WO2018196423A1 - 具有无缝帽顶的帽子及其制作方法 - Google Patents

具有无缝帽顶的帽子及其制作方法 Download PDF

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Publication number
WO2018196423A1
WO2018196423A1 PCT/CN2017/118613 CN2017118613W WO2018196423A1 WO 2018196423 A1 WO2018196423 A1 WO 2018196423A1 CN 2017118613 W CN2017118613 W CN 2017118613W WO 2018196423 A1 WO2018196423 A1 WO 2018196423A1
Authority
WO
WIPO (PCT)
Prior art keywords
cap
knitted fabric
hat
punch
fiber material
Prior art date
Application number
PCT/CN2017/118613
Other languages
English (en)
French (fr)
Inventor
张迎庆
Original Assignee
张迎庆
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 张迎庆 filed Critical 张迎庆
Priority to KR1020207032364A priority Critical patent/KR102323495B1/ko
Priority to US16/334,085 priority patent/US20210289877A1/en
Priority to KR1020187033559A priority patent/KR102213002B1/ko
Priority to EP17907578.3A priority patent/EP3616542A4/en
Publication of WO2018196423A1 publication Critical patent/WO2018196423A1/zh

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C7/00—Heating or cooling textile fabrics
    • D06C7/02—Setting
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
    • A42C1/00—Manufacturing hats
    • A42C1/04—Blocking; Pressing; Steaming; Stretching
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B1/00—Hats; Caps; Hoods
    • A42B1/018—Hats; Caps; Hoods with means for protecting the eyes, ears or nape, e.g. sun or rain shields; with air-inflated pads or removable linings
    • A42B1/0181—Hats; Caps; Hoods with means for protecting the eyes, ears or nape, e.g. sun or rain shields; with air-inflated pads or removable linings with means for protecting the eyes
    • A42B1/0182—Peaks or visors
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B1/00—Hats; Caps; Hoods
    • A42B1/02—Hats; Stiff caps
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B1/00—Hats; Caps; Hoods
    • A42B1/04—Soft caps; Hoods
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
    • A42C1/00—Manufacturing hats
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
    • A42C1/00—Manufacturing hats
    • A42C1/02—Making hat-bats; Bat-forming machines; Conical bat machines; Bat-forming tools
    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42C—MANUFACTURING OR TRIMMING HEAD COVERINGS, e.g. HATS
    • A42C1/00—Manufacturing hats
    • A42C1/08—Hat-finishing, e.g. polishing, ironing, smoothing, brushing, impregnating, stiffening, decorating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/002—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor characterised by the choice of material
    • B29C51/004—Textile or other fibrous material made from plastics fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/18—Thermoforming apparatus
    • B29C51/20—Thermoforming apparatus having movable moulds or mould parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/264—Auxiliary operations prior to the thermoforming operation, e.g. cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/48—Wearing apparel
    • B29L2031/4807—Headwear
    • B29L2031/4814—Hats

Definitions

  • the present disclosure relates to a hat, and more particularly to a hat having a seamless top and a method of making the same.
  • a hat is a piece of clothing worn on the head that covers the entire top of the head.
  • the hat is mainly used to protect the user's head.
  • Some hats have an extended visor to block the sun. Hats can also be used as accessories for dressing up.
  • the cap of the hat is mostly sewn through a plurality of pieces of fabric cut into a fan shape.
  • this process needs to go through multiple processes such as splitting, splicing, and sewing of the cap, and the production process is lengthy, which is not conducive to saving production time and production cost.
  • the produced hat top can be seen from the appearance of the seam marks, is prone to wrinkles, and can not fully fit the user's head shape, thereby affecting the aesthetics and comfort when wearing.
  • CN105747343A discloses a cap integrally formed with a cap and a cap, the cap of the cap being formed by pressure thermocompression bonding between at least two layers of flexible materials of sponge, TPU, PPC and PU. .
  • the material is reserved for 2-3 openings prior to thermocompression and the opening is sewn after thermocompression. Therefore, this process requires a number of additional processes such as opening and slitting, which is disadvantageous for saving production time and production cost.
  • the resulting top of the hat can also be seen from the appearance of the seam traces, thus affecting the aesthetics when worn.
  • the cap produced is made of sponge, TPU, PPC and PU, and has poor air permeability, which affects the comfort when wearing.
  • CN106049072A discloses a method of manufacturing a polyester felt hat which is formed by pressing a heat-treated two-layer polyester cloth under pressure between complementary positive and negative dies. This method can only be used to produce imitation felt caps and the raw materials can only be selected from polyester. Therefore, the types of hats and raw materials that can be produced are limited.
  • the imitation felt cap needs to undergo the unsynchronized production process of the fabric after the fabric is heated first, which is not conducive to saving production time and production cost.
  • the purpose of the present disclosure is to overcome the deficiencies of the prior art and to provide a novel hat having a seamless top and a method of making the same.
  • the cap of the cap of the present disclosure can save production time and production cost without undergoing multiple redundant processes such as splitting, splicing, sewing, or opening, slitting, or first pressing the fabric after heating the fabric.
  • the cap of the cap of the present disclosure can be made into a variety of hat types and can be selected from a variety of raw materials.
  • the cap of the cap of the present disclosure is a seamless cap with no seams, fully conforms to the user's head shape, and can be made of a breathable material to improve aesthetics and comfort when worn.
  • a first aspect of the present disclosure discloses a method of making a hat comprising a seamless cap without seams and a visor joined to the seamless cap, the seamless cap being formed by a cap top
  • the apparatus is integrally formed by integrally stretching a flat piece of knitted fabric blank, and the knitted fabric blank comprises a vitrified petrochemical fiber material, the cap top forming apparatus comprising a punch, opposite to the punch and capable of An open chamber housing the male mold, and a fabric holder retaining the knitted fabric blank during cap forming, the method comprising the steps of heating the male mold to be equal to or higher than a glass transition temperature of the petrochemical fiber material and a temperature lower than a melting point temperature of the petrochemical fiber material; the knitted fabric blank is placed such that a central portion thereof completely covers an open opening of the chamber; While the holder holds the circumference of the knitted fabric blank, the punch is moved through the opening of the chamber toward the inside of the chamber until the punch reaches the crown forming position, Drawing the knitted fabric
  • the gap width is controlled between 0.6 mm and 3 mm during stretching of the knitted fabric blank.
  • the petrochemical fiber material changes from a high elastic state to a glass state at a temperature equal to or higher than a glass transition temperature thereof and lower than a melting point thereof.
  • the knitted fabric blank completely conforms to the outer contour of the punch.
  • the predetermined time is between 30 seconds and 70 seconds.
  • the engaging comprises stitching the visor and the top of the cap together.
