Molded body and inner for hat

Abstract

To provide a molded article of a three-dimensional knitted fabric formed in a bowl shape without reducing functionality such as cushioning, breathability, and wearing comfort, and to provide an inner for a hat which can be attached to and detached from various hats, does not produce gaps during wearing, and can be worn comfortably. [Solution] The three-dimensional knitted fabric 1 is formed in a bowl shape and comprises a three-dimensional knitted fabric 1 in which a front ground knitted structure 11 and a back ground knitted structure 12 are connected by a connecting yarn 13, and an edge portion 2 provided on the outer periphery 15 of the three-dimensional knitted fabric 1 and having lower elasticity than the three-dimensional knitted fabric 1.

Description

[Technical Field]

[0001] The present invention relates to a bowl-shaped molded article made of a three-dimensional knitted fabric, and an inner for a hat made of the molded article. [Background technology]

[0002] Hats have the role of protecting the wearer's head from impacts and blocking sunlight. Hats are constructed with a bowl-shaped part called a crown that covers the head. This crown is formed into a three-dimensional bowl shape by sewing together pieces of fabric cut to form a predetermined development pattern called a renge. In general, the front sides of the fabrics are placed face to face, and the edges are sewn together with a straight stitch, backstitch, etc., leaving a seam allowance. Then, by opening the front sides of each fabric, the stitching can be hidden on the back side.

[0003] On the other hand, to add functionality such as cushioning to a hat, a thick, resilient material may be inserted inside the crown fabric. Such a material is called a hat liner, and may be integrated with the hat or may be configured as a separate, detachable piece. This hat inner is also formed in a bowl shape that fits the head. Here, when a three-dimensional knitted fabric is selected as the material for the hat inner, it is necessary to form the bowl shape by sewing, just like fabric.

[0004] Conventionally, there have been disclosed techniques for protecting the head from impact by using cushioning materials in hats. For example, the technique in Patent Document 1 has a configuration in which multiple face panels made of three-dimensional mesh sheets are placed inside the crown, and strips made of similar three-dimensional mesh sheets are placed in the gaps between the face panels. This configuration is said to make it possible to fold the helmet, provide excellent cushioning for the crown, reduce the weight of the crown, prevent the inside of the crown from becoming stuffy, and improve washability.

[0005] Patent Document 2 discloses a hat with a cushion member between two bowl-shaped members. The cushion member has a petal-like shape with multiple arms attached to it. The cushion member is made of a material with cushioning properties, such as rubber or polyester resin. This configuration is said to have the effects of reducing costs by simplifying the manufacturing process, improving the head protection function, and giving the head a natural roundness. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-132850 [Patent Document 2] Japanese Patent Application Publication No. 2019-167655 Summary of the Invention [Problem to be solved by the invention]

[0007] In Patent Document 1, the multiple panel materials made of three-dimensional mesh sheets are separated from one another. Each panel material, which is a separate member, is stored in a pocket-like space formed by the outer and inner linings of the crown. With this construction, each panel must be sewn together to form a bowl shape that fits over the crown of the hat.

[0008] When adjacent face panels are sewn together with thread, the stitching tends to concentrate in one area, and the overlapping of the panels by compression can make the stitched area thicker. This not only reduces the cushioning and breathability of the three-dimensional mesh seat, but also causes the hardened area to irritate the head, reducing comfort.

[0009] In contrast, with the technology of Patent Document 2, the multiple arm sections are separated like petals, and are not sewn together, so they do not harden partially. However, because the arm sections are not joined together, gaps occur between the arm sections, which can cause significant shifting while wearing the garment or result in poor cushioning in the gaps. Patent Document 2 describes fastening the cushion member and the bowl-shaped body together in part with grommets, stitching, etc. to prevent slippage. However, using grommets or stitching results in hardened portions, just like Patent Document 1.

[0010] These problems are not limited to hat innerwear, but also apply to any product that utilizes a bowl-shaped three-dimensional knit fabric to provide cushioning, breathability, and other functional properties. Therefore, as described above, the conventional technology has had the problem that forming the three-dimensional knitted fabric into a bowl shape may result in a decrease in cushioning, breathability, and wearing comfort.

