Hair-transplanting apparatus and method and resulting hair-transplanted piece

A base sheet (11 ) of elastic material is stretched, and the intermediate portion of a hair segment is caught by reciprocating needles (41a) to form a shape-retainable turn (30a) at said intermediate portion. The turn remains on one side of the base sheet and secured to said one side with a first adhesive layer (111), whereas a pair of lengthwise hair extensions (30b) extending from the opposite ends of the turn pass through holes (11a), formed by penetration of the needles during elevation thereof, to beyond the other side of the base sheet. After a predetermined number of the hair segments are transplanted and secured to the base sheet, the stretched condition of the base sheet is released or loosened, so that it contracts due to elasticity to thereby reduce the diameter of the holes. Then, a second adhesive layer (112) is formed entirely on the said one side of the base sheet for fitting on human skin.

FIELD OF INVENTION

The present invention relates to wig manufacturing in general, and more particularly to a hair-transplanting apparatus and method. The present invention also relates to a resulting product or piece comprising a thin base onto which a number of hair segments are transplanted and secured, which may be a disposable base. Such product may be recognized as a wig, hairpiece, toupee, etc. However, the product in accordance with the present invention may be worn on any part of human body skin, including head, arm, shin, etc.

BACKGROUND ART

Traditional wigs are hand-made, and often expensive. A hand-made wig is typically manufactured in such a way that an artificial hair segment is folded in two, and hairs are one by one transplanted by handwork onto a three-dimensional, relatively thick base. When one folded hair segment is transplanted on the base, it looks as if two hairs are transplanted. To manufacture a wig with 20,000 hairs transplanted, this laborious task must be repeated 10,000 times. This, of course, considerably increases time and costs for manufacturing the wig.

Therefore, a need exists for an easily manufactured and inexpensive wig, which can be disposable.

SUMMARY OF INVENTION

Accordingly, it is a principal object of the present invention to overcome the drawbacks and disadvantages of the prior art wig manufacturing system.

Another object of the present invention is to manufacture a piece on which a number of hair segments are fixedly transplanted at reasonable cost.

Still another object of the present invention is to manufacture a hair-transplanted piece of a disposable type.

Still another object of the present invention is to manufacture a hair-transplanted piece which looks like the user's own hairs when fitted to any portion of human skin.

Still another object of the present invention is to provide a novel apparatus and method capable of transplanting hair segments substantially in upstanding condition with respect to a thin base sheet.

To achieve these and other objects, in accordance with aspects of the present invention, there is provided a hair-transplanting apparatus comprising a first supplying unit for supplying a base sheet of elastic material to a predetermined position; a base stretching unit for stretching the base sheet at the predetermined position; a second supplying unit for supplying a hair segment of a predetermined length to a first side of the base sheet; at least two reciprocating needles with hook ends having origins positioned below a second side of the base sheet, the needle hook ends piercing the base sheet to form holes and reaching beyond the first side of the base sheet during ascending movement of the needles, the needle hook ends catching an intermediate portion of the hair segment at the first side of the base sheet and then passing down through the holes to reach beyond the second side of the base sheet so that the intermediate portion of the hair segment caught by the hook ends remains on the first side of the base sheet, whereas a pair of lengthwise hair extensions extending from opposite sides of the intermediate portion pass through the holes to below the second side of the base sheet; a hair-curling unit for giving a shape-retainable turn at the intermediate portion of the hair segment which has been caught by the hook ends of the needle on the first side of the base; a first adhesive applicator for applying first adhesive to each of the turns of the hair segments remaining on the first side of the base sheet, thereby forming a first adhesive layer each surrounding the turn; and a second adhesive applicator for applying a second adhesive to all over the first side of the base sheet, including the first adhesive layers, to form a second adhesive layer; the needle, the hair-curling unit and the first adhesive applicator being operable while the base sheet is maintained stretched by the base stretching unit, the stretched condition of the base sheet being released or loosened after a predetermined number of the hair segments are transplanted to the base sheet by the needles and secured thereto by the first adhesive layers, followed by forming said second adhesive layer by the second adhesive applicator.