  • the chamber is heated to a temperature equal to or higher than a glass transition temperature of the petrochemical fiber material and lower than a melting point temperature of the petrochemical fiber material while the punch is heated.
  • the knitted fabric blank is cut to a shape and size suitable for retention by the fabric holder prior to the placing.
  • the knitted fabric blank is subjected to a water spray treatment after the placing and before the punch is moved.
  • the excess portion of the bottom of the cap is removed after the cooling and prior to the joining.
  • a decorative process such as embroidering, printing, transferring hot pressing, sewing decorative flowers, and the like is performed on the top of the cap.
  • the lining is applied within the crown and the edges of the lining are covered with a rubber strip to stiffen the top.
  • the knitted fabric blank comprises one or more layers of knitted fabric.
  • At least one of the one or more layers of knitted fabric has a vitrified petrochemical fiber material.
  • At least one of the one or more layers of knitted fabric has a vitrified petrochemical fiber material in an amount of from 5% to 100%.
  • the vitrifiable petrochemical fiber material is selected from the group consisting of polyester, nylon, spandex, and acrylic.
  • the glue strip is secured to the edge of the bottom of the cap by a press after the cooling and prior to the joining.
  • the press comprises an upper wheel and a lower wheel, the upper wheel feeding the rubber strip to the gap between the upper wheel and the lower wheel, and the lower wheel feeding the bottom of the cap toward the gap between the upper wheel and the lower wheel edge.
  • the rotational speed of the upper wheel is different from the rotational speed of the lower wheel.
  • the rubber strip is made of an elastic fabric or an elastic band attached to the hot melt adhesive.
  • the visor is made of a laminate comprising a layer of TPU material and two cloth layers bonded to the TPU material layer from above and below.
  • a second aspect of the present disclosure discloses a cap that is manufactured in accordance with the method described in the above aspects.
  • a third aspect of the present disclosure discloses a cap comprising: a seamless cap without a seam integrally formed by thermally stretching a piece of flat knit fabric blank comprising a vitrified petrochemical fiber material; A visor joined to the top of the seamless cap.
  • the top of the cap is fitted with a lining cloth and has a rubber strip covering the edge of the lining to make the top of the hood stiff.
  • the top of the cap has decorative parts such as embroidery, printing, transfer hot pressing, and sewing decorative flowers.
  • the cap is integrally formed by thermally stretching the flat knitted fabric blank at a temperature equal to or higher than a glass transition temperature of the petrochemical fiber material and lower than a melting point temperature of the petrochemical fiber material. Seamless cap top.
  • the knitted fabric blank comprises one or more layers of knitted fabric.
  • At least one of the one or more layers of knitted fabric has a vitrified petrochemical fiber material.
  • At least one of the one or more layers of knitted fabric has a vitrified petrochemical fiber material in an amount of from 5% to 100%.
  • the vitrifiable petrochemical fiber material is selected from the group consisting of polyester, nylon, spandex, and acrylic.
  • the rubber strip is secured to the edge of the bottom of the cap.
  • the rubber strip is made of an elastic fabric bonded to a hot melt adhesive.
  • the visor is made of a laminate comprising a layer of TPU material and two cloth layers bonded to the TPU material layer from above and below.
  • a fourth aspect of the present disclosure discloses a cap forming apparatus for manufacturing a seamless cap without seams, the cap forming apparatus integrally forming the none by thermally stretching a flat piece of knitted fabric blank a cap top, and the knitted fabric blank contains a vitrifiable petrochemical fiber material
  • the cap top forming apparatus comprising: a molding device, the molding device having: a base; a punch, the punch Fixed to the underside of the base and having a shape that matches the seamless cap for thermally drawing the seamless top of the knitted fabric blank into a desired shape; and a fabric retaining member, a fabric holder slidably coupled to the base and for retaining a periphery of the cap fabric blank during cap top forming; and a support device located vertically below the molding device, and An outer casing and an open chamber recessed inwardly from the outer casing are included, the opening of the chamber being opposite the male mold, and the chamber being capable of completely receiving the male mold entering through the opening thereof.
  • the punch enters the chamber through the opening, and there is a gap between the punch and the opening and the gap width remains uniform.
  • the gap width is controlled between 0.6 mm and 3 mm during the hot drawing of the knitted fabric blank.
  • the fabric holder comprises: a retaining frame for retaining a circumference of the cap fabric blank during the cap forming process; a guiding rod fixed to the retaining frame and guiding the same
  • the retaining frame is vertically movable relative to the base; and a spring device disposed between the base and the retaining frame.
  • Figure 1 shows a perspective view of a hat in accordance with the present disclosure
  • FIG. 2 shows a perspective view of a cap top forming apparatus in accordance with the present disclosure
  • 3a and 3b respectively show a perspective view and a cross-sectional view of a molding apparatus of a cap top forming apparatus according to the present disclosure
  • FIG. 4a and 4b respectively show a perspective view and a cross-sectional view of a support device of a cap top forming apparatus according to the present disclosure
  • Figures 5a-5e show schematic views of the steps of producing a cap and a hat using a cap top forming apparatus in accordance with the present disclosure.
  • Figure 6 shows a perspective view of a cap produced by a cap top forming apparatus in accordance with the present disclosure.
  • Figures 7a and 7b show perspective and side views of a glue press in accordance with the present disclosure.
  • Figure 8 shows a perspective view of the crown of the cap after it has been applied with a glue press in accordance with the present disclosure.
  • the seamless cap 2 is integrally formed by a hot drawing process of the cap forming apparatus 10 (see Fig. 2, which will be described later in detail), and may be substantially hemispherical, substantially semi-elliptical, substantially cylindrical, or substantially truncated. It has a conical shape or the like, but may have other shapes as needed, for example, a cartoon shape suitable for children.
  • the visor 3 can be formed in a duck tongue shape, a frustoconical shape or any other suitable shape as long as it can be engaged with the cap top 2.
  • the prior art utilizes the pressure between the positive and negative modes of complementary shapes to press or extrude the material previously placed in the gap between the positive and negative dies into a cap top.
  • the present disclosure utilizes the tensile force of the male mold of the cap forming apparatus (without the need for a corresponding female mold) to thermally stretch a flat piece of fabric into a shape that matches the outer contour of the punch.
  • the seamless top 2 of the present disclosure selects a resilient knit fabric rather than an inelastic woven fabric.
  • the knitted fabric in order to make the knitted fabric more conform to the outer contour of the punch during the hot drawing process, the knitted fabric preferably contains 5%-100% of vitrifiable petrochemical fiber material, such as polyester, nylon, spandex, acrylic, etc. .
  • the visor 3 can be selected with any suitable fabric.
  • the seamless cap top 2 is integrally formed by the cap top forming apparatus 10.
