Cap manufacturing process and corresponding cap
The cap manufacturing process is simplified by thermoforming a multi-layer textile panel to create both the crown and visor as a single unit, addressing the complexity and environmental issues of conventional methods while reducing costs and waste.
Patent Information
- Application Number
- FR2023010045
- Authority / Receiving Office
- FR · FR
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2023-09-22
- Publication Date
- 2025-03-28
- Estimated Expiration
- 2043-09-22
Smart Images

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Abstract
Description
Title of the invention: Method of manufacturing a cap and corresponding cap Technical field
[0001] The present invention relates to the field of clothing accessories, and more particularly to that of caps. The invention relates more specifically to the field of thermoformed caps. Prior art
[0002] Caps are conventionally manufactured from a plurality of elements generally assembled by hand and requiring several steps. Thus, the crown, or cap, intended to be positioned on the user's head comprises, in a known manner, several adjacent textile panels, identical or different, of generally triangular shape, assembled together in order to obtain a general half-sphere shape. In particular, the panel positioned on the front side of the cap may differ, in shape and / or material, from the other panels of the crown.
[0003] A visor is then added to the crown, on one side of it, as well as an inner band mounted on the inner peripheral edge of the crown.
[0004] Furthermore, other accessories may be added to the cap, such as: an upper button positioned at the junction of the tops of the different textile panels forming the crown, one or more eyelets allowing ventilation through the crown, and / or a means of adjusting the peripheral length of the crown, generally mounted on the crown opposite the visor.
[0005] However, such a cap design remains relatively complex and is difficult to automate industrially, leading to mainly manual manufacturing. This therefore implies a longer manufacturing time and costs.
[0006] It is also known to manufacture a cap by thermoforming a stretchable textile panel to form the crown. Such a design is described in particular in document WO2018 / 010124. Once the crown is thermoformed, the various accessories are added, in particular a front triangular panel mounted inside the crown, and a visor mounted on the crown and said front triangular panel.
[0007] However, such a cap still requires several manufacturing steps, particularly manual ones, and does not provide any substantial gain, in terms of time or manufacturing costs, compared to caps manufactured in the traditional manner.
[0008] Furthermore, such caps were not designed in an ecological context of reducing industrial waste, and / or reusing industrial waste. industrial or recycled materials, in order to limit their environmental impact. More specifically, the caps of the prior art are designed and developed according to the same traditional process implemented for several decades, and not to adapt to current constraints of recyclability or reuse of recyclable materials. Statement of the invention
[0009] The present invention aims to solve the various technical problems stated above. In particular, the present invention aims to propose a cap designed to limit industrial waste, and to exploit recycled materials. More specifically, the present invention aims to propose a cap of simplified and less expensive design, making it possible to take into account environmental constraints in order to limit their impact.
[0010] Thus, according to one aspect, there is provided a method of manufacturing a cap comprising: - a crown configured to be positioned on the user's head, and - a visor positioned and extending from one side of the crown.
[0011] In particular, - a multi-layer textile panel is produced comprising: a non-woven web, or felt, comprising a mixture of recycled, natural and / or synthetic fibres, and thermofusible fibres, and at least one woven or knitted layer, for example a knit, positioned on one face of said non-woven web, preferably two woven or knitted layers positioned on two opposite faces of the non-woven web, then - a thermoforming step is carried out on said multi-layer textile panel so as to, at least in part and preferably entirely, form said crown and said visor in a unitary manner, the thermoforming step being configured to at least partially secure the thermofusible fibers to recycled fibers by melting the thermofusible fibers, and to secure the woven or knitted layer(s) on the face(s) of the non-woven web.
[0012] In other words, the crown and the visor of the cap according to the present invention are formed, at least in part and preferably entirely, from a single panel which is thermoformed to have on the one hand, or on one side, the shape of a crown, and on the other hand, or on the other side, that of a visor. The multilayer textile panel is therefore a single, or unitary, multilayer textile panel, forming, at least in part and preferably entirely, both the crown and the visor of the cap. The multilayer textile panel of the cap extends continuously between the crown and the visor. The crown and the visor of the cap are therefore already connected to each other without needing to be assembled. together.