In one embodiment, the first supplying unit supplies the base sheet upside down, and the second supplying unit supplies the hair segment to above an underside of the base sheet.

The second supplying unit may comprise means for supplying a continuous, endless hair material in parallel with the base sheet, and a cutter for cutting the continuous, endless hair material when it is supplied by a predetermined amount, thereby obtaining the hair segment of predetermined length.

The second supplying unit may comprise a hair catcher including a pair of opposed inverted-triangular frames through which the artificial hair extends substantially horizontally, with a space therebetween for allowing insertion of the needle hook ends. Preferably, the hair catcher is rotatable and swingable about a vertical axis in synchronization with reciprocating movement of the needles.

The hair-curling unit may comprise a heater operable between the hair segment and the first side of the base sheet, the heater making contact with the intermediate portion of the hair segment when the hair segment carried by the needle hook ends is moved down, whereby the intermediate portion of the hair segment is heated to be partly molten or soften to form the turn of a given shape which remains unchanged after being solidified.

Preferably, the second adhesive applicator applies the second adhesive by transfer.

The apparatus may further comprise a base lifting member operable in synchronization with the needles for lifting the base sheet, remaining in a stretched condition by the base stretching unit, to keep the holes unclosed, thereby allowing smooth entry and passage of the needle hook ends through the holes when the needle hook ends returns to the original position (or origins) after catching the hair segment.

The apparatus may further comprise a hole repairing unit for injecting repairing liquid to the holes after the needle hook ends carrying the hair segment have separated from the base sheet.

In accordance with another aspect of the present invention, there is provided a hair-transplanting method comprising the steps of stretching a base sheet of elastic material; moving needles so that their hook ends pierce the base sheet to form holes and reach beyond a first side of the base sheet; returning the needles to their original position (or origins) beyond a second side of the base sheet, during which an intermediate portion of the hair segment is caught by the needle hook ends; transforming the hair segment to provide a shape-retainable turn at the intermediate portion of the hair segment, after the needle hook ends catch the hair segment but before the needle hook ends carrying the hair segment pass through the holes; forming first adhesive layers of first adhesive in a dot pattern on the first side of the base sheet around the shape-retainable turns to secure the shape-retainable turns onto the first side of the base sheet; repeating the needle moving step, the needle returning step, the transforming step and the turn-securing step until a predetermined number of the hair segments are transplanted and secured on the base sheet in such manner that the shape-retainable turn at the intermediate portion of the hair segment remains on the first side of the base sheet between the holes whereas a pair of lengthwise hair extensions extends from opposite ends of the shape-returnable turn through the holes to beyond the second side of the base sheet; releasing or loosening the base sheet from being stretched to contact the base sheet due to its elasticity and reduce diameter of the holes; and applying second adhesive to form a second adhesive layer entirely covering the first side of the base sheet for fitting on a human skin.

In one embodiment, the needle moving step comprises elevating the needles from the original position (or origins) below the second side of the base sheet, and the needle returning step comprises moving said needles down from their upper dead points toward said origins. In another embodiment, the needle moving step comprises moving the needles down from the origins positioned above the second side of the base sheet, and the needle returning step comprises elevating the needles from their lower dead points toward the origins.

The first adhesive layer may be formed by applying the first adhesive to the shape-retainable turn substantially at the same time or immediately after the transforming step is carried out to form the shape-retainable turn. The first adhesive may also be formed by applying in advance the first adhesive onto the first side of the base sheet between the holes formed by elevation of the needles and transferring the first adhesive to the shape-retainable turn when the shape-retainable turn makes contact with the first side of the base sheet during the needle returning step.

In accordance with still another aspect of the present invention, there is provided a hair-transplanted piece comprising a thin base sheet of elastic material; a predetermined number of hair segments transplanted onto the base sheet in such manner that an intermediate portion of each of the hair segment provides a shape-retainable turn remaining and lying on an underside of the base sheet between a pair of holes whereas a pair of lengthwise hair extensions extending from opposite ends of the turn and passing through the holes to orient far from a external surface of the base sheet; first adhesive layers in a dot pattern, each overlapping the turn of the hair segment and securing the same onto the underside of the base sheet; and a second adhesive layer entirely covering the underside of the base sheet, including the first adhesive layers, to provide a flat surface to be fitted onto human skin.

