 ° C. The regular fibers 3 and the low melting point fibers 4 are laminated and blended at a ratio of about 4: 6, and are entwined with each other by the needle punch 10 to form the hard felt 2 as shown in FIG. In addition, 11 is a feed roll.

Further, as shown in FIGS. 3 and 4, the hollow fiber 6 and the low melting point fiber 4 similar to those described above are entangled with each other to form the first fiber.
The soft felt 5 is formed. The hollow fiber 6 has a hollow interior made of regular polyester having a melting point of about 230 ° C., and is crimped mechanically to form a crimp shape. Laminated and compounded in a ratio of 3 and, as shown in FIG. 7, these are entwined with each other by a needle punch 10 to form a first soft felt 5.

As shown in FIGS. 5 and 6, the second soft felt 7 is formed by entwining the hollow polymer fiber 8 and the low melting point fiber 4 similar to the above. The hollow polymer fiber 8 is a regular polyester having a melting point of about 230 ° C., and one half peripheral portion 8a and the other half peripheral portion 8b having different shrinkage ratios are joined in a palm shape to form a hollow, and the shrinkage occurs. The hollow polymer fiber 8 and the low melting point fiber 4 are laminated and blended in a ratio of about 8 to 2 by a difference in the ratio, and these are entangled with each other by a needle punch 10 as shown in FIG. The second soft felt 7 is formed.

Next, as shown in FIG. 9, the first soft felt 5 and then the hard felt 2 are sequentially laminated on the upper surface of the second soft felt 7, and the fibers of the above three members are needle punched 1
The two are entangled with each other to form a three-layer laminated felt 1. The laminated felt 1 is, as shown in FIG.
The hard felt 2 may be laminated on the upper surface of the first soft felt 5 or the second soft felt 7, and the two fibers may be entangled with each other by the needle punch 12 to form a two-layer laminated felt 1 ′.

Next, as shown in FIG. 10, the periphery of the above-mentioned laminated felt 1 (1 ') is held by frame-shaped upper and lower pressers 15 and 16, and the inner peripheral portion of the laminated felt 1 (1') is inside the laminated felt 1 by a far infrared heater 17. Sheath 4 of low melting point fiber 4 mixed in
The sheath 4b is melted or softened by heating it to a temperature at which b melts, for example, about 150 ° C to 200 ° C.

Then, as shown in FIG. 11, the heated laminated felt 1 is sandwiched between upper and lower molds 20 to form a hat mold. That is, the mold 20 is a male mold (lower mold) having a hemispherical convex portion 21a protruding upward in the central portion.
A female mold (upper mold) 22 having a hemispherical concave portion 22a in which the convex portion 21a of the male mold 21 is fitted in the central portion 21 with the lower portion 21 arranged below.
Is placed above, and the heated laminated felt 1 is placed with the second soft felt 7 facing downward, that is, facing the male mold 21 between the male mold 21 and the female mold 22. The female die 22 and the female die 22 are moved in the directions approaching each other from above and below, and the heated laminated felt 1 is clamped at a pressure of about 0.4 kg / cm ² or more, and in this state, the head is naturally cooled to have a semicircular arc cross section. The intermediate product 25 is integrally formed with the portion 25a and the annular flange 25b that spreads outward in the radial direction. The shapes of the convex portion 21a and the concave portion 22a of the mold 20 are appropriately set depending on the type of product.

Next, as shown in FIG. 12, the intermediate product 25 is placed on the base 23, and the outer peripheral portion of the flange 25b is cut and removed by a blade die 24 having an annular blade 24a at the lower end, and the intermediate product 25 shown in FIG. Thus, the hat-shaped protective hat 26 having the soft felt layer (a), the medium soft felt layer (a), and the hard felt layer (c) is obtained from the inner surface to the outer surface.

If necessary, as shown in FIG.
An inner 27 made of soft felt is fitted and fixed inside the head 26a of the protective cap 26. This inner 27
As shown in FIG. 15, a rib portion 27b having a cross shape in plan view is curved upward in an arc shape and integrally connected to the ring portion 27a. The inner member 27 is adapted to smoothly fit the user's head and absorbs moisture such as sweat. Approximately 45% of plant fibers such as rayon absorb moisture such as silica gel into the hollow polymer fibers 8 described above. About 45% of the hygroscopic polyester fiber made by kneading the material and about 10% of the low melting point fiber 4 described above are laminated and blended, and these are entwined with each other by needle punching, and the soft felt 27- 1 is formed, and the adhesive 28 is applied to the outer surface of the soft felt 27-1.
8 is covered with a release paper 29, and the release paper 29 is peeled off and fitted into the inside of the head portion 26a of the protective cap 26 described above, and detachably fixed via an adhesive 28.