  • the cap top forming apparatus 10 includes a molding device 11 and a support device 21 located vertically below the molding device 11.
  • the molding apparatus 11 is used to form the seamless cap top 2 in a thermally stretched manner and includes a base 12, a punch 13 and a fabric holder 14.
  • the susceptor 12 guides the entire molding apparatus 11 to move vertically between the upper initial position and the lower cap forming position by a driving device (not shown).
  • the punch 13 is secured below the base 12 and has a shape that matches the crown 2 for hot stretching the top fabric blank into the desired shape.
  • the inside or outside of the punch 13 may be provided with a heating means for heating it, such as a resistance heating wire or the like.
  • the fabric holder 14 is used to hold the periphery of the cap fabric blank on the top surface of the support device 21 during the cap top forming process, and includes a guide bar 15, a spring device 16, and a retaining frame 17.
  • the guide rod 15 includes a straight rod body 15a of uniform size and a flange 15b or other protruding member that protrudes horizontally from the upper end of the rod body 15a.
  • the rod body 15a has a horizontal size smaller than the through hole 12a at the periphery of the susceptor 12, and the flange 15b has a horizontal size larger than the through hole 12a, whereby the rod body 15a can vertically move up and down in the through hole 12a, but cannot be at the flange 15b Pass through the through hole 12a.
  • the holding frame 17 is fixed to the rod body 15a at the lower end of the rod body 15a.
  • the vertical height calculated by the rod body 15a from the lower surface of the base 12 is greater than the vertical height calculated from the lower surface of the base 12 by the punch 13, whereby in the initial position, the punch 13 is defined at the base 12, the guide rod 15 And in the space formed by the holding frame 17.
  • the spring means 16 is disposed between the base 12 and the retaining frame 17, and biases the retaining frame 17 against the base 12 when in a biased state, thereby retaining the periphery of the cap top blank in the retaining frame 17 and the support means Between the top surfaces of 21.
  • the spring means 16 may be a coil spring surrounding the shaft 15a of the guiding rod 15.
  • the support device 21 is used to support the cap fabric blank during the cap top forming process and includes an outer casing 22 and an open chamber 23 recessed inwardly from a central portion of the top surface of the outer casing 22.
  • the opening 24 of the chamber 23 is opposed to the punch 13, and the chamber 23 can completely accommodate the punch 13, but need not be provided as a die complementary to the shape of the punch 13.
  • the gap width between the opening 24 of the chamber 23 and the outer contour of the punch 13 is kept uniform, whereby the punch 13 can drive the cap
  • the top fabric blank is stretched evenly downward.
  • a heating device (not shown) for heating the chamber 23 is provided inside or outside the support device 21.
  • the cap top panel blank 2a of the seamless cap top 2 can be selected from one or more layers of flat knit fabric.
  • the top fabric blank 2a is a layer of knitted fabric
  • the one layer of knitted fabric contains 5%-100% vitrified petrochemical fiber materials, such as polyester, nylon, spandex, acrylic, etc.
  • the fabric blank 2a is a multi-layer knitted fabric
  • at least one layer of the multi-layer knitted fabric contains 5%-100% vitrified petrochemical fiber material, and other layers may be cotton fabric or other fabrics.
  • the cap top panel blank 2a of the seamless cap top 2 is cut to be larger than the shape and size of the retaining frame 17, such as rectangular or elliptical, to maintain the frame 17 capable of retaining the periphery of the cap top panel blank 2a during cap forming In order to allow the top fabric blank 2 to enter the chamber 23 uniformly at a controlled rate.
  • the punch 13 is heated by a heating means (not shown) to a temperature equal to or higher than the glass transition temperature of the petrochemical fiber material and lower than the melting point temperature of the petrochemical fiber material; in a preferred embodiment
  • the chamber 23 is also heated to a temperature equal to or higher than the glass transition temperature of the petrochemical fiber material and lower than the melting point temperature of the petrochemical fiber material.
  • the cap top fabric blank 2a is sprayed with a spray gun so that when the cap top fabric blank 2a contacts the heated punch 13, the water is atomized at a high temperature and penetrates into the cap top fabric blank 2a, so that the entire cap
  • the top fabric blank 2a is uniformly heat-transferred, which is advantageous for stabilizing the shape of the cap top 2.
  • the water sprayed top hat blank 2a is placed flat on the top surface of the outer casing 22 of the support device 21 and finished flat, and the central portion of the top fabric blank 2a completely covers the chamber Opening 24 of 23.
  • a driving device (not shown) of the molding device 11 is actuated to drive the molding device 11 to move vertically downward from the initial position toward the support device 21 until the holding frame 17 contacts the cap top fabric blank. 2a.
  • the molding apparatus 11 then continues to move vertically downward, and the base 12 biases the spring means 16 downward along the guide rod 15 passing through its through hole 12a.
  • the biasing force of the spring means 16 acts on the retaining frame 17, thereby maintaining the periphery of the cap top blank 2a between the retaining frame 17 and the top surface of the outer casing 22 to enable the cap top panel blank 2a to be controllable
  • the velocity is evenly entered into the chamber 23.
  • the molding apparatus 11 continues to move vertically downwards, at which time the punch 13 begins to contact the cap fabric blank 2a and into the chamber 23 of the support device 21. Since the retaining frame 17 retains the periphery of the cap fabric blank 2a, the downward movement of the punch 13 causes the cap top panel blank 2a to stretch downwardly and uniformly enter the chamber 23 through the opening 24 at a controlled rate.
  • the molding apparatus 11 continues to move vertically downward until the spring means 16 is fully compressed, at which point the cap forming position of the molding apparatus 11 is reached, as shown in Figure 5e.
  • the molding apparatus 11 is held at the crown forming position for a predetermined time, for example, between 30 seconds and 70 seconds, and the heat of the heated punch 13 and the chamber 23 is transferred to the top fabric blank 2a.
  • the petrochemical fiber material (such as polyester, nylon, spandex, acrylic, etc.) contained in the cap top fabric blank 2a is changed from a high elastic state to a glass state at a temperature equal to or higher than the glass transition temperature and lower than the melting point temperature, thereby cap
  • the top fabric blank 2a completely conforms to the outer contour of the punch 13 and forms a cap 2 that matches the shape of the punch 13.
  • the drive means (not shown) is reversely actuated so that the molding apparatus 11 is moved vertically upward from the crown forming position back to the initial position.
  • the cap top 2 is removed from above the chamber 23 and naturally cooled to produce a shaped cap 2, as shown in FIG.
  • the press machine 30 includes a rubber strip storage portion 31, a rubber strip nip 32, and a cutter 33.
  • the rubber strip 4 is made of an elastic fabric bonded with hot melt adhesive and has a width of preferably about 6 mm, and the rubber strip storage portion 31 stores the unused wound rubber strip 4.
