Method for manufacturing thin knitted shaped cap and thin knitted shaped cap

Abstract

The present invention discloses a method for manufacturing a thin knitted shaped cap and the thin knitted shaped cap, comprising the following steps: preparing TPU monofilaments and heat-setting yarns, wherein the TPU monofilaments are made of pure TPU material, and the heat-setting yarns are made of a blend of ES fiber and polyester staple fiber; doubling the TPU monofilaments and the heat-setting yarns to obtain synthetic shaped yarns; preparing basic yarns, weaving the basic yarns with the synthetic shaped yarns to form a semi-finished cap body; heating the semi-finished cap body until the TPU in the synthetic shaped yarns melts and the ES fibers soften; and cooling and setting the cap body to form a three-dimensional cap body. The present invention utilizes synthetic shaped yarns containing TPU monofilaments and ES fibers to weave a cap, which is then heated and cooled to set. After the TPU monofilaments melt and cool, they bond with the ES fibers, resulting in improved tear strength of the fabric, making it less prone to deformation and tearing, and suitable for making thin summer caps.

Description

Technical Field

[0001] The present invention relates to the technical field of knitted hats, in particular to a method for manufacturing a thin knitted shaped hat and the thin knitted shaped hat. Background Art

[0002] The production of existing knitted shaped caps is to blend ES fiber with other fibers to form a shaped yarn. This shaped yarn is then woven again with other basic yarns to form a cap-shaped fabric, which is then heated and cooled in a shaped mold to obtain a cap of a certain shape.

[0003] For example, Chinese patent application number CN 201910591716.6 discloses a shaped top hat and its preparation method, which is implemented according to the following steps: first, ES fiber and polyester chopped fiber are blended to prepare heat-set yarn, and multiple heat-set yarns prepared are arranged in parallel as core yarns, and animal hair fiber is used as outer yarns for spinning to obtain yarn for shaped top hats; the yarn for shaped top hats is woven using a knitting machine to obtain top hat blanks, which are then connected on a looping machine to prepare hat blanks; the hat blanks are subjected to a shrinking treatment, and the shrunken hat blanks are placed in a shrinking machine for shrinking treatment, and finally cooled to obtain the finished shaped top hat. This solution takes advantage of the low melting point of ES fiber and the high melting point of other fibers, allowing the ES fiber to be thermally bonded and hardened when cooled, thereby achieving the purpose of shaping. However, the thicker the shaping yarn, the better the shaping effect, and vice versa. When the yarn is of a certain fineness, the shaping effect cannot be achieved. Obviously, this solution is feasible for shaping hats, but it cannot achieve the ideal effect for thin and breathable shaping hats in summer.

[0004] In addition, a Chinese patent application with publication number CN 108813787 A discloses a hat manufacturing process, which completes the production of a knitted hat through the processes of waxing the raw material yarn, adding new yarn, weaving, cutting, sewing and finishing. This solution adds shaping yarn to the raw material yarn. By adding the shaping yarn, the steps in the traditional production process are reduced. During the sewing process, the knitted hat piece is put on a looping machine and tightened to the top to form a bowl shape, which reduces the splicing and sewing steps in the traditional production process. The brim of the hat also uses knitting technology, which reduces the cutting and splicing steps. Therefore, this solution is only to reduce the process steps of the hat and simplify the production process by using setting yarn, and the setting yarn is generally prepared by ES fiber blending. Therefore, the quality of the setting mainly depends on the thickness of the setting yarn. The thicker the setting yarn, the better the setting effect, and vice versa. Moreover, the thickness of the setting yarn also directly affects the tensile strength of the hat. The thicker the setting yarn, the better the tensile effect, and vice versa. Therefore, in order to achieve better setting effect and tensile strength, thicker setting yarn is needed, but this will inevitably increase the thickness of the hat. Therefore, this solution can only be applied to thicker hats in winter, and is not applicable to thin hats in spring, summer and autumn. Summary of the Invention

[0005] The purpose of the present invention is to provide a method for manufacturing a thin knitted shaped hat and a thin knitted shaped hat to solve the problems existing in the above-mentioned prior art. The hat is knitted with a synthetic shaped yarn containing TPU monofilament and ES fiber, and then heated and cooled to shape. After the TPU monofilament is melted and cooled, it is bonded with the ES fiber, so that the tear strength of the fabric is improved, and it is not easy to deform or tear, and is suitable for the production of thin summer hats.