In one embodiment of the hair-transplanted piece according to the present invention, the base sheet comprises a plane sheet. The base sheet may be colorless and transparent.

A main component of the adhesive used to form the first adhesive layer is preferably identical to the base sheet material. By way of example, the base sheet is made from urethane-base material and the adhesive forming the first adhesive layer comprises urethane-base adhesive.

A main component of the adhesive used to form the second adhesive layer is preferably different from that of the adhesive used to form the first adhesive layer. By way of example, the adhesive used to form the first adhesive layer comprises urethane-base adhesive, whereas the adhesive used to form the second adhesive layer comprises acrylic-base adhesive.

The second adhesive layer is formed preferably by transfer.

Note that when the term wig is employed herein, the term covers any product with a number of hair segments transplanted and secured thereto for wearing or adhering to any part of human body skin.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention provides methods, systems and devices to manufacture inexpensive wigs. These wigs can be employed as disposable products.

In initial attempts to manufacture a disposable wig, the inventors tried to apply an adhesive by coating or spraying to the underside of a base to form an adhesive layer to be fitted onto a skin of a human body. However, the adhesive layer thus formed was relatively thick and its thickness was not uniform. When using such a wig, anyone can soon spot that he or she wears a wig, because a boundary between the hem of the wig base and the human skin is quite easy to observe.

Other attempts were made to use a very thin base sheet of thickness equivalent to human skin. However, it has often been found that a thin base sheet between adjacent two holes, formed by penetration of a pair of needles, could easily tear off to form a continuous slit, so that the hair-transplantation becomes infeasible.

This is because an excessive degree of tension should be applied to the thin base sheet during hair transplanting process, whereby the thin base sheet could be split by the root of the folded artificial hair when it is pulled away from the base sheet.

Another problem is that an adhesive layer of uneven thickness tends to cause the base sheet to wrinkle when the wig is fitted onto the human skin, which could be spotted that he or she wears a wig.

Still another problem is that, when a folded artificial hair is simply interconnected onto a wig base, it tends to lie down along the base. This is not preferable, because it looks just like a wig.

A disposable hairpiece and its manufacturing apparatus and method embodying the present invention will be described in more detail with reference to the accompanying drawings. Elements and parts having the same function are indicated by the same reference numerals throughout the drawings and explanation thereof will not be repeated.

First, one concept underlying the present invention will be outlined as follows. A base sheet11is made from an elastic material, which expands when stretched and restored to its original state when the stretched condition is removed. It is to be noted that base sheet11is shown in the drawings upside down, so that the underside is shown at an upper side of base sheet11and the external surface is shown at a lower side thereof. The supplied base sheet11is stretched. Then, each artificial hair30is subjected to a curling or transforming step to provide a shape-retainable turn30aat an intermediate portion of artificial hair30. The intermediate turn30aof each artificial hair30is positioned on an underside of base sheet11, while a pair of opposite lengthwise hair extensions30b, extending from opposite ends of turn30aare drawn toward and beyond an external surface of base sheet11, as shown inFIG. 2(A).

Then, as shown inFIG. 2(B), while keeping the stretched condition of base sheet11, an adhesive is applied onto the intermediate turn30aof each artificial hair30to form first adhesive layer111which fixedly bonds the intermediate turn30ato the underside of base sheet11. These steps are repeated so that a predetermined number of artificial hairs30are transplanted and secured onto base sheet11, as shown inFIG. 14. Then, as shown inFIG. 1(C), another adhesive is applied onto the entire underside of base sheet11to form a second adhesive layer112, which provides a flat surface. The first adhesive layers111are formed in a dot pattern on base sheet11at the respective position of turns30a. The first adhesive layers111are entirely covered with the second adhesive layer112. A separator113is layered on the second adhesive layer112, which is in use removed to expose the second adhesive layer112for fitting the hairpiece to a human skin.