  • the rubber strip nip 32 includes an upper wheel 32a and a lower wheel 32b.
  • the upper wheel 32a feeds the rubber strip 4 from the rubber strip storage portion 32 toward the gap between the upper and lower wheels, and the lower wheel 32b feeds the gap between the upper and lower wheels.
  • the rubber strip 4 is heat-sealed to the bottom edge of the cap top 2 by the pressure between the upper wheel 32a and the lower wheel 32b, as shown in FIG.
  • the circumference of the bottom of the cap top 2 is generally larger than the actual required circumference, so that the required crown circumference can be made by the difference in rotational speed between the upper wheel 32a and the lower wheel 32b; whereas in the conventional method, the flat seam is utilized.
  • the machine or the edger sews the elastic band to the bottom of the hat, which does not control the circumference of the hat well.
  • the excess portion of the bottom of the cap top 2 is removed by the cutter 33 at the same time as or before the heat-sealing of the rubber strip 4 to the bottom edge of the cap top 2.
  • a decorative process such as embroidering, printing, transferring hot pressing, sewing decorative flowers, and the like may be performed on the formed cap top 2.
  • the lining may be applied to the front of the inner surface of the forming hood 2 and the lining edge may be covered with a rubber strip to stiffen the hood 2 .
  • the bill 3 is made of a laminate comprising a layer of TPU material and two cloth layers bonded to the TPU material layer from above and below.
  • the laminate is cut into the shape of the visor and wrapped around its circumference, and then the hood 2 is sewn together with the desired visor 3 and an elastic sweat strip is applied to form a complete cap 1 such as Figure 1 shows.
  • the traditional visor is made of a hard plastic tongue, which cannot be curled and is prone to creases.
  • the visor 3 is elastic and can be curled together with the cap 2 to carry the cap 1 into a plastic cylinder or other bag.
  • the rear hat 1 can be restored to its original shape, thereby maintaining a good hat shape.
  • the forming of the cap top does not need to go through the prior art cap segmentation, splicing and sewing process, or the open seam process, or the fabric process after the fabric is heated first, which can save production time. And production costs.
  • the cap of the cap of the present disclosure can be made into a variety of hat types and can be selected from a variety of raw materials.
  • the punch 13 can drive the cap top fabric blank 2a evenly downward. Stretch without creating any wrinkles on the top of the cap.
  • the cap produced according to the method described above is a seamless cap with no seams, fully conforms to the user's head shape, and can be made of a breathable material, thereby improving the aesthetics and comfort when worn.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)