[0006] To achieve the above object, the present invention provides the following solutions:

[0007] The present invention provides a method for manufacturing a thin knitted shaped cap, comprising the following steps:

[0008] Prepare TPU monofilament and heat-set yarn, wherein the TPU monofilament is made of pure TPU material, and the heat-set yarn is made of a blend of ES fiber and polyester staple fiber;

[0009] Doubling the TPU monofilament and the heat-set yarn to obtain a synthetic heat-set yarn;

[0010] preparing a basic yarn, and knitting the basic yarn with the synthetic setting yarn to form a semi-finished hat body;

[0011] Heating the semi-finished cap body until the TPU of the synthetic sizing yarn is melted and the ES fiber is softened;

[0012] The semi-finished hat body is cooled and shaped to form a three-dimensional hat body.

[0013] Preferably, the TPU monofilament has a melting point of 85° C. and a specification of 50D, 75D, 100D or 150D.

[0014] Preferably, a computerized flat knitting machine is selected to first weave the basic yarn and the synthetic shaping yarn into a fabric hat blank, and then splice the ends of the fabric hat blank to form a semi-finished hat body. The needle pitch of the computerized flat knitting machine is 14 needles / inch, and the density parameter is set to 300 during weaving.

[0015] Preferably, the semi-finished cap body is placed on a hot mold at 120° C. for 15-20 seconds to be heated.

[0016] Preferably, the semi-finished cap body is transferred to a cold mold and blown with cold air for 10 seconds to cool and shape it.

[0017] Preferably, the basic yarn is made of high twist 60S / 2 mercerized singed cotton yarn with a twist coefficient of 750-850.

[0018] Preferably, the knitting structure is a single-sided pointillism and transfer stitch coexistence, two basic yarns are selected, and the needle covering technology is used to cover the synthetic setting yarn with the basic yarn, and the single-sided three-dimensional shape of the fabric cap blank is knitted through knitting.

[0019] Preferably, the basic yarn is a high twist 60S / 2 mercerized Lenzing Tencel yarn with a twist coefficient of 650-750.

[0020] Preferably, the weaving structure is a double-layer bag jacquard structure, two of the basic yarns are selected as the front needle bed yarns, and the synthetic setting yarn is selected as the rear needle bed yarns. During weaving, the basic yarn and the synthetic setting yarn are woven into the fabric cap blank by shovel needles.

[0021] The present invention also provides a thin knitted shaped cap, comprising a three-dimensional cap body made by the above-mentioned manufacturing method, and also comprising a sweatband, wherein the sweatband is sewn onto the three-dimensional cap body.

[0022] Compared with the prior art, the present invention has achieved the following technical effects:

[0023] (1) The present invention utilizes a synthetic shaped yarn comprising TPU monofilaments and ES fibers to weave a hat, which is then heated and cooled to set the shape. The TPU monofilaments are melted and cooled to bond with the ES fibers, thereby increasing the tear strength of the fabric, making it less prone to deformation and tearing, and making it suitable for the production of thin hats for summer.

[0024] (2) The present invention utilizes the characteristics of TPU and ES fiber, combined with computerized flat knitting machines, to ensure the excellent effects of stiffness, tear resistance, and non-deformation of the hat, without using chemical adhesives, and can also use jacquard instead of printing, greatly reducing the possibility of environmental pollution;

[0025] (3) The present invention can directly weave the yarn into shape, which greatly reduces the production time of the hat. It overcomes the problem that the traditional process requires the yarn to be woven into fabric, and then the fabric is bonded, cut, and sewn to make a hat, which consumes a lot of time. The hat can be made in a short time with high speed. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0027] Figure 1 It is a process flow chart of the present invention. DETAILED DESCRIPTION

[0028] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0029] The purpose of the present invention is to provide a method for manufacturing a thin knitted shaped hat and a thin knitted shaped hat to solve the problems existing in the prior art. The hat is knitted with a synthetic shaped yarn containing TPU monofilament and ES fiber, and then heated and cooled to shape. After the TPU monofilament is melted and cooled, it is bonded with the ES fiber, so that the tear strength of the fabric is improved, and it is not easy to deform or tear. It is suitable for the production of thin summer hats.

