JP3202625B2 - Hat core material and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a hat and a method for manufacturing a core material thereof. More specifically, the present invention relates to a core material for a collar used for manufacturing a hat with a collar, which has a bend, and a method for manufacturing the same.

[0002]

2. Description of the Related Art In general, a collar 11 of a hat 10 having a collar such as a baseball cap shown in FIG. 3 (a) is coated with a core material formed by cutting a foam material sheet such as foamed polyethylene into a collar shape. It is manufactured after sewing. A foam material sheet used as a core material in such an application is a long sheet-like material obtained by molding a raw material by extrusion foam molding or the like. Therefore, it is said that the core material obtained by cutting this is also a planar member, and rather high quality when it is not bent.

[0003] On the other hand, in recent years, there has been a demand in particular for a hat product with a brim to bend the brim in advance. That is, the shape of the head of the person wearing the hat varies, and as shown in FIG. 3 (b), even if the collar 11 of the hat 10 itself is flat, 3
This is because the collar 11 is often bent in accordance with the deformation of the crown 12 of the hat 10, as shown in FIG. In such a case, the elastic force of the initially flat brim acts to tighten the wearer's head, thereby giving the wearer discomfort. In addition, because a general hat purchaser wears the collar after bending the collar in an attempt to imitate the state of an athlete or the like wearing a hat with the collar bent for various reasons, it has been bent from the beginning. There is also a demand from the market to commercialize a hat with a brim.

[0004]

In response to the above demands, it has been already performed to process and bend core materials one by one. However, bending one by one prior to the manufacture of the hat results in a price increase that cannot be ignored in terms of the manufacturing cost of the hat. Also, it is not industrially practical to remodel the production line, such as introducing a forming roll, only for producing the core material of the hat. Therefore, a new method for efficiently manufacturing a bent core material at low cost is required.

The main object of the present invention is to solve the problems of the prior art as described above and to provide a novel manufacturing method capable of efficiently providing a core material bent by its unique structure at low cost. The purpose is.

[0006]

According to the present invention, there is provided, according to the present invention, a core material for a brim of a hat formed of a bent foam material, wherein the first foam material sheet immediately after extrusion foam molding is separately formed by extrusion molding. A foam material sheet formed by laminating a molded second foam material sheet, wherein the foam material sheet has a warp in a direction perpendicular to a traveling direction of the foam material sheet during extrusion molding. A core is provided. In the core material of the hat, the foam material sheet is
A foam sheet of polyethylene, polypropylene or vinyl chloride can be used.

According to the present invention, as a method for manufacturing the core material of the brim of the hat according to the present invention, a first foamed material sheet immediately after being extruded into a sheet shape by extrusion foam molding is used. A second step in which a molded second foam material sheet is brought into close contact with each other to form a laminate sheet, and a second step in which the laminated foam material sheet is cooled while being held while maintaining a predetermined curvature. And a method. In this way,
A foam sheet having a warp in a direction perpendicular to the traveling direction of the foam sheet during lamination is obtained. Therefore,
By cutting this as appropriate, a core material for a warped hat can be easily manufactured.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The method according to the present invention makes it possible to easily manufacture a warped foam sheet by laminating foam sheets having different manufacturing conditions. However, "different manufacturing conditions"
However, no special equipment or materials are required. That is, in the method according to the present invention, the foamed material that has already been formed into a sheet shape and the foamed material sheet that has just been formed into a sheet shape by extrusion molding are laminated by a unique method. It is possible to manufacture material sheets. When a foamed laminate sheet is manufactured by the above-described method under appropriate conditions as described below, a strong warp can be given in a direction perpendicular to the extrusion direction at the time of extrusion molding.

That is, according to the present invention, the foamed material sheet which finally becomes a core material having a predetermined thickness is manufactured by laminating two thin foamed material sheets. Here, the laminating equipment is disposed immediately after the extruder for preparing one foam material sheet. On the other hand, the other foamed material sheet that has been processed into a sheet shape by extrusion molding and then wound up is used. By passing these two sheets in a laminated state between at least one pair of rolls, one foam material sheet is finally obtained.

In the above laminating step,
Each foam sheet is treated under different conditions. That is, the first foam sheet immediately after being extruded is at a high temperature close to the melting point. On the other hand, the second foam material sheet previously processed into a sheet shape is at a temperature close to room temperature, but receives a tensile stress applied by a roll in a series of steps.

Further, according to a preferred embodiment of the present invention,
In the above series of steps, of the plurality of rolls that are in contact with the foamed material sheet, the temperature of the roll that is in contact with the first foamed material sheet is kept higher than the other rolls. Specifically, the temperature of the roll in contact with the first foam material sheet is lower than the temperature of the sheet in contact with the second foam material.
By increasing the temperature by 20 ° C. to 50 ° C., the warpage of the finally obtained foam laminate sheet can be increased or decreased.