[0011] The present invention has been made in consideration of the above-mentioned problems, and its object is to provide a three-dimensional knitted fabric formed into a bowl shape without reducing functionality such as cushioning, breathability, and wearing comfort. Another object of the present invention is to provide an inner layer for hats that can be attached to and detached from various hats, does not create gaps when worn, and can be worn comfortably. [Means for solving the problem]

[0012] The means adopted by the present inventors to solve the above problems will be described below. The present invention is a molded body comprising a three-dimensional knitted fabric in which a front ground knitting structure and a back ground knitting structure are connected by a connecting yarn, and an edge portion provided on the outer periphery of the three-dimensional knitted fabric and having lower elasticity than the three-dimensional knitted fabric, and is characterized in that the three-dimensional knitted fabric is formed in a bowl shape.

[0013] When a force is applied to the front ground knit structure or the back ground knit structure, the connecting yarns connecting them elastically bend and rebound, providing cushioning properties. However, because the structure involves connecting two ground knit structures with connecting yarns, the fabric generally has a predetermined thickness. Therefore, when sewing with a machine such as a sewing machine, the stitching is performed while pressing down, which can cause the sewn portion to lose its cushioning properties and become hard.

[0014] The molded article of the present invention is a molded article in which the outer periphery of a three-dimensional knitted fabric formed into a bowl shape has an edge portion that is less stretchable than the three-dimensional knitted fabric. The three-dimensional knitted fabric has stretchability because it has a front ground knit structure and a back ground knit structure or knit structure. The three-dimensional knitted fabric can be formed into a three-dimensional bowl shape by the front ground knit structure stretching and the back ground knit structure contracting. However, if it is simply formed into a bowl shape by stretching, it will return to a flat shape due to its elasticity. Therefore, by providing an edge portion with lower elasticity than the three-dimensional knitted fabric at the outer periphery of the bowl-shaped three-dimensional knitted fabric, the elastic force of the edge portion is greater than the elastic force that tries to return the three-dimensional knitted fabric to a flat shape, thereby making it possible to maintain the bowl-shaped shape without partially losing functionality such as cushioning.

[0015] As a means adopted by the present invention to solve the above-mentioned problem, it is possible to make the edge portion a separate component from the three-dimensional knitted fabric, and to configure the circumference of the edge portion to be shorter than the circumference of the outer periphery when the three-dimensional knitted fabric is unfolded on a flat surface. The edge may be integrally formed by folding back the three-dimensional knitted fabric, or may be formed using a separate member. In this configuration, when the three-dimensional knitted fabric is shaped like a bowl, the perimeter of its outer periphery will be equal to the perimeter of the member that forms the edge.

[0016] With this configuration, the edge of the bowl-shaped molded body can be made of a separate member, improving the appearance. In addition, the stretchability of the edge can be easily adjusted by selecting a different material.

[0017] As a means adopted by the present invention to solve the above problems, it is possible to configure the edge portion to be circular so that the entire fabric is hemispherical. When forming a three-dimensional knitted fabric into a bowl shape, the edge portion can be configured to have various shapes such as a rectangle, a polygon, an ellipse, etc.

[0018] Among these, by configuring it to be circular, the stretch state of the front ground knit structure and the back ground knit structure of the three-dimensional knitted fabric becomes symmetrical with respect to the central axis, and therefore, when functionality such as cushioning and breathability is exhibited, uniform performance can be exhibited regardless of direction.

[0019] On the other hand, in the present invention, as a means for solving the above problem, a means can also be adopted in which an inner hat is inserted inside the hat and worn to be placed between the hat and the head. The inner for a hat of the present invention comprises a three-dimensional knitted fabric in which the front ground knitted structure and the back ground knitted structure are connected by a connecting yarn, and an edge portion provided on the outer periphery of the three-dimensional knitted fabric which is less elastic than the three-dimensional knitted fabric, and the three-dimensional knitted fabric is formed in a bowl shape.

[0020] A typical hat is made by sewing together pieces of fabric to form a three-dimensional crown. When this hat is made to have a functional inner layer, such as cushioning, it is common for the inner layer to be embedded in the fabric that makes up the crown in order to maintain the shape of the inner layer. However, with such a configuration, the inner layer cannot be easily removed, and the entire hat becomes a specialized hat with that functionality.