[0030] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] The following are some of the terms used in this invention:

[0032] Shovel needle: The knitting machine knits into pieces of cloth by forming loops with the needles arranged on the front and rear needle beds. Generally, if the number of needles corresponding to the width of A4 paper is selected for knitting, and if the needles selected for each row are knitted in loops, then the fabric woven will be a rectangular fabric with a certain length and width in the shape of A4 paper. Sometimes, in order to make the fabric have a certain shape, the machine head will stop knitting when it moves to a certain position, and restart knitting for one row. In this way, the fabric will have a certain shape. This needle stopping process is called shovel needle.

[0033] TPU: Thermoplastic polyurethane elastic rubber.

[0034] Covering needles / covering wool: using a special yarn mouth to guide two different wool materials or yarns into the knitting process from different positions of the yarn mouth, so that the effect of the woven shirt or fabric is that one wool material or yarn covers another wool material or yarn, and the bottom and top show the weaving method of different wool materials or yarns.

[0035] ES fiber: A type of polyolefin fiber. After heat treatment, the fibers adhere to each other to form a non-woven fabric without the need for adhesives.

[0036] like Figure 1 As shown, the present invention provides a method for manufacturing a thin knitted shaped cap, comprising the following steps:

[0037] Prepare TPU monofilament and heat-set yarn. TPU monofilament is made from pure TPU material. TPU has high hardness, high elasticity, good flexibility, extremely high wear resistance and tear resistance, high tensile strength, and high elongation. By adjusting the raw material properties, it can be produced into pure monofilament with a specific melting point and thickness. Heat-set yarn is made from a blend of ES fiber and polyester staple fiber. ES fiber has a lower melting point than ordinary yarn, allowing it to bond with each other during heat treatment and harden when cooled, thus achieving a fixed shape.

[0038] The TPU monofilament and the heat-set yarn are subjected to a doubling process using a doubling machine to obtain a synthetic heat-set yarn.

[0039] Prepare basic yarn, which can be cotton yarn, polyester yarn or other yarn, and use computerized flat knitting machine to knit the basic yarn and synthetic shaped yarn into a fabric hat blank, and then process the fabric hat blank into a semi-finished hat body by means of looping or the like.

[0040] The semi-finished cap body is heated until the TPU of the synthetic setting yarn is melted and the ES fiber is softened. During heating, a heat setting mold, such as an aluminum mold, a steel mold or other metal mold, can be used.

[0041] The semi-finished cap body is cooled and shaped. The cooling process can be carried out on a mold that is consistent with the shape of the cap body. After cooling and shaping, a three-dimensional cap body is formed. The mold can be consistent with the shape and material of the heat-setting mold and does not have a heating function.

[0042] By adjusting the properties of the raw materials, the melting point of the prepared TPU monofilament can be limited to around 85°C, and the specifications can be 50D, 75D, 100D or 150D.

[0043] When knitting, you can use a computer knitting machine. First, weave the basic yarn and the synthetic shaping yarn into a fabric hat blank, and then splice the ends of the fabric hat blank to form a semi-finished hat body. The needle pitch of the computer knitting machine is 14 needles / inch, and the density parameter is set to 300 when knitting.

[0044] During heating, the semi-finished cap body can be placed on a hot mold at about 120°C for 15-20 seconds to heat. The hot mold can be an aluminum cap mold that is consistent with the target cap shape.

[0045] During cooling, the semi-finished hat body is transferred to a cold mold and blown with cold air for 10 seconds to cool and shape it. The cold mold can be an aluminum hat mold with the same shape as the hot mold.

[0046] The basic yarn can be made of high twist 60S / 2 mercerized singed cotton yarn with a twist coefficient of 750-850.

[0047] The knitting structure can be a single-sided pointillism and transfer needle coexistence, select two basic yarns, use the needle covering technology, cover the basic yarn with the synthetic shaping yarn, and knit it into a single-sided three-dimensional fabric cap blank.

[0048] The basic yarn can also be made of high twist 60S / 2 mercerized Lenzing Tencel yarn with a twist coefficient of 650-750.

[0049] The knitting structure can be a double-layer bag jacquard structure, with two basic yarns selected as the front needle bed yarns and synthetic setting yarns selected as the rear needle bed yarns. During knitting, the basic yarns and the synthetic setting yarns are knitted into a fabric cap blank by shovel needles.

