METHOD FOR MANUFACTURING AN INTEGRALLY FORMED CAP AND A CAP MANUFACTURED BY THE METHOD

Abstract

A method is providing for manufacturing an integrally formed cap, the method comprising: in step 1, providing a shell fabric B and a thermoplastic lining fabric C, superposing the shell fabric on a surface of the lining fabric and tightly attaching the shell fabric to the lining fabric, to obtain the fabric A needed, and providing the shaping mold matched with the shape of a cap; in step 2, cutting the fabric A obtained in Step 1 into set dimensions; and in step 3, tightly attaching the fabric A cut in Step 2 onto the shaping mold obtained in Step 1, thermally shaping the fabric A by a container, so as to integrally shape the fabric A into the cap. With the method of the invention, the production speed and quality stability can be increased, the production cost reduced, and the production process is energy-saving and environment-friendly.

Claims

1. A method for manufacturing an integrally formed cap, the method comprising: at a first step: preparing a fabric A and providing a shaping mold; providing a shell fabric B and a thermoplastic lining fabric C; superposing the shell fabric B on a surface of the lining fabric C; tightly attaching the shell fabric B to the lining fabric C, to obtain the fabric A, and providing a shaping mold which matches the shape of a cap; at a second step: cutting the fabric A obtained in the first step to set dimensions; and at a third step: tightly attaching the fabric A cut in the second step onto the shaping mold obtained in the first step; and thermally shaping the fabric A by a container, so as to integrally shape the fabric A into the cap, thereby obtaining a product needed.

2. The method of claim 1, wherein the shell fabric B of the first step comprises one or two or more layers of fabric, and the lining fabric C is a woven piece woven from stabilized yarns or from stabilized yarns and yarns.

3. The method of claim 1, wherein the lining fabric C is chemical fiber lining, cotton lining, or wool lining or combinations thereof.

4. The method of claim 1, wherein in the first step before the shell fabric B and the lining fabric C are appressed together to form the fabric A, the shell fabric B is subjected to one or more of printing, embroidery, laser cutting and dyeing and finishing.

5. The method of claim 1, wherein in the first step the shell fabric B and the lining fabric C are bonded or sewed together.

6. The method of claim 5, wherein in the first step the shell fabric B and the lining fabric C are bonded together by adhesive, and the adhesive is one or more of environment-friendly resin, TPU and hot melt adhesive.

7. The method of claim 1, further comprising a step of shape correction after the fabric A is thermally shaped into the cap in the third step.

8. A cap manufactured using the method of claim 1, the cap comprising a cap body, which comprises a decorative layer located in the outer and a supporting layer located inside the decorative layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present invention is further described in detail below in reference to the drawings and specific embodiments.

[0024] FIG. 1 is a schematic view of a cap produced by the method according to the present invention; and

[0025] FIG. 2 is a schematic view of a fabric A used to manufacturing the cap according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] As shown in FIG. 1 and FIG. 2, a method for manufacturing an integrally formed cap is disclosed. The method comprises the following steps.

[0027] Step 1preparing a fabric A 10 and a shaping mold: providing a shell fabric B 20 and a thermoplastic lining fabric C 30, superposing the shell fabric B 20 on a surface of the lining fabric C 30 and tightly attaching the shell fabric B 20 and the lining fabric C 30 to each other, to obtain the fabric A 10 needed; wherein, according to needs, the area of the lining fabric C 30 may be equal to or smaller than it of the shell fabric B 20, i.e. the shell fabric B 20 may be partially or completely covered by the lining fabric C 30, even no lining fabric C 30 is comprised; providing the shaping mold which matches a cap in shape; wherein the shell fabric B 20 comprises one or two or more layers of fabric, and the lining fabric C 30 is a woven piece woven from stabilized yarns or from stabilized yarns and yarns; the lining fabric C 30 may be another material or combinations of various materials, including chemical fiber lining, cotton lining, and wool lining.