[0013] Thus, thanks to the method according to the invention, it then becomes possible to produce, in a simple and inexpensive manner, caps similar in shape to those of the prior art. More precisely, the simultaneous shaping of the crown and the visor, from a single multi-layer textile panel, makes it possible to dispense with the traditional steps of assembling different textile panels in order to obtain the three-dimensional shape of the cap. In the context of the present invention, a thermoforming step makes it possible to simultaneously form the hemispherical crown and the substantially flat visor, and to freeze such a shape over time thanks, in particular, to the thermofusible fibers.
[0014] Furthermore, in addition to simplifying the manufacturing process, the present invention also makes it possible to reuse recycled materials, thanks to the non-woven fabric of the multi-layer textile panel. The multi-layer textile fabric advantageously comprises, in addition to the thermofusible fibers allowing the shaping and maintenance of the cap, the incorporation of recycled fibers within the material forming the cap. The cap according to the present invention therefore also makes it possible to recover unused materials from industrial processes or materials from recycling or recovery processes. In addition to limiting the environmental impact, such use of materials also makes it possible to reduce the manufacturing costs of the cap.
[0015] For example, the non-woven web may have, before thermoforming, a thickness of between 10mm and 30mm, preferably between 12mm and 20mm.
[0016] In order to provide better mechanical resistance, in particular to abrasion, the non-woven web may be covered, on one side or on both sides, with a woven or knitted layer, for example a knit. Such a woven or knitted layer thus limits premature wear of the non-woven web, even thermoformed, by improving the mechanical resistance of the surface of the multi-layer textile panel. Furthermore, the addition of such a woven or knitted layer also makes it possible to choose the aesthetic and / or tactile rendering of the multi-layer textile panel. It is then possible to choose more freely the recycled fibers used to form the non-woven web, since the latter could potentially be hidden by the woven or knitted surface layer(s).In particular, the colours and / or the mix of recycled fibres will not necessarily be visible to the user, making it even easier to choose the fibres that can be used in the non-woven fabric within this cap.
[0017] Alternatively, the woven or knitted layer(s) may be chosen to be partly transparent in order to leave, at least partly, the non-woven veil visible and in particular its composition based on recycled fibers.
[0018] Preferably, the production of the multilayer textile panel comprises in particular a step of producing said non-woven web during which the fibers are dispersed in an air flow before being deposited on a support.
[0019] The production of the non-woven web is chosen so as to allow on the one hand a homogenization of the different fibers constituting it, in particular a homogenization between the recycled fibers and the thermofusible fibers so as to obtain a homogeneous thermoformed multi-layer textile panel. Such a method of producing the non-woven web also makes it possible to have a multi-layer textile panel, before thermoforming, having a thickness, or volume, relatively large compared to the thickness, or volume, of the same multi-layer textile panel after thermoforming. In particular, such a variation in thickness, or volume, can be advantageously used during the three-dimensional shaping of said multi-layer textile panel.
[0020] Preferably, the step of producing said non-woven web also comprises, after the dispersion and deposition of the fibers, a fixing of the fibers together, for example thermal, such as calendering, or mechanical, such as needling.
[0021] In order to improve the durability of the non-woven web over time, and also to facilitate implementation of the subsequent steps of the cap manufacturing process, the fibers of the non-woven web can be fixed together. This also makes it possible to obtain better adhesion of the woven or knitted layer(s) to the face(s) of the non-woven web at the end of the thermoforming step.
[0022] Preferably, during the thermoforming step, a step of embossing the multi-layer textile panel is also carried out, so as to create a pattern on the crown and / or the visor.
[0023] The thermoforming step is preferably carried out using a mold inside which the multilayer textile panel is positioned and deformed with the application of heat. It is thus possible to provide a mold having surface reliefs so as to obtain, in addition to the thermoforming of the multilayer textile panel, an embossing intended to reproduce a pattern on the surface of the cap. For example, the pattern may suggest the presence of seams at the level of the visor or the crown, for example by creating lines corresponding to the assembly seams of traditional caps, or imitate the presence of a button on the upper part of the crown. Such an embossing step, simultaneous with the thermoforming step, makes it possible to increase the details provided during the three-dimensional shaping of the cap, without adding an additional step to the manufacturing process.
[0024] Preferably, the thermoforming step comprises a prior step of preheating the multilayer textile panel.