[0050] The present invention also provides a thin knitted shaped cap, which may include a three-dimensional cap body made using the manufacturing method described above, and a sweatband, which is sewn onto the three-dimensional cap body to ultimately form a thin knitted shaped cap.

[0051] The present invention provides a method for making a thin knitted shaped cap, and a specific embodiment of making the thin knitted shaped cap is as follows:

[0052] Example 1:

[0053] Step 1: Select TPU monofilament with a melting point of about 85°C and a count of 50D.

[0054] Step 2: Select high twist 60S / 2 mercerized singed cotton yarn with a twist coefficient of 750-850 as the basic yarn.

[0055] Step 3: Select a heat-set yarn with a count of 21 (a yarn blended from ES fiber and polyester staple fiber that hardens when heated and cooled).

[0056] Step 4: The heat-set yarn and 50D TPU monofilament are subjected to a doubling process to obtain a synthetic set yarn.

[0057] Step 5: Use a computerized flat knitting machine with a gauge of 14 needles / inch and a knitting density of 300. The weave is a single-sided, pointel-and-tuck pattern with both transfer and pick stitches. Use two basic yarns and a synthetic sizing yarn. Using the needle-covering technique, the basic yarns are covered with the synthetic sizing yarns. The warp is knitted into a single-sided, three-dimensional fabric cap blank. Although the fabric cap blank is single-sided, the top layer is cotton yarn and the bottom layer is synthetic sizing yarn.

[0058] Step 6: Connect the ends of the fabric hat blank through the loop to form a semi-finished hat body with the same shape as the hat.

[0059] Step 7: Place the semi-finished hat body onto a high-temperature aluminum mold that matches the target hat shape (with the surface close to the mold surface). The high-temperature aluminum mold temperature is controlled at around 120°C and left for 15-20 seconds. During this time, the synthetic styling yarn is heated, the ES fibers soften, and the TPU melts, while the base yarn is not affected.

[0060] Step 8: Remove the semi-finished cap from the hot aluminum mold and place it on a cold aluminum mold of the same shape, keeping the surfaces close together. Blow cold air for 10 seconds, and then remove it to obtain the three-dimensional cap. At this point, the ES fiber hardens upon cooling, providing a basic setting for the cap. The TPU monofilament melts under the heat, attaching its structure to the woven coils of the heat-set yarn containing the ES fiber. Cooling firmly bonds the coils of the heat-set yarn. The properties of the TPU enhance the setting effect, making it less prone to deformation and tearing.

[0061] Step 9: Sew the sweatband onto the three-dimensional hat body to obtain a thin knitted hat that is light, breathable, difficult to tear and deform.

[0062] Example 2:

[0063] Step 1: Select TPU monofilament with a melting point of about 85°C and a count of 50D.

[0064] Step 2: Select high twist 60S / 2, mercerized Lenzine Tencel yarn (composed of 100% Tencel) with a twist coefficient between 650-750 as the basic yarn.

[0065] Step 3: Select a heat-set yarn with a count of 16 (a yarn made by blending ES fiber and polyester staple fiber that becomes hard when heated and cooled).

[0066] Step 4: The heat-set yarn and 50D TPU monofilament are subjected to a doubling process to obtain a synthetic set yarn.

[0067] Step 5: Use a computerized flat knitting machine with a needle gauge of 14 needles / inch and a density parameter of 300. The weaving structure is a double-layer bag jacquard structure. Two basic yarns are used as the front needle bed yarns, and synthetic setting yarns are used as the back needle bed yarns. During weaving, the basic yarns and synthetic setting yarns are knitted into a fabric hat blank with the target three-dimensional shape of the hat body by shoveling needles. The fabric hat blank has a double-layer bag structure structure on both sides, with one layer being the surface Tencel fabric structure and the other layer being the synthetic setting yarn structure (which plays a supporting role after setting).

[0068] Step 6: Connect the ends of the fabric hat blank through a looping machine to form a three-dimensional hat body semi-finished product.

[0069] Step 7: Place the semi-finished hat body onto a high-temperature aluminum mold that matches the target hat shape (with the surface close to the mold surface). The high-temperature aluminum mold temperature is controlled at around 120°C and left for 15-20 seconds. During this time, the synthetic styling yarn is heated, the ES fibers soften, and the TPU melts, while the base yarn is not affected.