Abstract

一种帽子及其制造方法和帽顶成形设备，所述帽子包括：通过热拉伸一片含有可玻璃化的石油化纤材料的平坦针织面料坯件而一体成形的没有接缝的无缝帽顶；以及接合至所述无缝帽顶的帽舌。所述帽子的帽顶能够节约生产时间和生产成本。所述帽子的帽顶可以制成各种帽子类型并且可以选自多种原材料。所述帽子的帽顶是没有接缝的无缝帽顶，完全贴合使用者的头型，并且可以选择透气性材料制成，从而改进了佩戴时的美观性和舒适性。

Description

具有无缝帽顶的帽子及其制作方法 技术领域
本公开涉及一种帽子，更具体地说涉及一种具有无缝帽顶的帽子及其制作方法。
背景技术
帽子是一种戴在头部的服饰，可以覆盖头的整个顶部。帽子主要用于保护使用者的头部。一些帽子具有伸出的帽舌，用于遮挡太阳。帽子也可以作为装扮用的配饰。
现有技术中，帽子的帽顶大多通过若干片裁成扇状的面料拼接缝制而成。然而，这种工艺需要经历帽片分裁、拼接、缝制等多道工序，生产流程冗长，不利于节约生产时间和生产成本。另外，生产出的帽顶从外表能够看出缝线痕迹，容易出现褶皱，并且无法完全贴合使用者的头型，从而影响佩戴时的美观性和舒适性。
CN105747343A公开了一种帽舌和帽顶一体成形的帽子，该帽子的帽顶通过形状互补的正负模之间的压力热压合海绵、TPU、PPC和PU中的至少两层柔性材料而形成。为了避免产生褶皱，材料在热压合之前预留2-3个开口，并且在热压合之后将开口缝合。因此，这种工艺需要经历开口和缝口等多道额外工序，不利于节约生产时间和生产成本。生产出的帽顶从外表也能够看出缝线痕迹，从而影响佩戴时的美观性。另外，生产出的帽顶由海绵、TPU、PPC和PU等材料形成，透气性不好，从而影响佩戴时的舒适性。
CN106049072A公开了一种制造涤纶仿毡帽的方法，该仿毡帽通过形状互补的正负模之间的压力挤压热处理过的两层涤纶布而形成。该方法只能用于生产仿毡帽并且原材料只能选取涤纶，因此，所能生产的帽子类型和原材料受到限制。该仿毡帽需要经历先加热面料后挤压面料的不同步的生产工序，不利于节约生产时间和生产成本。
本公开的目的在于克服现有技术的不足，提供一种新颖的具有无缝帽顶的帽子及其制作方法。本公开的帽子的帽顶无需经历帽片分裁、拼接、缝制、或者开口、缝口、或者先加热面料后挤压面料等多道冗余工序，能够节约生产时间和生产成本。本公开的帽子的帽顶可以制成各种帽子类型并且可以选自多种原材料。本公开的帽子的帽顶是没有接缝的无缝帽顶，完全贴合使用者的头型，并且可以选择透气性材料制成，从而改进了佩戴时的美观性和舒适性。
发明内容
本公开的第一方面公开了一种制造帽子的方法，所述帽子包括没有接缝的无缝帽顶和接合至所述无缝帽顶的帽舌，所述无缝帽顶通过帽顶成形设备热拉伸一片平坦的针织面料坯件而一体成形，并且所述针织面料坯件中含有可玻璃化的石油化纤材料，所述帽顶成形设备包括凸模、与所述凸模相对且能容纳所述凸模的敞开的腔室、以及在帽顶成形过程中保持所述针织面料坯件的面料保持件，所述方法包括以下步骤：将所述凸模加热到等于或高于所述石油化纤材料的玻璃化温度、且低于所述石油化纤材料的熔点温度的温度；将所述针织面料坯件放置成其中心部分完全覆盖所述腔室的敞开的开口；在利用所述面料保持件保持所述针织面料坯件的周缘的同时，使所述凸模穿过所述腔室的开口朝向所述腔室的内部移动，直到所述凸模到达帽顶成形位置为止，由此将所述针织面料坯件拉伸成与所述凸模的外轮廓相匹配的形状；使所述凸模在所述帽顶成形位置停留预定的时间；使所述凸模移动离开所述腔室的内部，并将成形的所述帽顶从所述腔室上方取下并冷却；将所述帽顶和所述帽舌接合在一起以形成所述帽子。
优选的，在所述针织面料坯件拉伸期间，所述凸模和所述开口之间存在间隙且间隙宽度保持均匀。
优选的，在所述针织面料坯件拉伸期间，所述间隙宽度控制在0.6mm-3mm之间。
优选的，在所述凸模在所述帽顶成形位置停留期间，所述石油化纤材料在等于或高于其玻璃化温度且低于其熔点温度的温度下由高弹态转变为玻璃态，从而所述针织面料坯件完全贴合所述凸模的外轮廓。
优选的，所述预定的时间为30秒到70秒之间。
优选的，所述接合包括将所述帽舌和所述帽顶缝合在一起。
优选的，在所述凸模加热的同时，将所述腔室加热到等于或高于所述石油化纤材料的玻璃化温度、且低于所述石油化纤材料的熔点温度的温度。
优选的，在所述放置之前，将所述针织面料坯件裁剪成适合由所述面料保持件保持的形状和尺寸。
优选的，在所述放置之后且所述凸模移动之前，对所述针织面料坯件进行喷水处理。
优选的，在所述冷却之后且所述接合之前，去除所述帽顶的底部的多余部分。
优选的，在所述冷却之后且所述接合之前、或者在所述接合之后，在所述帽顶上进行刺绣、印花、转移热压烫花、缝制装饰花等装饰工艺。
优选的，在所述冷却之后且所述接合之前，在所述帽顶内贴合衬布并且用压胶条覆盖住所述衬布的边缘，以使所述帽顶挺括。
优选的，所述针织面料坯件包括一层或多层针织面料。
优选的，所述一层或多层针织面料中的至少一层具有可玻璃化的石油化纤材料。
优选的，所述一层或多层针织面料中的至少一层具有含量为5％-100％的可玻璃化的石油化纤材料。
优选的，所述可玻璃化的石油化纤材料选自包括涤纶、锦纶、氨纶、腈纶的组。
优选的，在所述冷却之后且所述接合之前，利用压胶机将压胶条固定至所述帽顶的底部的边缘。
优选的，压胶机包括上轮和下轮，上轮朝上轮和下轮之间的空隙给送压胶条，而下轮朝上轮和下轮之间的空隙给送帽顶的底部边缘。
优选的，上轮的转速和下轮的转速不同。
优选的，压胶条采用弹性面料或松紧带贴合热熔胶制成。
优选的，帽舌采用层压材料制成，所述层压材料包括TPU材料层、以及从上方和下方贴合至TPU材料层的两个布料层。
本公开的第二方面公开了一种帽子，所述帽子根据以上方面所述的方法制造而成。
本公开的第三方面公开了一种帽子，所述帽子包括：通过热拉伸一片含有可玻璃化的石油化纤材料的平坦针织面料坯件而一体成形的没有接缝的无缝帽顶；以及接合至所述无缝帽顶的帽舌。
优选的，所述帽顶内贴合有衬布并且具有覆盖住所述衬布的边缘的压胶条，以使所述帽顶挺括。
优选的，所述帽顶上具有刺绣、印花、转移热压烫花、缝制的装饰花等装饰件。
优选的，所述帽顶是通过在等于或高于所述石油化纤材料的玻璃化温度且低于所述石油化纤材料的熔点温度的温度下热拉伸所述平坦针织面料坯件而一体成形的无缝帽顶。
优选的，所述针织面料坯件包括一层或多层的针织面料。
优选的，所述一层或多层针织面料中的至少一层具有可玻璃化的石油化纤材料。