[0025] In order to improve and reduce the duration of the thermoforming step, a preliminary preheating step may be provided, for example by infrared. It is facilitated in particular the deformation of the multi-layer textile panel when closing the thermoforming mold.
[0026] Preferably, the thermoforming step comprises a prior step of adding a means for stiffening the visor, such as thermosetting powder, for example thermosetting EVA (ethylene-vinyl acetate) or such as an additional textile panel added to the multilayer textile panel.
[0027] In order to obtain different rigidities between the crown and the visor, it is possible to add a stiffening means in certain specific areas of the cap, in particular at the level of the visor. The stiffening means can for example be in the form of thermosetting powder or in the form of an additional textile panel, and be added before the thermoforming step, on the areas to be stiffened, for example on the visor. It then becomes easy to obtain a cap according to the present invention, with different rigidities, while retaining the advantages detailed previously.
[0028] Preferably, the thermoforming step comprises a subsequent step of cutting off excess from the thermoformed multi-layer textile panel.
[0029] In order to avoid any step of fine positioning of a pre-cut multi-layer textile panel in the thermoforming mold, it is preferable to provide a multi-layer textile panel of a size larger than that of the thermoforming mold, then to cut off the excess after thermoforming said cap. In order to facilitate such cutting, the thermoforming mold may comprise an integrated cutting means configured to perform a cut along the peripheral contour of the mold cavity during or just after the thermoforming step. The peripheral contour of the cavity of one of the parts of the cap mold may thus form a counter-blade for the cutting means.Such an integrated cutting means makes it possible in particular to have a cut corresponding to the shape of the mold cavity, and therefore to the final shape desired for the cap, which facilitates and accelerates the manufacturing process of the cap and in particular avoids a subsequent manual cutting step. Such a cutting means integrated into the mold also and above all makes it possible to implement the cutting step following the thermoforming step, that is to say simultaneously or just after, preferably in the same vertical movement of the mold. This avoids in particular an additional cutting machine and the associated handling step.
[0030] According to another aspect, there is also provided a cap obtained by the method described above.
[0031] A cap is thus proposed which can be obtained by the method described above, comprising: - a crown configured to be positioned on the user's head, and - a visor positioned and extending from one side of the crown.
[0032] The visor and the crown are, at least in part and preferably entirely, formed in a unitary manner by a multi-layer textile panel, said multi-layer textile panel comprising: - a non-woven veil, or felt, comprising a mixture of recycled, natural and / or synthetic fibers, and at least partially melted fibers joined to recycled fibers, and - at least one woven or knitted layer, secured on one side of said non-woven web, preferably two woven or knitted layers secured on two opposite sides of the non-woven web.
[0033] Thus, and as indicated previously, the crown and the visor are formed, at least in part, from a single multi-layer textile panel extending continuously between the crown and the visor. The cap thus obtained, in addition to being easier to manufacture than traditional caps and incorporating recycled materials, allows the visor and the crown to be joined together.
[0034] Preferably, the non-woven web is obtained by thermoforming a flat layer of recycled fibers and thermofusible fibers formed by an aerodynamic process.
[0035] The aerodynamic process makes it possible to obtain a homogeneous mixture of recycled fibers and thermofusible fibers prior to the thermoforming step.
[0036] Preferably, the fibers of the non-woven web are also entangled with each other.
[0037] Preferably, the non-woven web comprises between 5% and 40% by mass of at least partially melted fibers, preferably between 10% and 20% by mass.
[0038] The proportion of at least partially melted fibers in the non-woven web makes it possible to modify the mechanical and holding properties of the multi-layer textile panel forming the cap.
[0039] Preferably, the non-woven web has a surface mass of between 150 and 400g / m2, preferably between 250 and 300g / m2, and / or said at least one woven or knitted layer has a surface mass of between 50 and 200g / m2, preferably between 100 and 150g / m2.
[0040] Preferably, the visor also comprises an added stiffening means, for example a thermosetting element or an additional textile panel, added to the multi-layer textile panel.