According to the above-described embodiment, the protective cap 26 is made of the felt material (laminated felt 1), so that it is lightweight and breathable. Also,
The outer surface side is a hard felt layer (c), the inner surface side is a medium soft felt layer (a), and a soft felt layer (a),
The hard felt layer (c) is mainly responsible for the collision of obstacles, etc. The impact due to the collision of this obstacle is buffered by the medium soft felt layer (a) and the soft felt layer (a), and the impact on the head is alleviated. Will be done. Further, since the felt material is heated and softened to be formed into a predetermined shape by the mold 20, it is possible to easily obtain a variety of shapes.

[0014]

As described above, the present invention is lightweight and breathable, suitable for light work, exercise, etc., which requires agile motion, and can obtain a variety of designs. . Further, since the outer surface side is made hard and the inner surface side is made soft, the effect of enhancing the protection function against obstacles is exhibited.

[Brief description of drawings]

1 is an enlarged cross-sectional view of a hard felt according to the present invention.

FIG. 2 is an enlarged sectional view taken along line II-II of FIG.

FIG. 3 is an enlarged sectional view of a first soft felt according to the present invention.

FIG. 4 is an enlarged sectional view taken along the line IV-IV of FIG.

FIG. 5 is an enlarged cross-sectional view of a second soft felt according to the present invention.

6 is an enlarged sectional view taken along line VI-VI of FIG.

FIG. 7 is a side view showing a needle punched state for obtaining a hard felt and first and second soft felts.

FIG. 8 is a side view showing a needle punching state for obtaining a double laminated felt according to the present invention.

FIG. 9 is a side view showing a needle-punched state for obtaining a triple laminated felt according to the present invention.

FIG. 10 is a cross-sectional view showing a heated state of the laminated felt according to the present invention.

FIG. 11 is a cross-sectional view showing a molded state of the laminated felt according to the present invention.

FIG. 12 is a cross-sectional view showing a finished state of an intermediate product according to the present invention.

FIG. 13 is a sectional view of a protective cap according to the present invention.

FIG. 14 is a sectional view showing a state in which an inner is attached to a protective cap according to the present invention.

FIG. 15 is a perspective view of an inner according to the present invention.

FIG. 16 is a partially enlarged sectional view of the inner according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Laminated felt 2 Hard felt 3 Regular fiber 4 Low melting point fiber 4a Core part 4b Sheath part 5 1st soft felt 6 Hollow fiber 7 2nd soft fiber 8 Hollow polymer fiber 8a One half circumference part 8b The other half circumference part 10 Needle punch 11 Feed roll 12 Needle punch 15 Presser foot 16 Presser foot 17 Far infrared heater 20 Mold 21 Male 21a Convex part 22 Female 22a Recess 25 Intermediate product 25a Head 25b Flange 26 Protective cap 27 Inner 27-1 Soft felt 27a Ring Part 27b Rib part 28 Adhesive 29 Release paper

Claims (3)

[Claims] 1. A hard felt comprising a mixture of regular fibers having a solid interior and a low-melting fiber having a lower melting point than the regular fibers; hollow fibers having a melting point substantially the same as that of the regular fibers and a hollow interior; Providing a soft felt formed by mixing a low melting point fiber having a lower melting point than the hollow fiber, and laminating the hard felt and the soft felt and entwining both fibers to provide a laminated felt,
A male mold having a hemispherical convex portion and a female mold having a hemispherical concave portion that fits the convex portion of the male mold are provided, and the laminated felt is heated to a temperature at which the low melting point fiber melts, and the heating is performed. The laminated felt is placed between a male mold and a female mold with its soft felt side facing the male mold, and the heated laminated felt is clamped by the male mold and the female mold to be deformed into a semi-circular cross section. A method of manufacturing a protective hat made of felt, which is characterized in that 2. The production of a felt protective cap according to claim 1, wherein the hollow fiber is a hollow polymer fiber having a different shrinkage rate on one half circumference side and a shrinkage rate on the other half circumference side. Method. 3. A hard felt comprising a mixture of regular fibers having a solid interior and a low melting point fiber having a melting point lower than that of the regular fibers; hollow fibers having a melting point substantially the same as that of the regular fibers and a hollow interior; A first soft felt obtained by mixing low melting point fibers having a lower melting point than hollow fibers;
A mixture of hollow polymer fibers having a melting point substantially the same as that of the regular fibers and different shrinkage rates on one half-circumferential side and the shrinkage rate on the other half-circular side and low-melting point fibers having a lower melting point than the hollow polymer fibers. A second soft felt, the first soft felt and the second soft fiber are sequentially laminated on the hard felt, and the three felt fibers are entangled with each other to provide a laminated felt, which has a hemispherical convex portion. A mold and a female mold having a hemispherical concave portion for fitting the convex portion of the male mold to each other, heating the laminated felt to a temperature at which the low melting point fiber melts, and heating the laminated felt to a second softness thereof. The felt layer is disposed between the male mold and the female mold toward the male mold, and the heated laminated felt is pressed by the male mold and the female mold to be deformed into a semi-circular cross section. Made of felt protective hat Method.