[0028] Step 2cutting: cutting the fabric A 10 obtained in Step 1 into set dimensions.

[0029] Step 3thermally shaping: tightly attaching the fabric A 10 cut in Step 2 onto the shaping mold provided in Step 1, thermally shaping the fabric A 10 by a container, so as to integrally shape the fabric A into the cap expected; wherein the fabric A 10 first is covered on the shaping mold, a rope or an elastic is then used to tie the lower edge of the fabric A 10 to allow the fabric A 10 to be appressed completely on the surface of the shaping mold, after that both the shaping mold and the fabric A 10 are placed into a sealed container for thermoplastic shaping; alternatively, the shaping mold is placed into a container first, the fabric A 10 is then covered on the shaping mold, next the container is sealed, and finally the fabric A 10 is shaped thermoplastically by the container; as a preferred embodiment of the present invention, the container can be hermetically closed, that is, the container can be opened or closed.

[0030] According to the invention, the shell fabric B 20 and the thermoplastic lining fabric C 30 are appressed together to form the fabric A 10, which is then appressed on the outer surface of the shaping mold for thermoplastically shaping, whereby a cap with a shape matched with the shaping mold is formed from the fabric A 10, and thus the objective of producing an integrally formed cap is achieved. Therefore, for cap production, production speed is greatly increased and quality stability is effectively guaranteed. Furthermore, as the fabric no longer needs to be cut into multiple splicing pieces, thereby resulting in greatly reduced rags, fabrics are saved. Resulting from above, the production process according to the present invention is characterized in reduced production costs, energy-saving and environment-friendly.

[0031] Moreover, before being produced into the fabric A 10, the shell fabric B 20 in the present invention is a piece of flat fabric, thus printing, embroidery, laser cutting or dyeing and finishing can be easily carried out on the shell fabric B 20 to produce various patterns or textures or three-dimensional patterns on the surface of the shell fabric B 20, for divers appearances, to satisfy individualized demands from different users.

[0032] In addition, the fabric A 10 according to the present invention is attached tightly to and covers the outer surface of the shaping mold, and then shaped integrally into the cap by thermoplastic shaping, thus the conventional method in which fabric pressing or squeezing is required in cap production by integral forming is abandoned, and whereby creases, raveled yarns or broken yarns caused by pressing or squeezing are prevented from occurring on fabrics.

[0033] For more attractive, elegant and diversified appearance, with the production process of the present invention, preferably, before the shell fabric B 20 and the lining fabric C 30 in Step 1 are appressed together to form the fabric A 10, the shell fabric B 20 has been subjected to one or more of printing, embroidery, laser cutting and dyeing and finishing. That is, before the shell fabric B 20 and the lining fabric C 30 are combined, one or more of printing, embroidery, laser cutting and dyeing and finishing are carried out on the shell fabric B 20.

[0034] By performing printing, embroidery, laser cutting or dyeing and finishing processes on the shell fabric B 20, the shell fabric B 20 can be more three-dimensional and diversified in shape or pattern, so that the produced cap can be more diversified and three-dimensional in appearance as well, and thereby satisfying the demands of different users on different appearances of caps.

[0035] According to the present invention, for tighter and firmer bonding between the shell fabric B 20 and the lining fabric C 30, preferably, in Step 1 the shell fabric B 20 and the lining fabric C 30 can be stuck or sewed together. As a preferred embodiment of the present invention, in Step 1 the shell fabric B 20 and the lining fabric C 30 are stuck together by adhesive, and the adhesive is one or more of environment-friendly resin, TPU and hot melt adhesive.

[0036] For more attractive and elegant appearance, preferably, formed from the fabric A 10 by thermoplastically shaping in Step 3, the cap is then processed by shape correction. By carrying out shape correction on the cap, deformed parts of the cap which are caused during the production process can be corrected, such that the cap produced can be in consistence with the designed shape, for better appearance.