[0041] Preferably, the cap includes patterns, in particular imitating seams on the visor, obtained by embossing the multi-layer textile panel. Brief description of the drawings
[0042] [Fig.l] [Fig.l] schematically represents a cap according to the present invention, seen from the side;
[0043] [Fig.2] [Fig.2] schematically represents the cap illustrated in [Fig.l], top view; and
[0044] [Fig.3] [Fig.3] schematically represents the cap illustrated in [Fig.l], with an enlarged edge to detail its structure. Description of the embodiments
[0045] Figures 1 to 3 schematically illustrate an example of a cap 1 according to the present invention. The cap 1 has a conventional general shape with a crown 2 in the shape of a half-sphere to accommodate the user's head, and a visor 4 which is substantially flat and extends from an edge of the crown 2.
[0046] In particular, and as described below with the manufacturing method, the crown 2 and the visor 4 are formed, for example integrally, in a unitary manner, that is to say from a single piece, in this case a multi-layer textile panel 6 illustrated in [Fig. 3]. In other words, the crown 2 and the visor 4 are manufactured in continuity with each other, unlike the caps of the prior art for which the visor is a piece added to the crown.
[0047] The cap 1 according to the present invention is therefore mainly a cap formed from a single piece, possibly with added accessories such as an adjustment means, which facilitates its manufacture by reducing the steps, and therefore the duration and the cost.
[0048] Furthermore, the multi-layer textile panel 6 forming both the crown 2 and the visor 4 also makes it possible to recover underused materials such as unused fibers from industrial processes or recycling or recovery processes. Such fibers are thus mixed with thermofusible fibers to form a non-woven web 8 intended to be thermoformed to obtain the crown 2 and the visor 4 of the cap 1.
[0049] The method for obtaining the cap 1 according to the present invention is described more specifically below.
[0050] In a first step, the non-woven web 8 is manufactured. This comprises on the one hand recycled fibers, to recover little-used waste, and thermofusible fibers intended to bind the fibers of the non-woven web 8 after thermoforming, thanks to the at least partial fusion of said thermofusible fibers which will allow a mechanical bond between at least a part of the fibers (recycled and thermofusible) of the thermoformed non-woven web 8.
[0051] In order to have a uniform mixture of recycled fibers and thermofusible fibers, these are mixed together by an aerodynamic process: thus, the fibers are dispersed in an air flow, before being deposited on a support. A homogeneous deposit of recycled and thermofusible fibers is then obtained. In a second step, the fibers thus mixed can be, at least partially, entangled with each other, for example by calendering or by needling, so as to obtain a non-woven web 8 having sufficient mechanical strength to allow in particular its handling for the subsequent stages of the process.
[0052] For example, the nonwoven web 8 may comprise between 5% and 40% by mass of thermofusible fibers, preferably between 10% and 20% by mass.
[0053] Furthermore, the non-woven web 8 may have a surface mass of between 150 and 400g / m2, preferably between 250 and 300g / m2.
[0054] In order to improve the surface mechanical strength, in particular the wear resistance, and in order to obtain the desired appearance for the cap, the non-woven web 8 is covered, on one or both faces, with a woven or knitted layer. Thus, the non-woven web 8 may be covered on its upper face with a woven or knitted layer 10, and / or covered on its lower face with a woven or knitted layer 12. The assembly formed by the non-woven web 8 and the woven or knitted layer(s) 10, 12 constitutes the multi-layer textile panel 6.
[0055] In particular, the thermofusible fibers of the non-woven web 8 also allow a chemical bond with the woven or knitted layer(s) 10, 12.
[0056] Preferably, the woven or knitted layer(s) 10, 12 are knits. Such knitted layers 10, 12 have both sufficient elasticity to allow their deformation during the thermoforming process, and on the other hand a mechanical resistance, in particular wear resistance, higher than that of the non-woven web 8.
[0057] The woven or knitted layer(s) 10, 12 may have a surface mass of between 50 and 200g / m2, preferably between 100 and 150g / m2.
[0058] The multi-layer textile panel 6 thus obtained is still flat, but ready to be thermoformed to the desired shape of the cap 1.
[0059] Thus, the multilayer textile panel 6, the surface area of which is much greater than that of the cap 1, is positioned inside a thermoforming mold. For example, the mold may comprise two parts, and the two parts of the thermoforming mold are placed opposite each other, on either side of the multilayer textile panel 6. The thermoforming mold has, at the interface between the two parts of the mold, a cavity having the general shape desired for the cap 1. The multilayer textile panel 6 protrudes from the thermoforming mold over the entire periphery of the mold cavity, so that no part of the mold remains empty during thermoforming.