[0021] On the other hand, if the inner layer is made separate from the hat so that it can be attached and detached, it will be difficult to put on and will easily slip off unless the inner layer itself is configured to be bowl-shaped so that it fits the head. When sewing together thick, three-dimensional knitted fabrics to form a bowl shape, the seams must be crushed before sewing, which makes the crushed areas hard, resulting in a loss of cushioning and breathability, as well as a poor fit on the head.

[0022] In the configuration of the hat inner of the present invention, a bowl-shaped edge is provided on the outer periphery of the three-dimensional knitted fabric. This edge is configured to be less stretchable than the three-dimensional knitted fabric. By providing an edge that is less stretchable than the three-dimensional knitted fabric on the outer periphery of the bowl-shaped three-dimensional knitted fabric, the stretch force of the edge is greater than the elastic force that tries to return the three-dimensional knitted fabric to a flat shape. This makes it possible to maintain a bowl-shaped shape that is appropriate for a hat inner without partially losing functionality such as cushioning.

[0023] In addition to the above configuration, the means adopted by the present invention to solve the above-mentioned problems can also be a means of laminating a nonwoven fabric on the surface of both or either of the front ground knitted structure and the back ground knitted structure, sewing the nonwoven fabric and each compressed portion of the three-dimensional knitted fabric together in an overlapping state, and configuring the nonwoven fabric so that it is on the head side when worn.

[0024] By laminating a fine-meshed nonwoven fabric on the front ground knitted structure or the back ground knitted structure, the sewing thread can be firmly fixed during stitching. Furthermore, by positioning it so that it faces the head when worn as an inner layer for a hat, the ground knit structure of the three-dimensional knitted fabric and connecting yarns do not come into direct contact with the head, thereby improving the wearing comfort. [Effects of the Invention]

[0025] In the molded article of the present invention, by providing an edge portion with lower elasticity than the three-dimensional knitted fabric at the outer periphery of the bowl-shaped three-dimensional knitted fabric, the elastic force of the edge portion is greater than the elastic force that tries to return the three-dimensional knitted fabric to a flat shape. This has the effect of allowing the three-dimensional knitted fabric to be molded into a bowl shape without reducing its functionality such as cushioning, breathability, and wearing comfort. Furthermore, by using the above-mentioned molded article, the hat inner of the present invention can be attached and detached to various hats as a hat inner, and has the advantage of being comfortable to wear without any gaps occurring when worn. [Brief explanation of the drawings]

[0026] [Figure 1] FIG. 2 is a perspective view showing a three-dimensional knitted fabric used in the molded article of the present invention. [Figure 2] FIG. 1 is a perspective view showing a molded article of the present invention. [Figure 3] FIG. 2 is a cross-sectional view showing an edge portion of the molded article of the present invention. [Figure 4] 1 is a perspective view showing an inner layer for a hat according to the present invention. [Figure 5] FIG. 2 is a cross-sectional view showing a first modified example of the molded article of the present invention. [Figure 6] FIG. 10 is a perspective view showing a second modified example of the molded article of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0027] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. The shapes in the drawings are shown schematically for the purpose of explanation.

[0028] [About 3D knitting] The molded article 100 of the present invention is formed by curving a three-dimensional knitted fabric 1 into a bowl shape, for example, as shown in Fig. 1. Each three-dimensional knitted fabric 1 is configured by connecting a front ground knitted structure 11 and a back ground knitted structure 12 with connecting yarns 13, 13.... Here, bowl-shaped refers not only to the state in which the three-dimensional knitted fabric 1 is deformed into a hemispherical shape, but also to a three-dimensionally curved state in which the vicinity of the center of the three-dimensional knitted fabric 1 protrudes in the thickness direction and the circumference of the outer periphery shrinks to be shorter than the circumference when in a flat state.

[0029] Filament yarn, spun yarn, etc. can be used for the front ground knit structure 11. From the viewpoint of cushioning properties, monofilament yarn is preferable, and materials such as nylon, polyester, polyurethane, carbon fiber, aramid fiber, etc. can be appropriately selected in consideration of strength, tension, elasticity, etc. In addition to monofilament yarn, multifilament yarn can also be used.

[0030] The back side ground knitted structure 12 can use the same yarn material as the front side ground knitted structure 11, or can use a different yarn material. Furthermore, the yarn material of the connecting yarn 13 may be the same as that of the front and back ground knit structures 11 and 12, or a different yarn material may be used.