[0037] The present invention will be described in detail with different embodiments in which different materials are used to produce the cap.

Embodiment 1

[0038] The method for manufacturing an integrally formed cap comprises the following steps.

[0039] Step 1preparing a fabric A 10 and a shaping mold: a cotton fabric is selected as the shell fabric B 20, a woven piece woven from stabilized yarns is selected as the lining fabric C 30, the adhesive is applied on the shell fabric B 20 and/or the lining fabric C 30, the shell fabric B 20 is attached gently to the lining fabric C 30 and the two are then pressed gently towards each other, whereby the shell fabric B 20 and the lining fabric C 30 are bonded by the adhesive applied on the shell fabric B 20 and/or the lining fabric C 30 to form the fabric A 10; preferably, while the shell fabric B 20 and the lining fabric C 30 are squeezed to against each other, the temperature is 10 C. to 110 C., the squeezing pressure is 0.3 MPa to 0.6 MPa, and the duration is 5 to 90 seconds; in addition, the shaping mold matched with the shape of a cap is provided, and the shape of the shaping mold can be various, depending on the shape of the cap to be produced;

[0040] Step 2cutting: the fabric A 10 obtained in Step 1 is cut into set dimensions;

[0041] Step 3thermoplastic shaping: The fabric A 10 cut in Step 2 is attached tightly to and covers the shaping mold provided in Step 1, the fabric A 10 is then shaped thermoplastically by a container, to integrally shaping the fabric A 10 into the cap, thereby obtaining the needed product; in the embodiment, the thermoplastic shaping is performed on the fabric A 10 with the shaping mold in the container, the temperature in the container is 100 C. to 160 C., the pressure is 0.4 MPa to 0.5 MPa, and the time is 10 to 60 seconds; after that, the temperature in the container is kept between 5 C. and 30 C., cooling the fabric A 10 for 10 to 30 seconds.

[0042] The container is then opened, the temperature in the container is kept between 90 C. to 130 C., and shape correction is carried out on the fabric A 10 in the atmospheric environment for correcting deformed parts of the fabric A 10, lasting for 10 to 60 seconds.

[0043] Finally, the temperature of the container is kept between 5 C. to 30 C. for 10 to 60 seconds for cooling, the fabric A 10 is then taken off from the shaping mold, and the desired cap is obtained by integral forming.

Embodiment 2

[0044] The method for manufacturing an integrally formed cap comprises the following steps.

[0045] Step 1preparing a fabric A 10 and a shaping mold: a woolen is selected as the shell fabric B 20, a woven piece woven from stabilized yarns is selected as the lining fabric C, the adhesive is applied on the shell fabric B 20 and/or the lining fabric C 30, the shell fabric B 20 is attached gently to the lining fabric C 30 and the two are then pressed gently towards each other, whereby the shell fabric B 20 and the lining fabric C 30 are bonded by the adhesive applied on the shell fabric B 20 and/or the lining fabric C 30 to form the fabric A 10; preferably, while the shell fabric B 20 and the lining fabric C 30 are squeezed to against each other, the temperature is 10 C. to 100 C., the squeezing pressure is 0.3 MPa to 0.5 MPa, and the duration is 5 to 100 seconds; in addition, the shaping mold matched with the shape of a cap is provided, and the shape of the shaping mold can be various, depending on the shape of the cap to be produced;

[0046] Step 2cutting: the fabric A 10 obtained in Step 1 is cut into set dimensions;

[0047] Step 3thermoplastic shaping: The fabric A 10 cut in Step 2 is attached tightly to and covers the shaping mold provided in Step 1, the fabric A 10 is then shaped thermoplastically by a container, to integrally shaping the fabric A 10 into the cap, thereby obtaining the needed product; in the embodiment, the thermoplastic shaping is performed on the fabric A 10 with the shaping mold in the container, the temperature in the container is 100 C. to 140 C., the pressure is 0.3 MPa to 0.6 MPa, and the time is 10 to 60 seconds; after that, the temperature in the container is kept between 0 C. and 30 C., cooling the fabric A 10 for 10 to 40 seconds.