According to still another preferred embodiment of the present invention, it is preferable to apply a high tensile force to the foam material sheet in the above-mentioned series of steps. In other words, even in the production process of the ordinary foam material sheet, by controlling the rotation speed of each roll, a certain amount of tensile force is applied to simultaneously transport the sheet on the line and eliminate looseness of the sheet. . In contrast, in the method according to the present invention, the roll is controlled so that a higher tensile force, for example, a tensile force greater than 1 kg / cm ^{2 and} less than 6 kg / cm ² is applied. The specific value of the preferable tensile force is appropriately determined depending on the material used, the thickness of the sheet, and the like.
The reason why the upper limit is set for the tensile force is that if the tensile force acting on the sheet is excessively high, the sheet may be defective.

The foamed laminate sheet finally obtained by the various operations described above has a strong warp in the width direction. Therefore, by appropriately cutting such a foamed material laminate sheet, a core material of a hat having permanent warpage can be obtained.

When a hat with a brim is manufactured using the core material bent as described above, the brim becomes flexible when the shape of the opening of the hat is deformed according to the shape of the head of each user. There is less pressure on the head because it follows.

Further, since the bent brim has a higher bending rigidity in the depth direction than the flat brim, the brim of the same length can maintain the shape even if the thickness of the material is reduced, and the same thickness can be maintained. If material is used, a longer brim shape can be maintained. Therefore, the degree of freedom in designing the hat is increased.

Hereinafter, the semiconductor laser module according to the present invention will be described more specifically with reference to the drawings. However, the following disclosure is merely an example of the present invention and does not limit the technical scope of the present invention. Not something.

[0017]

FIG. 1 is a diagram schematically showing a configuration example of a manufacturing apparatus for carrying out a method according to the present invention.

As shown in FIG. 1, the apparatus includes a first foam material sheet 2 supplied directly from an extrusion foam molding machine 1.
And a plurality of rolls 4 for laminating a coil-shaped second foam material sheet 3 which has been prepared and wound in advance in a sheet shape and then sends it to the next step. Here, among the plurality of rolls, some of the rolls 4a that are in direct contact with the first foam material sheet 2 are heated to about 70 to 100 ° C. The temperature of the remaining roll 4b is set at about 50 to 70 ° C., and there is a remarkable temperature difference between the two.

When the apparatus having the above configuration is operated,
The first foam sheet 2 is warped such that it shrinks relatively to the second foam sheet. The second foam material sheet 3 itself that is in contact with the unheated roll does not warp in particular, but the first foam material sheet laminated with the first and second foam material sheets is the first foam material sheet. 2 causes warpage.

The foamed laminate sheet manufactured in this manner is cut into predetermined lengths, and then laminated on a jig 6 having a curved upper surface as shown in FIG. Let cool. The direction indicated by arrow A in FIG. 2 is the direction in which the material is fed when the foamed material sheet is laminated, and the warpage given to the sheet according to the present invention is the warpage in the width direction of the long sheet. .

The foamed laminate sheet manufactured through the above steps permanently retains the warpage given in the manufacturing process, and the core cut out from this foamed laminated sheet also has a warp. ing. In addition, since the foamed laminate sheet having warpage is easily elastically deformed, the work for cutting the same can be performed using the same equipment as that for cutting the normal foamed sheet.

[Preparation Example 1] A core material was actually manufactured by the method described above. As the first foam material sheet, specific gravity 0.6,
A polyethylene low-foam sheet having a thickness of 1 mm was used, and a polyethylene low-foam sheet having a specific gravity of 0.6 and a thickness of 0.7 mm was used as a second foam material sheet. These materials used what was marketed. Extrusion of the first foamed sheet is performed using a T-die extruder manufactured by Toshiba Machine Co., Ltd.
The pressure on the foam sheet on the laminating roll is
It was adjusted appropriately in the range of 2.5 to 3.0 kg / cm ² . Also, the second
The roll was controlled such that a tensile stress of 5 kg / cm ² was applied to the laminate sheet from the coil of the foam material sheet to the end of the line. Further, each of the rolls was provided such that the surface temperature of a series of rolls 4a in contact with the first foam material sheet was 80 ° C. and the surface temperature of the series of rolls 4b in contact with the second foam material sheet was 50 ° C. The heater was controlled. In addition, although a pigment, a stabilizer and the like are mixed in the foaming material actually used, the same additives as used in the case of manufacturing a normal foaming agent sheet are used for these additives.

The foamed laminate sheet prepared as described above is cut at intervals of 1 m, and placed on a jig having a width of about 1 m and a height of 20 cm each having a cylindrical upper surface and a length of about 1 m. It was left to cool to room temperature for 24 hours. The core material thus obtained continued to maintain its shape even when dropped from the jig.