[0031] The knitting structures of the front ground knitting structure 11 and the back ground knitting structure 12 can have various configurations, but in consideration of breathability, a knitting structure having a predetermined number of holes is preferable. For example, as shown in Figure 1, a knitting structure having a continuous hexagonal shape or a knitting structure having a predetermined pattern may be used. Also, a knitting structure having large holes in some parts may be used.

[0032] The three-dimensional knitted fabric 1 in the molded product 100 of the present invention is formed in a bowl shape, as shown in Figure 2. Specifically, the central portion 14 of the three-dimensional knitted fabric 1 protrudes in a semi-spherical shape toward the front ground knitted structure 11. Note that in Figure 2, only a portion of the mesh pattern of the ground knitted structure is shown to make the shape easier to understand. The molded body 100 is formed by bending a three-dimensional knitted fabric 1, which has been cut in advance to have a circular shape, into a bowl shape using a mold or the like, and sewing the edge portion 2. When sewing the edge portion 2, the fabric is temporarily fixed in the curved state using a marking pin or the like, and then sewn.

[0033] One method of forming a three-dimensional knitted fabric into a bowl shape is to use heat pressing, but when heat pressing is performed, the connecting yarns of the three-dimensional knitted fabric become fixed in a collapsed state, resulting in a loss of functionality such as cushioning and breathability. In contrast, the molded body 100 of the present invention is temporarily fixed in a bowl-shaped curved state and the edge portion 2 is sewn together without applying heat or great pressure, so the connecting threads 13·13... will not collapse or be crushed.

[0034] Furthermore, when the fabric is curved into a bowl shape, the front ground knitted structure 11 near the central portion 14 expands, and the back ground knitted structure 12 contracts. At the same time, in the outer circumferential portion 14, the front ground knitted structure 11 and the back ground knitted structure 12 contract overall in the circumferential direction. In this way, due to the stretchability of the knitted fabrics constituting the three-dimensional knitted fabric 1, wrinkles do not form even when the fabric is curved into a three-dimensional bowl shape. Therefore, functionality such as cushioning and breathability can be made uniform.

[0035] As shown in Figure 3, the edge portion 2 is made of a material different from that of the three-dimensional knitted fabric 1. This material can be sewn using a so-called hem fabric, which is used for the edges of towels, etc. A material that is less stretchy and less likely to stretch than the three-dimensional knitted fabric 1 is used for the hem fabric. The length of the hem fabric is cut shorter than the perimeter of the three-dimensional knitted fabric 1 before it is curved into a bowl shape, and is set to a dimension equal to the perimeter of the outer periphery 15 when it is shaped into a bowl. This hem fabric is sewn using a sewing machine. In the sewn state, the three-dimensional knitted fabric 1 tries to return to a flat shape, but because the hem fabric has low elasticity, the outer periphery of the three-dimensional knitted fabric 1 does not expand, and the bowl shape can be maintained.

[0036] In this way, in the molded body 100 of the present invention, the three-dimensional knitted fabric 1 can be formed into a bowl shape while maintaining its cushioning properties, etc., and it is possible to prevent the bowl-shaped portion from being compressed to become hard or from having protruding threads due to stitching.

[0037] [About hat innerwear] Next, an inner liner 1000 for a hat using the molded article 100 of the present invention will be described with reference to FIG. As shown in FIG. 4, the inner cap 1000 of the present invention can be inserted inside an existing cap C and worn to be placed between the cap C and the head.

[0038] The hat inner 1000 uses the bowl-shaped molded body 100 shown in Figures 1 to 3, but by making it an axisymmetric hemispherical shape in particular, it is possible to form a three-dimensional crown that fits tightly to the inside of the hat C.

[0039] The axially symmetrical and precise bowl shape allows it to be inserted into the existing hat C in any orientation, making it easy to wear. In addition, it can fit snugly to the head, so it does not slip off while being worn and provides even cushioning.

[0040] The inner cap 1000 of the present invention has excellent cushioning properties due to the crown being made of a three-dimensional knitted fabric. In addition, the three-dimensional knitted fabric having a gap between the cap C and the head allows for an appropriate amount of space to be provided, resulting in excellent breathability. Conversely, if the knitting structures of the front and back ground knitting structures of the three-dimensional knitted fabric are dense knitting structures, air can be retained between the front and back ground knitting structures, resulting in excellent heat insulation properties.