优选的，所述一层或多层针织面料中的至少一层具有含量为5％-100％的可玻璃化的石油化纤材料。
优选的，所述可玻璃化的石油化纤材料选自包括涤纶、锦纶、氨纶、腈纶的组。
优选的，压胶条被固定在所述帽顶的底部的边缘。
优选的，压胶条采用弹性面料贴合热熔胶制成。
优选的，帽舌采用层压材料制成，所述层压材料包括TPU材料层、以及从上方和下方贴合至TPU材料层的两个布料层。
本公开的第四方面公开了一种用于制造没有接缝的无缝帽顶的帽顶成形设备，所述帽顶成形设备通过热拉伸一片平坦的针织面料坯件来一体成形所述无缝帽顶，并且所述针织面料坯件中含有可玻璃化的石油化纤材料，所述帽顶成形设备包括：模制装置，所述模制装置具有：基座；凸模，所述凸模固定至基座下方，并且具有与所述无缝帽顶相匹配的形状，以用于将所述无缝帽顶的针织面料坯件热拉伸成所需的形状；以及面料保持件，所述面料保持件可滑动地连接至基座，并且用于在帽顶成形过程中保持帽顶面料坯件的周缘；和支撑装置，所述支撑装置位于所述模制装置的竖直下方，并且包括外壳和从所述外壳向内凹陷的敞开的腔室，所述腔室的开口与所述凸模相对，并且所述腔室能够完全容纳穿过其开口进入的所述凸模。
优选的，在热拉伸所述针织面料坯件的过程中，所述凸模通过所述开口进入所述腔室，并且所述凸模和所述开口之间存在间隙且间隙宽度保持均匀。
优选的，在热拉伸所述针织面料坯件的过程中，所述间隙宽度控制在0.6mm-3mm之间。
优选的，所述面料保持件包括：保持框架，所述保持框架用于在帽顶成形过程中保持帽顶面料坯件的周缘；引导杆，所述引导杆固定至所述保持框架并引导所述保持框架相对于所述基座竖直移动；和弹簧装置，所述弹簧装置设置在所述基座和所述保持框架之间。
附图说明
在本文中参考附图描述本公开的多个方面和特征，其中：
图1示出根据本公开的帽子的立体图；
图2示出根据本公开的帽顶成形设备的立体图；
图3a和3b分别示出根据本公开的帽顶成形设备的模制装置的立体图和剖视图；
图4a和4b分别示出根据本公开的帽顶成形设备的支撑装置的立体图和剖视图；
图5a-5e示出利用根据本公开的帽顶成形设备生产帽顶以及帽子的步骤的示意图。
图6示出根据本公开的帽顶成形设备生产出的帽顶的立体图。
图7a和7b示出根据本公开的压胶机的立体图和侧视图。
图8示出利用根据本公开的压胶机贴合压胶条后的帽顶的立体图。
具体实施方式
以下将参照附图描述本公开的实施例。然而，应当了解的是，本公开不局限于下文所提出的结构或操作步骤的细节。本公开能够有其它实施例，并能够以多种方式来实施或执行。
图1示出根据本公开一个实施例的帽子1，该帽子1包括主体部分没有任何接缝的无缝帽顶2、以及通过缝合等工艺接合至无缝帽顶2的帽舌3。无缝帽顶2通过帽顶成形设备10(参见图2，下文将详述)的热拉伸工艺一体成形，并且可以呈大致半球体形、大致半椭圆体形、大致圆筒体形、或者大致截头圆锥体形等形状，但是根据需要也可以呈其他形状，例如适合儿童佩戴的卡通形状等。帽舌3可以制成鸭舌形、截头圆锥体形或者任何其他合适的形状，只要能够与帽顶2接合即可。
如上文所述，现有技术利用形状互补的正负模之间的压力，将事先放置在正负模之间的间隙中的材料压合或挤压成帽顶。然而，本公开利用的是帽顶成形设备的凸模(无需相应的凹模)的拉伸力，将一片平坦的面料热拉伸成与凸模的外轮廓相匹配的形状。为此，本公开的无缝帽顶2选择有弹性的针织面料，而非无弹性的梭织面料。另外，为了在热拉伸过程中让针织面料更贴合凸模的外轮廓，该针织面料中优选地含有5％-100％的可玻璃化石油化纤材料，例如涤纶、锦纶、氨纶、腈纶等。帽舌3可以选择任意合适的面料进行搭配。
如图2所示，无缝帽顶2通过帽顶成形设备10一体成形而成。帽顶成形设备10包括模制装置11和位于模制装置11竖直下方的支撑装置21。
参见图3a和3b，模制装置11用于以热拉伸的方式成形无缝帽顶2，并且包括基座12、凸模13和面料保持件14。基座12通过驱动装置(未示出)引导整个模制装置11在上方的初始位置和下方的帽顶成形位置之间竖直移动。凸模13固定至基座12下方，并且具有与帽顶2相匹配的形状，以用于将帽顶面料坯件热拉伸成所需的形状。凸模13内部或外部可以设有用于其加热的加热装置，例如电阻加热丝等。
面料保持件14用于在帽顶成形过程中将帽顶面料坯件的周缘保持在支撑装置21的顶表面上，并且包括引导杆15、弹簧装置16和保持框架17。引导杆15包括尺寸均匀的笔直杆体15a以及从杆体15a上端处水平突出的凸缘15b或其他突出件。杆体15a具有小于基座12周边的通孔12a的水平尺寸，而凸缘15b具有大于通孔12a的水平尺寸，由此杆体15a能够在通孔12a内竖直上下移动，但无法在凸缘15b处通过通孔12a。保持框架17在杆体15a的下端处固定至杆体15a。杆体15a从基座12下表面开始计算的竖直高度大于凸模13从基座12下表面开始计算的竖直高度，由此在初始位置，凸模13被限定在基座12、引导杆15和保持框架17所构成的空间内。弹簧装置16设置在基座12和保持框架17之间，并且当处于偏压状态时抵靠基座12偏压保持框架17，从而将帽顶面料坯件的周缘保持在保持框架17和支撑装置21的顶表面之间。在一个优选实施例中，弹簧装置16可以是围绕引导杆15的杆体15a的螺旋弹簧。
参见图4a和4b，支撑装置21用于在帽顶成形过程中支撑帽顶面料坯件，并且包括外壳22和从外壳22的顶表面的中心部分向内凹陷的敞开的腔室23。腔室23的开口24与凸模13相对，并且腔室23能够完全容纳凸模13，但无需设置成与凸模13的形状互补的凹模。在模制装置11通过驱动装置被向下引导到帽顶成形位置的过程中，腔室23的开口24与凸模13的外轮廓之间的间隙宽度保持均匀，由此凸模13能够带动帽顶面料坯件均匀地向下拉伸。在一个优选实施例中，支撑装置21内部或外部设有用于加热腔室23的加热装置(未示出)。
下面参考图5a-5e描述通过帽顶成形设备10制造无缝帽顶2的方法。首先选择制造无缝帽顶2的合适面料。如上所述，无缝帽顶2的帽顶面料坯件2a可以选择一层或多层平坦的针织面料。在帽顶面料坯件2a为一层针织面料的情况下，所述一层针织面料含有5％-100％的可玻璃化的石油化纤材料，例如涤纶、锦纶、氨纶、腈纶等；在帽顶面料坯件2a为多层针织面料的情况下，所述多层针织面料中的至少一层含有5％-100％的可玻璃化的石油化纤材料，而其他层可以为全棉面料或者其他面料。
接下来裁剪帽顶2的面料。将无缝帽顶2的帽顶面料坯件2a裁剪成大于保持框架17的形状和尺寸，例如矩形或椭圆形，从而在帽顶成形过程中保持框架17能够保持帽顶面料坯件2a的周缘，以使帽顶面料坯件2以可控的速度均匀进入腔室23。