[Preparation Example 2] Using the same equipment, a polyethylene low-foam sheet having the same specific gravity of 0.6 and a thickness of 1 mm was used as the first foam material sheet, and the expansion ratio was up to 30 times as the second foam material sheet. A commercially available polyethylene foamed sheet having an increased thickness of 2 mm was used. The conditions for the extrusion molding of the first foam material sheet are the same as in the case of Production Example 1. However, the pressure applied to the foam sheet on the laminating roll was in the range of 2.5 to 3.0 kg / cm ² . The roll was controlled so that the tensile stress applied to the laminate sheet from the coil of the second foam material sheet to the end of the line was about 5 kg / cm ² . Further, the surface temperature of the series of rolls 4a in contact with the first foam material sheet is 80 ° C.
The heater mounted on each roll was controlled so that the surface temperature of the series of rolls 4b in contact with the second foam material sheet was 50 ° C.

The foam laminate sheet prepared as described above was cut every 1 m, placed on the same jig as in Preparation Example 1, and cooled to room temperature. The core material thus obtained continued to maintain its shape even when dropped from the jig.

In the above description, only the core material of a hat, such as a so-called baseball cap, which has a brim in a part of the circumferential direction of the hat has been described. It goes without saying that the present invention can be applied to the manufacture of a core material for a brim of a hat having the following shape.

Although the foamed polyethylene is used in the examples, the method of the present invention can be similarly applied to other heat-flexible resins such as polypropylene and vinyl chloride and their foamed materials. As each foaming agent sheet, a sheet having a thickness of about 1 to 5 mm can be appropriately selected and used.

[0028]

As described above in detail, according to the method of the present invention, a foamed sheet having an optimum curvature as a core material of a brim of a hat can be efficiently manufactured with the same equipment and the same process as the conventional manufacturing method. Can be manufactured well. Therefore,
It is possible to manufacture a hat with a brim that can be worn comfortably and has a high degree of freedom in design at low cost.

[Brief description of the drawings]

FIG. 1 is a diagram schematically showing a configuration example of an apparatus for performing a method according to the present invention.

FIG. 2 is a diagram for explaining a configuration example of a jig used to carry out a method according to the present invention and a method of using the same.

FIG. 3 is a diagram showing a specific example of a hat using a core material targeted by the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Extrusion foam molding machine, 2 ... 1st foam material sheet, 3 ... 2nd foam material sheet, 4 ... Roll, 10
... hat with brim, 11 ... brim, 12 ... crown

────────────────────────────────────────────────── ─── Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI B32B 5/32 B32B 5/32 // B29K 23:00 27:06 B29L 31:48 (56) References (JP, U) Japanese Patent Publication No. 51-43056 (JP, B1) Japanese Patent Publication No. 51-8149 (JP, B2) Japanese Patent Publication No. 3-67021 (JP, B2) Japanese Patent Publication No. 4-506488 (JP, A) ( 58) Field surveyed (Int.Cl. ⁷ , DB name) B29C 53/04 A42B 1/00 A42C 1/00 B29C 47/06 B29C 47/88 B32B 5/32

Claims (8)

(57) [Claims] 1. A core material for a brim of a hat formed of a bent foam material, comprising: a first foam material sheet immediately after extrusion foam molding; and a second foam material sheet separately molded by extrusion molding. A core material, which is a foamed material sheet formed by laminating, and has a warp in a direction perpendicular to a traveling direction of the foamed material sheet during extrusion molding. 2. The core material according to claim 1, wherein said foam material sheet is made of polyethylene, polypropylene or vinyl chloride. 3. The core material according to claim 2, wherein the foam material sheet is foamed polyethylene having an expansion ratio of 1.5 to 3 times. 4. The core material according to claim 2, wherein the foam material sheet is foamed polyethylene having an expansion ratio of 25 to 35 times. 5. A method for producing a core material for a brim of a hat, comprising: a first foam material sheet immediately after being extruded into a sheet shape by extrusion foam molding; and a sheet material already formed by extrusion molding. A second step of bringing the second foamed material sheet into close contact with each other to form a laminate sheet, and a second step of holding the laminated foamed material sheet while maintaining a predetermined curvature and allowing it to cool A method comprising: 6. The method according to claim 5, wherein the temperature of the first foam sheet is higher than the temperature of the second foam sheet by 20 ° C. to 50 ° C. through the first step. A method characterized by holding. 7. The method according to claim 6, wherein in the first step, the temperature of a roll contacting only with the first foam material sheet is selectively controlled. 8. The method according to claim 5, wherein at least the tensile stress acting on the second foam material sheet is greater than 1 kg / cm ² and 6 kg / cm ^2. / Cm ² or less.