[0041] In this way, by making the inner hat 1000 have different knitting patterns, functionality can be exhibited according to the season, and it can be worn in a suitable manner. In addition, since it can be inserted into the inside of an existing hat C, it can be used with any hat without requiring a dedicated hat. Therefore, functionality can be added to any hat according to the wearer's preferences.

[0042] It is also possible to laminate a nonwoven fabric 4 on the back ground knit structure 12 of the three-dimensional knitted fabric 1. The nonwoven fabric 4 is fixed to the three-dimensional knitted fabric 1 by heat pressing, adhesive, etc., but the three-dimensional knitted fabric 1 and the nonwoven fabric 4 may be simply laminated without being fixed together. By laminating the nonwoven fabric, even if the connecting yarns 13 of the three-dimensional knitted fabric 1 protrude inward, they can be prevented from directly touching the head, thereby improving the wearing comfort.

[0043] Furthermore, by making the nonwoven fabric thicker, the heat insulating properties can be further improved when the fabric is used for purposes such as keeping warm (for example, as an inner layer for a hat used in winter).

[0044] "Variation 1" The present invention is not limited to the above-described embodiment, and other embodiments may be adopted. Note that the same reference numerals are used to designate common components, and the description thereof will be omitted. In this modification, as shown in FIG. 5, the edge 2 of the formed body 101 is formed by folding the outer periphery 15 of the three-dimensional knitted fabric 1 and sewing it together.

[0045] By compressing and folding the edge portion 2, it is possible to make the edge portion 2 less stretchable than the three-dimensional knitted fabric 1. Furthermore, since the molded body 101 can be constructed from a single member without preparing a separate member, it is possible to reduce manufacturing costs.

[0046] "Variation 2" The present invention can also adopt other forms. For example, as shown in FIG. 6, the molded body 102 of this modified example differs from the embodiment shown in FIG. 1 in that the edge portion 2 is formed to have an elliptical shape. By configuring it in an oval bowl shape, the crown can be fitted securely to an oval hat, boater hat, or the like.

[0047] In addition to the above, the molded article of the present invention can be made to be easily stretchable in one direction by forming the edges into a polygonal shape such as a hexagon, or by partially eliminating the edges. In addition to being used as an inner layer for hats, it can also be placed on the outside of a hat to create a cushion, and can be used for a variety of purposes, such as an inner layer for helmets, a cushion for the living room, a sports or medical supporter, a thermal bag, or an inner layer for a sleeping bag. [Explanation of symbols]

[0048] 100 Molded body 1. Three-dimensional knitting 11 Front ground knitting structure 12 Back side knitting structure 13 Connecting thread 14 Central part 15 Outer periphery 2 Edge 3 Suture area 31 Sutures 4. Nonwoven fabric 1000 Hat Inner C hat

Claims

1. The three-dimensional knitted fabric is made by connecting a front ground knitting structure and a back ground knitting structure with a connecting yarn, and an edge portion provided on the outer periphery of the three-dimensional knitted fabric and having lower elasticity than the three-dimensional knitted fabric, A molded body, wherein the three-dimensional knitted fabric is formed in a bowl shape.

2. The edge portion is a separate member from the three-dimensional knitted fabric, 2. The molded article according to claim 1, wherein the peripheral length of the edge portion is shorter than the peripheral length of the outer periphery of the three-dimensional knitted fabric when the three-dimensional knitted fabric is developed flat.

3. 3. The molded article according to claim 1, wherein the edge is circular and the entire molded article is hemispherical.

4. A hat inner that can be inserted into the inside of a hat and worn to be placed between the hat and the head, The three-dimensional knitted fabric is made by connecting a front ground knitting structure and a back ground knitting structure with a connecting yarn, and an edge portion provided on the outer periphery of the three-dimensional knitted fabric and having lower elasticity than the three-dimensional knitted fabric, The three-dimensional knitted fabric is formed in a bowl shape, and is an inner layer for a hat.

5. A nonwoven fabric is laminated on the surface of both or one of the front ground knitting structure and the back ground knitting structure of the three-dimensional knitted fabric, 5. The inner layer for a hat according to claim 4, wherein the nonwoven fabric is configured to face the head when worn.

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