[0060] During the thermoforming step, the multilayer textile panel 6 is therefore deformed by the closing of the mold, to conform to the shape of the imposed cavity. by the mold, and heated so as to melt, at least partially, the thermofusible fibers of the non-woven web 8. By melting, said thermofusible fibers will then become integral with the neighboring recycled fibers of the non-woven web 8, as well as with the woven or knitted layer(s) 10, 12.
[0061] At the end of the thermoforming step, the multilayer textile panel 6 thus formed is cooled, so that the melted thermofusible material solidifies in particular on the recycled fibers and / or the woven or knitted layer(s) 10, 12, thus leading to the formation of a cap whose elements of the multilayer textile panel 6 are linked, or secured, to each other by the at least partially melted fibers.
[0062] In particular, the fusion of the thermofusible fibers makes it possible to bind the fibers or elements of the multilayer textile panel 6 together, but also to freeze the shape of said multilayer textile panel 6 during the thermoforming process, that is to say to freeze the shape of the multilayer textile panel 6 to the shape of the cap 1. A cap comprising a crown and a visor is therefore obtained in a single step of thermoforming a given panel.
[0063] For example, the nonwoven web may comprise between 5% and 40% by mass of at least partially melted fibers, preferably between 10% and 20% by mass.
[0064] In order to facilitate the thermoforming step, this may comprise a step of preheating the multilayer textile panel 6. Such preheating may for example be implemented by exposing said multilayer textile panel to infrared rays. Such preheating makes it possible in particular to soften the multilayer textile panel before its positioning in the thermoforming mold, and therefore to facilitate its deformation in the thermoforming mold.
[0065] Furthermore, it is also possible to provide, before positioning the multilayer textile panel 6 in the thermoforming mold, the application or addition of a stiffening means 14 on one or more parts of the cap 1, in order to obtain a cap 1 having different rigidities. For example, a powder, preferably thermosetting such as thermosetting EVA, or an additional textile panel added can be deposited on the part of the multilayer textile panel 6 intended to form the visor 4, so as to obtain, after thermoforming, a cap 1 with a flexible crown 2 and a more rigid visor 4.
[0066] Similarly, during the thermoforming step, it is also possible to provide reliefs in the thermoforming mold, in order to obtain patterns 16 on the cap 1 by embossing. Thus, it becomes easy to suggest stitching lines, or other patterns 16, for example on the visor 4, by providing a thermoforming mold having the corresponding reliefs appropriate for forming such patterns 16 by embossing.
[0067] Finally, and as indicated previously, the multilayer textile panel 6 has a surface area greater than that of the thermoforming mold, so as not to require a prior step of fine positioning of said panel in the mold. Alternatively, it may be provided to use a multiple mold having several times the same cap shapes, arranged next to each other, and to position therein a multilayer textile panel 6 having a surface area greater than that of said multiple mold so as to allow, during a single thermoforming step, the manufacture of several caps.
[0068] However, once formed, the cap(s) must then be separated from the rest of the multilayer textile panel 6: such separation is carried out by cutting, during or after the thermoforming step and, preferably, using a cutting means integrated into the thermoforming mold. In other words, one of the parts of the thermoforming mold may comprise a retractable cutting means extending along the peripheral edge of the thermoforming cavity and cooperating with a peripheral edge of the cavity of the other part of the mold acting as a counter-blade. The cutting means is configured to deploy during or at the end of the thermoforming step, in order to cut the portion of multilayer textile panel 6 protruding from the cavity of said mold.
[0069] An individual cap is then obtained directly from the thermoforming mold.
[0070] It is possible to provide an additional cutout 18, for mounting a means of adjustment (not shown) of the peripheral length of the crown. Such conventional adjustment means already exist in traditional caps, which in particular allow the user to adjust the size of the cap to that of his head circumference.
[0071] Finally, further customization steps can then be planned, such as the addition of badges or accessories such as a top button on the top of the cap.