如图5a所示，利用加热装置(未示出)将凸模13加热到等于或高于石油化纤材料的玻璃化温度、且低于石油化纤材料的熔点温度的温度；在一个优选实施例中，也将腔室23加热到等于或高于石油化纤材料的玻璃化温度、且低于石油化纤材料的熔点温度的温度。利用喷枪对帽顶面料坯件2a进行喷水处理，从而在帽顶面料坯件2a接触加热过的凸模13时，水在高温下雾化并且渗入帽顶面料坯件2a内部，使整个帽顶面料坯件2a均匀传热，有利于稳定帽顶2的定形。
如图5b所示，将喷水处理过的帽顶面料坯件2a平坦地放置在支承装置21的外壳22的顶表面上并整理平整，并且帽顶面料坯件2a的中心部分完全覆盖腔室23的开口24。
如图5c所示，致动模制装置11的驱动装置(未示出)，以驱动模制装置11从初始位置朝支撑装置21向下竖直移动，直到保持框架17接触帽顶面料坯件2a。之后模制装置11继续向下竖直移动，基座12沿着穿过其通孔12a的引导杆15向下偏压弹簧装置16。弹簧装置16的偏压力作用在保持框架17上，从而将帽顶面料坯件2a的周缘保持在保持框架17和外壳22的顶表面之间，以使帽顶面料坯件2a能够以可控的速度均匀进入腔室23。
如图5d所示，模制装置11继续向下竖直移动，此时凸模13开始接触帽顶面料坯件2a并进入支承装置21的腔室23内。由于保持框架17保持帽顶面料坯件2a的周缘，因此凸模13的向下移动带动帽顶面料坯件2a向下拉伸并以可控的速度均匀通过开口24进入腔室23内。
模制装置11继续向下竖直移动，直至弹簧装置16被完全压缩为止，此时到达模制装置11的帽顶成形位置，如图5e所示。模制装置11在帽顶成形位置停留预定的时间，例如30秒到70秒之间，并且加热过的凸模13和腔室23的热量传递给帽顶面料坯件2a。帽顶面料坯件2a中含有的石油化纤材料(诸如涤纶、锦纶、氨纶、腈纶等)在等于或高于玻璃化温度且低于熔点温度的温度下由高弹态转变为玻璃态，从而帽顶面料坯件2a完全贴合凸模13的外轮廓并且形成与凸模13的形状相匹配的帽顶2。
在帽顶2成形后，反向致动驱动装置(未示出)，从而模制装置11从帽顶成形 位置竖直向上移回初始位置。将帽顶2从腔室23上方取下并自然冷却，从而产生出成形的帽顶2，如图6所示。
根据需要去除掉帽顶2底部的多余部分。在一个实施例中，利用压胶机30既可以去除掉帽顶2底部的多余部分，又可以将压胶条固定至帽顶2的底部边缘。如图7a和7b所示，压胶机30包括压胶条存储部31、压胶条压合部32和切刀33。压胶条4采用弹性面料贴合热熔胶制成并且宽度优选为约6mm，压胶条存储部31存储未使用的卷绕压胶条4。压胶条压合部32包括上轮32a和下轮32b。通过驱动装置(未示出)的驱动，上轮32a朝上下轮之间的空隙给送来自压胶条存储部32的压胶条4，而下轮32b朝上下轮之间的空隙给送帽顶2的底部边缘。利用上轮32a和下轮32b之间的压力将压胶条4热熔固定至帽顶2的底部边缘，如图8所示。帽顶2底部的周长通常大于实际需要的周长，因此通过上轮32a和下轮32b之间的转速差，可以制成所需要的帽顶周长；而在传统方法中，利用平缝机或拷边机将松紧带缝制在帽子底部，这不能很好地控制帽子的周长。在将压胶条4热熔固定至帽顶2的底部边缘的同时或之前之后，利用切刀33将帽顶2底部的多余部分去除掉。
在一个实施例中，可以在成形的帽顶2上进行刺绣、印花、转移热压烫花、缝制装饰花等装饰工艺。在一个实施例中，可以在成形帽顶2的内表面的前部贴合衬布并且用压胶条覆盖住衬布边缘，以使帽顶2挺括。
帽舌3采用层压材料制成，该层压材料包括TPU材料层、以及从上方和下方贴合至TPU材料层的两个布料层。将层压材料裁剪出帽舌形状并将其周缘包边，然后将帽顶2与所需的帽舌3缝合在一起并加上弹性的汗边条，从而形成一顶完整的帽子1，如图1所示。传统帽舌采用硬塑料舌芯制成，无法卷曲且易于产生折痕；而帽舌3回弹性好，可以随帽顶2一起卷曲以将帽子1放进塑料筒或其它包装袋随身携带，展开后帽子1能够恢复至原来的形状，从而保持好的帽型。
在上文所述的方法中，帽顶的成形无需经历现有技术的帽片分裁、拼接和缝制工序、或者开口缝口工序、或者先加热面料后挤压面料工序，能够节约生产时间和生产成本。本公开的帽子的帽顶可以制成各种帽子类型并且可以选自多种原材料。另外，在帽顶拉伸过程中，由于凸模13和开口24之间的间隙宽度均匀且控制在0.6mm-3mm之间，因此凸模13能够带动帽顶面料坯件2a均匀地向下拉伸而不会在帽顶上产生任何的褶皱。根据上文所述方法生产的帽顶是没有接缝的无缝帽顶，完全贴合使用者的 头型，并且可以选择透气性材料制成，从而改进了佩戴时的美观性和舒适性。
在整个说明书中涉及“一个实施例”、“替代实施例”、“一个或多个实施例”或者“实施例”的意思是结合该实施例所述的特殊特征、结构、材料或特性将包含在本公开的至少一个实施例中。因此，在整个说明书中在多个位置处出现的措辞例如“在一个或多个实施例中”、“在特定实施例中”、“在一个实施例中”或者“在实施例中”并不必须涉及本公开的相同实施例。而且，该特殊的特征、结构、材料或特性可以在一个或多个实施例中以任意合适方式组合。
尽管这里已经参考特殊实施例介绍了本公开，但是应当知道，这些实施例只是示例表示了本公开的原理和应用。本领域技术人员应当知道，在不脱离本公开的精神和范围的情况下能够对本公开的方法和装置进行多种变化和改变。因此，本公开将包括在附加权利要求和它们的等效物的范围内的变化和改变。

Claims (37)

  1. 一种制造帽子的方法，其特征在于，所述帽子包括没有接缝的无缝帽顶和接合至所述无缝帽顶的帽舌，所述无缝帽顶通过帽顶成形设备热拉伸一片平坦的针织面料坯件而一体成形，并且所述针织面料坯件中含有可玻璃化的石油化纤材料，所述帽顶成形设备包括凸模、与所述凸模相对且能容纳所述凸模的敞开的腔室、以及在帽顶成形过程中保持所述针织面料坯件的面料保持件，所述方法包括以下步骤：
    将所述凸模加热到等于或高于所述石油化纤材料的玻璃化温度、且低于所述石油化纤材料的熔点温度的温度；
    将所述针织面料坯件放置成其中心部分完全覆盖所述腔室的敞开的开口；
    在利用所述面料保持件保持所述针织面料坯件的周缘的同时，使所述凸模穿过所述腔室的开口朝向所述腔室的内部移动，直到所述凸模到达帽顶成形位置为止，由此将所述针织面料坯件拉伸成与所述凸模的外轮廓相匹配的形状；
    使所述凸模在所述帽顶成形位置停留预定的时间；
    使所述凸模移动离开所述腔室的内部，并将成形的所述帽顶从所述腔室上方取下并冷却；
    将所述帽顶和所述帽舌接合在一起以形成所述帽子。
  2. 根据权利要求1所述的方法，其特征在于，在所述针织面料坯件拉伸期间，所述凸模和所述开口之间存在间隙且间隙宽度保持均匀。
  3. 根据权利要求2所述的方法，其特征在于，在所述针织面料坯件拉伸期间，所述间隙宽度控制在0.6mm-3mm之间。
