Abstract:

Objective The existing protective hats primarily rely on cutting and sewing methods to accommodate the protection of the human head and face. It is important to make the protective hats better fit the contour curves of the human head, face and neck, to improve wearing comfort, and to combine functional yarns in order to enhance the added value of the protective hats and expand its application areas. This research is carried out to explore the three-dimensional structure of the protective hat based on the use of full-forming knitting technology.

Method The research took the human head-and-neck model as the starting point, aiming to determine the relevant feature size parameters. The protective hat was divided into five main characteristic areas according to the functional requirements. Based on the full-forming knitting process, the structural model of the front and side knit protective hat was constructed, and the process model of the knit requirements was achieved through two-dimensional template conversion.

Results Three types of protective hats were made through trial knitting on a four-needle-bed computerized flatbed knitting machine. This state-of-the-art equipment allows precise control of the knitting parameters and ensures high-quality knitting results. Front knitting made use of a partial knitting technique, whereby knitting was done selectively on certain needles to create a specific pattern or opening. This technique was used to manufacture the eye openings to ensure functionality and ergonomics for the wearer. In addition, the neck had a cylindrical structure which was optimized to enhance the fit of the neck, ensuring that the hat is comfortable and secure to wear so as to provide better protection without compromising on comfort. The side knitting was carried out based on the same partial knit technique to achieve a single longitudinal knit from the top of the head to the back of the neck. This design approach ensures that the hat would fit more naturally to the contours of the head, providing a seamless fit with improved comfort and protection. In general, the use of needle shifting technology played a vital role in the overall design. This technique enabled intricate designs and better fit. Combined with multi-size process calculations, this method ensured that the connection between the hat rim and the body of the hat is precise and tight. This meticulous approach made it certain that the face-wrapping area would fit closely to the contours of the face, providing superior protection and a more aesthetically pleasing appearance. By utilizing advanced seamless knitting technology, the front and side knitting process not only improved the performance of the protective hat but also met the specific needs of various protection scenarios.

Conclusion The structural design and knitting of the three-dimensional fully formed protective hat were investigated based on a four-needle bed computer flat knitting machine, and the application of front and side knitting technology in three-dimensional structure shaping of protective hat was deeply analyzed. Through the integrated forming technology, the knitted hat was made to fit the human head and face curves, which not only solves the problem of reduced comfort due to excessive sewing and splicing of the traditional hat, but also optimizes the adaptability of the hat body to the head features, which significantly improves the wearing experience and protection effectiveness. The added value of the protective hat can be added by introducing functional yarns and designing fabric structures for specific areas. The knitting material can be adjusted according to different use scenarios to meet the functional and safety requirements of the protective hat.

Key words: full-fashioned protective hat, head characteristic, structural model, transfer needle to shape, partial knitting to shape