[0070] Step 8: Remove the semi-finished cap from the hot mold and place it on a cold aluminum mold of the same shape, keeping the surfaces close together. Blow cold air for 10 seconds, and then remove it to obtain the three-dimensional cap. At this point, the ES fiber hardens upon cooling, providing a basic setting for the cap. The TPU monofilament melts under the heat, attaching its structure to the woven coils of the heat-set yarn containing the ES fiber. Cooling firmly bonds the coils of the heat-set yarn. The properties of the TPU enhance the setting effect, making it less prone to deformation and tearing.

[0071] Step 9: Sew the sweatband onto the three-dimensional hat body to obtain a thin knitted hat that is light, breathable, difficult to tear and deform.

[0072] The present invention uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only intended to help understand the method and core concept of the present invention. At the same time, those skilled in the art will find that the specific implementation methods and application scopes may vary based on the concept of the present invention. In summary, the contents of this specification should not be construed as limiting the present invention.

Claims

1. A method for making a thin knitted shaped cap, characterized in that: The following steps are involved: Prepare TPU monofilament and heat-set yarn, wherein the TPU monofilament is made of pure TPU material, and the heat-set yarn is made of a blend of ES fiber and polyester staple fiber; Doubling the TPU monofilament and the heat-set yarn to obtain a synthetic heat-set yarn; preparing a basic yarn, and knitting the basic yarn with the synthetic setting yarn to form a semi-finished hat body; Heating the semi-finished cap body until the TPU of the synthetic sizing yarn is melted and the ES fiber is softened; The TPU monofilament is subjected to heat melting and its structure is attached to the braided coils of the heat-set yarn containing ES fiber; The cap body semi-finished product is cooled and shaped to form a three-dimensional cap body, and the melted TPU is cooled to firmly bond the coils of the heat-setting yarn.

2. The method for making a thin knitted shaped cap according to claim 1, characterized in that: The TPU monofilament has a melting point of 85° C. and a specification of 50D, 75D, 100D or 150D.

3. The method for making a thin knitted shaped cap according to claim 2, characterized in that: A computerized flat knitting machine is selected to first weave the basic yarn and the synthetic shaping yarn into a fabric hat blank, and then splice the ends of the fabric hat blank to form a semi-finished hat body. The needle pitch of the computerized flat knitting machine is 14 needles / inch, and the density parameter is set to 300 during weaving.

4. The method for making a thin knitted shaped cap according to claim 3, characterized in that: The semi-finished cap body is placed on a hot mold at 120° C. for 15-20 seconds to heat.

5. The method for making a thin knitted shaped cap according to claim 4, characterized in that: The semi-finished cap body is transferred to a cold mold and blown with cold air for 10 seconds to cool and shape it.

6. The method for manufacturing a thin knitted shaped cap according to any one of claims 3 to 5, characterized in that: The basic yarn is selected from high twist 60S / 2 mercerized singed cotton yarn with a twist coefficient of 750-850.

7. The method for making a thin knitted shaped cap according to claim 6, characterized in that: The knitting structure is a single-sided pointillism and transfer stitch coexistence, two basic yarns are selected, and the synthetic setting yarn is covered with the basic yarn by the needle covering technology, and the single-sided three-dimensional fabric cap blank is knitted through the knitting.

8. The method for manufacturing a thin knitted shaped cap according to any one of claims 3 to 5, characterized in that: The basic yarn is made of high twist 60S / 2 mercerized Lanjing Tencel yarn with a twist coefficient of 650-750.

9. The method for making a thin knitted shaped cap according to claim 8, characterized in that: The knitting structure is a double-layer bag jacquard structure, two basic yarns are selected as the front needle bed feeding yarns, and the synthetic setting yarn is selected as the rear needle bed feeding yarns. During knitting, the basic yarns and the synthetic setting yarns are knitted into the fabric cap blank by shovel needles.

10. A thin knitted shaped cap, characterized by: The invention comprises a three-dimensional cap body manufactured by the manufacturing method according to any one of claims 1 to 9, and also comprises a sweatband, wherein the sweatband is sewn onto the three-dimensional cap body.

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