FIGS. 1(A)–1(C)show an example of a disposable hairpiece in accordance with the present invention. In this example, a base sheet11is made from a colorless, transparent, thin sheet of polyurethane having 20–30 micrometer thickness that is equivalent to that of a horny layer of a human skin. Each artificial hair30is made from thermoplastic resin such as acrylic fiber. Each artificial hair30is folded in two to form a curling turn30aat the middle of length of the artificial hair30. The turn30ais formed to substantially retain its shape, which may be letter U shape as shown. The artificial hair30is interconnected with base sheet11in such manner as shown inFIG. 2(A)wherein the turn30alies on the underside of base sheet11and a pair of opposite lengthwise hair extensions30bextends through holes or apertures11a,11aformed apart from each other with a predetermined distance. The hair extensions30bfurther extends to beyond the external surface of base sheet11. The adhesive swell or layer111comprises polyurethane-base adhesive, which surrounds each turn30aof artificial hair30to fixedly bond the same to the underside of base sheet11. The adhesive layer112comprises acryl-base adhesive, which is formed on the entire underside of base sheet11, which is dotted with the first adhesive layers111.

The disposable hairpiece manufacturing apparatus and method according to the present invention will be hereinbelow described in more detail. First, with reference toFIG. 3, base sheet11is horizontally supplied from a base sheet supply source1to a tensioning/positioning unit2. For example, base sheet11is a colorless, transparent, plane sheet of polyurethane of a thickness of 0.03 mm. Base sheet11is wound around a sheet roll13in the form of an endless, continuous sheet. As shown inFIG. 4, the sheet roll13is driven by a motor15to supply an endless base sheet11therefrom onto a conveyor table21. A reference numeral17indicates a stopper for preventing removal of the sheet roll13.

FIG. 5shows the tensioning/positioning unit2. The tensioning/positioning unit2has the conveyor table21movable, with a predetermined pitch “P” (FIG. 14), on a two-dimensional plane along X and Y axes which are perpendicular to each other. Table21is intermittently driven by X-axis and Y-axis motors, both not shown, to move in X and Y directions over a predetermined pitch “P” of 1 mm, for example. An artificial hair30is transplanted onto base sheet11supplied onto table21while table21remains in a fixed position. Thereafter, table21is moved to a different position for the next artificial hair transplanting operation. This is repeated until a predetermined number of artificial hairs30are transplanted onto base sheet11.

There are tension rollers23at four corners on table21for tensioning and stretching base sheet11which has been supplied to a predetermined position on table21. Each tension roller23comprises a pair of opposed tension nip rollers24,25and a tension motor26(26a,26b,26c,26d) for driving nip roller24,25to rotate in forward and reverse directions. A reference numeral27indicates a pair of opposed feeder rollers (of which only an upper one is shown inFIG. 5(A)) arranged at the base sheet supply side or inlet of unit2, which is driven by a motor27a(FIG. 15) to rotate in a predetermined direction for supplying base sheet11onto table21. A reference numeral28indicates a pair of opposed discharge rollers28(of which only an upper one is shown inFIG. 5(A)) arranged at the base sheet discharge side or outlet of unit2, which is rotatable in opposite directions by a motor28a(FIG. 15). A slack sensor29is mounted upstream of feeder rollers27for detecting a slack of base sheet11to be supplied to unit2.

An artificial hair supplying unit3includes bobbins31A,31B,31C and31D (which may be hereinlater referred to by numeral31), each carrying a continuous artificial hair30, and supplies artificial hair30to above base sheet11. Artificial hairs of different colors are reeled around the respective bobbins31. Each bobbin31is rotated by a separate motor, not shown, to provide a predetermined length of artificial hair30. Artificial hair30is supplied by operation of a separate vacuum generator32(32a,32b,32c,32d). One of vacuum generators32may cooperate with an additional, downstream vacuum generator33to unreel a predetermined length of artificial hair30of a selected color from a corresponding one of bobbins31. Each bobbin31is connected to a separate conduit35a,35b,35c,35d, which are all connected to a single conduit35. Artificial hair30is supplied through one of exclusive conduits35a,35b,35c,35dand then through the common conduit35to an artificial hair transplanting unit4. As shown inFIG. 3, between the outlets of exclusive conduits35a,35b,35c,35dand the inlet of common conduit35, there is a swingable hair cutter34driven by a motor, not shown, for cutting artificial hair30to a predetermined length during conveyance thereof from bobbin31to hair transplanting unit4. For allowing cutter34to swing across the respective travel path of artificial hairs30, there is a gap between the outlets of exclusive conduits35a,35b,35c,35dand the inlet of common conduit35. Artificial hair is supplied as an endless hair through conduit35to unit4and then cut to a predetermined length.

