Thermoforming Single-Set Patterns for Headwear Sizing
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Solution Overview
Problem
The existing manufacturing methods for size headwear with varying circumferential lengths require managing multiple sets of patterns and fabric panels, leading to increased production costs, labor, and size errors, as well as complexity in producing multiple sizes.
Innovation Solution
A manufacturing method involving a single set of patterns for forming headwear pieces with a low melting point fiber, such as polyester, which are thermoformed to achieve consistent sizing across different sizes, reducing the need for multiple pattern sets and simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sets of patterns and fabric panels are used for different sizes, then various sizes of headwear can be produced, but the number of patterns to be managed increases, leading to increased production costs, labor, and size errors
Solution Approach 1:
A single set of patterns is designed to produce fabric panels that can be used for multiple headwear sizes. The fabric panels are cut from a single piece of fabric using one pattern set, and then thermally formed into different sizes through heat treatment, eliminating the need to manage multiple pattern sets for different sizes
Solution Approach 2:
The size of the headwear is adjusted by changing the thermal forming parameters (temperature, time, pressure) rather than changing the pattern or fabric panel design. This allows a single set of fabric panels to be thermally formed into various sizes, reducing pattern management complexity while maintaining size variety
2Adaptability or versatility
If multiple sets of fabric panels are cut and managed separately for different sizes, then size-specific headwear can be produced, but the production process becomes more complex and time-consuming
Solution Approach 1:
Multiple size variations are produced by merging the cutting process into a single operation. All fabric panels are cut from one piece of fabric using one pattern set, then thermally formed into different sizes, consolidating what would otherwise require multiple separate cutting and management processes
Solution Approach 2:
The fabric panels are pre-cut from a single piece of fabric in one operation, and then the size-specific thermal forming is performed as a subsequent step. This preliminary cutting action eliminates the need for multiple cutting operations and size-specific panel preparations, improving production efficiency
3Adaptability or versatility
If size adjusting members are added to headwear, then size adjustment is possible, but the design becomes more complicated and additional manufacturing expense and labor are required
Solution Approach 1:
The mechanical size adjustment system (size adjusting members) is replaced with a thermal forming system. The fabric panels are thermally formed into different sizes through heat treatment, eliminating the need for mechanical adjustment components and simplifying the manufacturing process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs, minimizes size errors, and enhances productivity by allowing for the production of various size headwears using a single set of patterns, while maintaining a lightweight and aesthetically pleasing design.
Implementation Method 1
The low melting point fiber may include a polyester fiber and may be contained in range of 8 to 32%. The heating of the raw size headwear may include maintaining the thermoforming apparatus at a temperature of about 160° C. to 200° C. for 20 to 30 seconds
Implementation Method 2
The heating of the raw size headwear may include maintaining the thermoforming apparatus at a temperature of about 160° C. to 200° C. for 20 to 30 seconds
Implementation Method 3
maintaining the heated raw size headwear on thermoforming apparatus at a temperature of about 15° C. to 25° C. for 5 seconds
Data Source
AI summary
A manufacturing method of a size headwear including a head covering portion put on a head and a size tape member disposed on a lower portion of the head covering portion, the head covering portion has a single circumferential length, includes forming a single set of patterns for forming a single set of pieces of the head covering portion; cutting a fabric into the single set of pieces according to the single set of patterns; sewing the cut pieces with each other and connecting the size tape member along a circumferential direction on a lower portion of the sewed pieces to form a raw size headwear; and putting a raw size headwear on a plurality of thermoforming apparatuses to thermoform a size headwear, wherein the thermoforming apparatuses have the respective different sizes. The size headwear thermoformed in this manner may be inexpensively and easily produced and maintain a predetermined stereoscopic shape due to stiffness so that it may improve an esthetic sense without doing the ironing.