[0048] The container is then opened, the temperature in the container is kept between 90 C. to 130 C., and shape correction is carried out on the fabric A 10 in the atmospheric environment for correcting deformed parts of the fabric A 10, lasting for 10 to 60 seconds.

[0049] Finally, the temperature of the container is kept between 5 C. to 30 C. for 10 to 60 seconds for cooling, the fabric A 10 is then taken off from the shaping mold, and the desired cap is obtained by integral forming.

Embodiment 3

[0050] The method for manufacturing an integrally formed cap comprises the following steps.

[0051] Step 1preparing a fabric A 10 and a shaping mold: fibers are selected as the shell fabric B 20, a woven piece woven from stabilized yarns is selected as the lining fabric C, the adhesive is applied on the shell fabric B 20 and/or the lining fabric C 30, the shell fabric B 20 is attached gently to the lining fabric C 30 and the two are then pressed gently towards each other, whereby the shell fabric B 20 and the lining fabric C 30 are bonded by the adhesive applied on the shell fabric B 20 and/or the lining fabric C 30 to form the fabric A 10; preferably, while the shell fabric B 20 and the lining fabric C 30 are squeezed to against each other, the temperature is 40 C. to 180 C., the squeezing pressure is 0.3 MPa to 0.7 MPa, and the duration is 10 to 80 seconds; in addition, the shaping mold matched with the shape of a cap is provided, and the shape of the shaping mold can be various, depending on the shape of the cap to be produced;

[0052] Step 2cutting: the fabric A 10 obtained in Step 1 is cut into set dimensions;

[0053] Step 3thermoplastic shaping: The fabric A 10 cut in Step 2 is attached tightly to and covers the shaping mold provided in Step 1, the fabric A 10 is then shaped thermoplastically by a container, to integrally shaping the fabric A 10 into the cap, thereby obtaining the needed product; in the embodiment, the thermoplastic shaping is performed on the fabric A 10 with the shaping mold in the container, the temperature in the container is 100 C. to 150 C., the pressure is 0.3 MPa to 0.6 MPa, and the time is 10 to 60 seconds; after that, the temperature in the container is kept between 5 C. and 25 C., cooling the fabric A 10 for 10 to 30 seconds.

[0054] The container is then opened, the temperature in the container is kept between 90 C. to 120 C., and shape correction is carried out on the fabric A 10 in the atmospheric environment for correcting deformed parts of the fabric A 10, lasting for 10 to 60 seconds.

[0055] Finally, the temperature of the container is kept between 5 C. to 30 C. for 10 to 60 seconds for cooling, the fabric A 10 is then taken off from the shaping mold, and the desired cap is obtained by integral forming.

[0056] Referring to FIG. 1 and FIG. 2, disclosed is a cap produced by the above-mentioned production process. The cap of the invention comprises a cap body 40 comprising a decorative layer located on the outer and a supporting layer located inside the decorative layer. Specifically, the decorative layer is formed by the shell fabric B 20, and the supporting layer is formed by the lining fabric C 30 and plays a supporting role.

[0057] In the cap production according to the method of the present invention, once the mold matched with the shape of the head of a user is provided, the cap matched the shape of the head of the user can be formed thermoplastically on it and thus the cap produced by the production method of the present invention can be better adapted in shape to the head of the user. The shape of the head of the user can be measured by scanning, the mold with the same shape as the head of the user is then produced by 3D printing, and the cap which better matches the shape of the head of the user can be produced by adopting the mold. In addition, caps can be produced with different materials, and with certain elasticity rather than being completely solidified or hardened in form, for convenient wearing.

[0058] Described above are merely preferred embodiments of the present invention, and any technical solutions which achieve the objective of the present invention with basically the same means shall fall within the protection scope of the invention.