  4. 根据权利要求1所述的方法，其特征在于，在所述凸模在所述帽顶成形位置停留期间，所述石油化纤材料在等于或高于其玻璃化温度且低于其熔点温度的温度下由高弹态转变为玻璃态，从而所述针织面料坯件完全贴合所述凸模的外轮廓。
  5. 根据权利要求1所述的方法，其特征在于，所述预定的时间为30秒到70秒之 间。
  6. 根据权利要求1所述的方法，其特征在于，所述接合包括将所述帽舌和所述帽顶缝合在一起。
  7. 根据权利要求1至6中任一项所述的方法，其特征在于，在所述凸模加热的同时，将所述腔室加热到等于或高于所述石油化纤材料的玻璃化温度、且低于所述石油化纤材料的熔点温度的温度。
  8. 根据权利要求1至6中任一项所述的方法，其特征在于，在所述放置之前，将所述针织面料坯件裁剪成适合由所述面料保持件保持的形状和尺寸。
  9. 根据权利要求1至6中任一项所述的方法，其特征在于，在所述放置之前，对所述针织面料坯件进行喷水处理。
  10. 根据权利要求1至6中任一项所述的方法，其特征在于，在所述冷却之后且所述接合之前，去除所述帽顶的底部的多余部分。
  11. 根据权利要求1至6中任一项所述的方法，其特征在于，在所述冷却之后且所述接合之前、或者在所述接合之后，在所述帽顶上进行刺绣、印花、转移热压烫花、缝制装饰花等装饰工艺。
  12. 根据权利要求1至6中任一项所述的方法，其特征在于，在所述冷却之后且所述接合之前，在所述帽顶内贴合衬布并且用压胶条覆盖住所述衬布的边缘，以使所述帽顶挺括。
  13. 根据权利要求1至6中任一项所述的方法，其特征在于，所述针织面料坯件包括一层或多层针织面料。
  14. 根据权利要求13所述的方法，其特征在于，所述一层或多层针织面料中的至 少一层具有可玻璃化的石油化纤材料。
  15. 根据权利要求14所述的方法，其特征在于，所述一层或多层针织面料中的至少一层具有含量为5％-100％的可玻璃化的石油化纤材料。
  16. 根据权利要求1至6中任一项所述的方法，其特征在于，所述可玻璃化的石油化纤材料选自包括涤纶、锦纶、氨纶、腈纶的组。
  17. 根据权利要求1至6中任一项所述的方法，其特征在于，在所述冷却之后且所述接合之前，利用压胶机将压胶条固定至所述帽顶的底部的边缘。
  18. 根据权利要求17所述的方法，其特征在于，压胶机包括上轮和下轮，上轮朝上轮和下轮之间的空隙给送压胶条，而下轮朝上轮和下轮之间的空隙给送帽顶的底部边缘。
  19. 根据权利要求18所述的方法，其特征在于，上轮的转速和下轮的转速不同。
  20. 根据权利要求17所述的方法，其特征在于，压胶条采用弹性面料或松紧带贴合热熔胶制成。
  21. 根据权利要求1至6中任一项所述的方法，其特征在于，帽舌采用层压材料制成，所述层压材料包括TPU材料层、以及从上方和下方贴合至TPU材料层的两个布料层。
  22. 一种帽子，其特征在于，所述帽子根据权利要求1-21中任一项所述的方法制造而成。
  23. 一种帽子，其特征在于，所述帽子包括：通过热拉伸一片含有可玻璃化的石油化纤材料的平坦针织面料坯件而一体成形的没有接缝的无缝帽顶；以及接合至所述 无缝帽顶的帽舌。
  24. 根据权利要求23所述的帽子，其特征在于，所述帽顶内贴合有衬布并且具有覆盖住所述衬布的边缘的压胶条，以使所述帽顶挺括。
  25. 根据权利要求23所述的帽子，其特征在于，所述帽顶上具有刺绣、印花、转移热压烫花、缝制的装饰花等装饰件。
  26. 根据权利要求23至25中任一项所述的帽子，其特征在于，所述帽顶是通过在等于或高于所述石油化纤材料的玻璃化温度且低于所述石油化纤材料的熔点温度的温度下热拉伸所述平坦针织面料坯件而一体成形的无缝帽顶。
  27. 根据权利要求23至25中任一项所述的帽子，其特征在于，所述针织面料坯件包括一层或多层的针织面料。
  28. 根据权利要求27所述的帽子，其特征在于，所述一层或多层针织面料中的至少一层具有可玻璃化的石油化纤材料。
  29. 根据权利要求28所述的帽子，其特征在于，所述一层或多层针织面料中的至少一层具有含量为5％-100％的可玻璃化的石油化纤材料。
  30. 根据权利要求23至25中任一项所述的帽子，其特征在于，所述可玻璃化的石油化纤材料选自包括涤纶、锦纶、氨纶、腈纶的组。
  31. 根据权利要求23至25中任一项所述的帽子，其特征在于，压胶条被固定在所述帽顶的底部的边缘。
  32. 根据权利要求31所述的帽子，其特征在于，压胶条采用弹性面料或松紧带贴 合热熔胶制成。
  33. 根据权利要求23至25中任一项所述的帽子，其特征在于，帽舌采用层压材料制成，所述层压材料包括TPU材料层、以及从上方和下方贴合至TPU材料层的两个布料层。
  34. 一种用于制造没有接缝的无缝帽顶的帽顶成形设备，其特征在于，所述帽顶成形设备通过热拉伸一片平坦的针织面料坯件来一体成形所述无缝帽顶，并且所述针织面料坯件中含有可玻璃化的石油化纤材料，所述帽顶成形设备包括：
    模制装置，所述模制装置具有：基座；凸模，所述凸模固定至基座下方，并且具有与所述无缝帽顶相匹配的形状，以用于将所述无缝帽顶的针织面料坯件热拉伸成所需的形状；以及面料保持件，所述面料保持件可滑动地连接至基座，并且用于在帽顶成形过程中保持帽顶面料坯件的周缘；和
    支撑装置，所述支撑装置位于所述模制装置的竖直下方，并且包括外壳和从所述外壳向内凹陷的敞开的腔室，所述腔室的开口与所述凸模相对，并且所述腔室能够完全容纳穿过其开口进入的所述凸模。
  35. 根据权利要求34所述的帽顶成形设备，其特征在于，在热拉伸所述针织面料坯件的过程中，所述凸模通过所述开口进入所述腔室，并且所述凸模和所述开口之间存在间隙且间隙宽度保持均匀。
  36. 根据权利要求35所述的帽顶成形设备，其特征在于，在热拉伸所述针织面料坯件的过程中，所述间隙宽度控制在0.6mm-3mm之间。
  37. 根据权利要求34至36中任一项所述的帽顶成形设备，其特征在于，所述面料保持件包括：保持框架，所述保持框架用于在帽顶成形过程中保持帽顶面料坯件的周缘；引导杆，所述引导杆固定至所述保持框架并引导所述保持框架相对于所述基座竖直移动；和弹簧装置，所述弹簧装置设置在所述基座和所述保持框架之间。
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KR102213002B1 (ko) 2021-02-09
US20210289877A1 (en) 2021-09-23
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EP3616542A1 (en) 2020-03-04

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