[0072] Thus, thanks to the method according to the invention, it becomes easier and less expensive to manufacture a cap of traditional shape. The various characteristics of the cap, and in particular the composition of the multi-layer textile panel, make it possible to both recover recycled or unused materials in industrial processes, while retaining mechanical properties corresponding to the use of the cap, in particular its resistance to wear and the rigidity of the visor. Finally, such a cap remains compatible with personalization and adjustment accessories, so as to please the target audience while remaining comfortable to wear.
Claims
Claims
1. Method for manufacturing a cap (1) comprising: - a crown (2) configured to be positioned on the user's head, and - a visor (4) positioned and extending from one side of the crown (2), in which: - a multi-layer textile panel (6) is produced comprising: a non-woven web (8) comprising a mixture of recycled, natural and / or synthetic fibers, and thermofusible fibers, and at least one woven or knitted layer (10, 12), for example a knit, positioned on one face of said non-woven web (8), preferably two woven or knitted layers (10, 12) positioned on two opposite faces of the non-woven web (8), then - a thermoforming step is carried out on said multi-layer textile panel (6) so as to, at least in part and preferably entirely, form said crown (2) and said visor (4) in a unitary manner,the thermoforming step being configured to at least partially secure the thermofusible fibers to said recycled fibers by melting the thermofusible fibers, and to secure the woven or knitted layer(s) (10, 12) on the face(s) of the non-woven web (8).,
2. Method according to the preceding claim, in which the production of the multilayer textile panel (6) comprises a step of producing said non-woven web (8) during which the fibers are dispersed in a flow of air before being deposited on a support.
3. Method according to the preceding claim, in which the step of producing said non-woven web (8) also comprises, after the dispersion and deposition of the fibers, a fixing of the fibers together, for example thermal, such as calendering, or mechanical, such as needling.
4. Method according to any one of claims 1 to 3, in which, during the thermoforming step, a step of embossing the multilayer textile panel (6) is also carried out, so as to create a pattern (16) on the crown (2) and / or the visor (4).
5. A method according to any one of claims 1 to 4, wherein the thermoforming step comprises a prior step of pre- heating of the multi-layer textile panel (6).
6. Method according to any one of claims 1 to 5, in which the thermoforming step comprises a prior step of adding a stiffening means (14) of the visor (4), such as thermosetting powder, for example thermosetting EVA (ethylene-vinyl acetate), or such as an additional textile panel, on the multilayer textile panel (6).
7. Method according to any one of claims 1 to 6, in which the thermoforming step comprises a subsequent step of cutting excess from the thermoformed multi-layer textile panel (6).
8. Cap (1) comprising: - a crown (2) configured to be positioned on the user's head, and - a visor (4) positioned and extending from one side of the crown (2), wherein the visor (4) and the crown (2) are, at least in part and preferably integrally, formed in a unitary manner by a multi-layer textile panel (6), said multi-layer textile panel (6) comprising: - a non-woven web (8) comprising a mixture of recycled, natural and / or synthetic fibers, and at least partially melted fibers secured to said recycled fibers, and - at least one woven or knitted layer (10, 12), secured on one face of said non-woven web (8), preferably two woven or knitted layers (10, 12) secured on two opposite faces of the non-woven web (8).
9. Cap (1) according to claim 8, wherein the non-woven web (8) is obtained by thermoforming a flat layer of recycled fibers and thermofusible fibers formed by an aerodynamic process.
10. Cap (1) according to claim 8 or 9, wherein the fibers of the nonwoven web (8) are also entangled with each other.
11. Cap (1) according to any one of claims 8 to 10, wherein the non-woven web (8) comprises between 5% and 40% by mass of at least partially melted fibers, preferably between 10% and 20% by mass.
12. Cap (1) according to any one of claims 8 to 11, in which the non-woven web (8) has a surface mass of between 150 and 400g / m2, preferably between 250 and 300g / m2, and / or in wherein said at least one woven or knitted layer (10, 12) has a surface mass of between 50 and 200g / m2, preferably between 100 and 150g / m2.
13. Cap (1) according to any one of claims 8 to 12, in which the visor (4) also comprises an added stiffening means (14), for example a thermosetting element or an additional textile panel added to the multi-layer textile panel (6).
14. Cap (1) according to any one of claims 8 to 13, comprising patterns (16), in particular imitating seams on the visor (4), obtained by embossing the multi-layer textile panel (6).
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