The hair transplant unit4is shown in detail inFIGS. 6–9. This unit4comprises a needle assembly41positioned beneath base sheet11and a head unit42positioned above base sheet11in opposition to needle assembly41. As shown inFIGS. 8 and 9, needle assembly41includes a reciprocating needle shaft41e. As best seen inFIG. 9(C), a pair of needles41a,41aare mounted on a top of needle shaft41ewith a predetermined space therebetween. For instance, there is a 1 mm space between the center axes of needles41a,41a. Each needle41ahas an extending superfine needle body with an acute end41b. The outer edge of acute end41bis provided with a cutter41cwhich is useful to form a hole11awhen needle41apierces base sheet11during its ascending movement. The inner edge of acute end41bprovides an engaging hook41dfor engaging, catching and entraining an intermediate portion of artificial hair30.

As shown inFIG. 9, needle shaft41eis received in a holder41fwhich is elevatable by a motor49a(FIG. 3). Also, needle shaft41eitself is elevatable with respect to holder41fby a cylinder41m. In opposition to needle shaft41eis mounted a supporting member41hwhich is elevatable by a cylinder41g. To the upper end of supporting member41his connected to a horizontally extending base supporter41ihaving an upstanding arm with an inwardly slanting end or base lifting member41j. Supporter41ibegins to elevate substantially at the same time when needle41abegins to move down from the upper peak position, so that the upper end member41jpushes upwardly base sheet11at an area close to a hole11awhich has been formed in base sheet11by needle41aduring its ascending movement. The hole11ais, therefore, enlarged, as specifically shown inFIG. 17. Thus, base sheet11is supported by base supporter41ito prevent the descending needle41afrom becoming engaged with base sheet11, which also prevents base sheet11in an area between adjacent two holes11a,11afrom tearing off. If the needle41ashould dash against base sheet11during the descending movement of needle41acarrying artificial hair30from the upper peak point toward the lower peak point, base sheet11could tear off between two adjacent holes11a,11ato form a continuous slit, which makes the artificial hair transplantation infeasible.

Referring now toFIGS. 6 and 7, head unit42has a post43and a hair catcher44at the lower end of post43. Head unit42is driven by a motor42ato swing like a pendulum on a plane of base sheet11, describing a predetermined arc. Another motor42brotates an upper disc43aso that head unit42including catcher44rotates about a vertical axis of post43. A reference numeral42cindicates a frame for attachment of head unit42. A rotation angle sensor48acomprises an encoder for detecting a rotation angle or position of head unit42in its swinging arc. Another rotation angle sensor48balso comprises an encoder, which detects a rotation angle or position of head unit42in its axial rotation. A motor49ais provided for elevation of needle shaft41e, and another motor49boperates in synchronization with motor42bto rotate a lower disc41k, so that needle shaft41ewith needles41arotates about a vertical axis of post43. InFIG. 6, artificial hair30is supplied to base sheet11in a direction (X) shown by an arrow inFIG. 6A.

As best seen inFIG. 10, catcher44includes a pair of opposed inverted triangular frames44A,44B, each having an interior space44d(FIG. 6(B)) for allowing insertion of artificial hair30. Each frame44A,44B comprises an upper horizontal side44band a pair of oblique sides44a,44aextending from the opposite ends of the upper horizontal side44band intersecting with each other at their lower ends to form a lower apex44c. After being discharged from a nozzle37(FIG. 3) arranged near the outlet of conduit35, artificial hair30is supported horizontally by catcher frames44A,44B and extends through the interior space44denclosed by frames44A,44B. Frames44A,44B are secured to a rectangular boss45having four telescoping rods45awith semi-spherical feet45bat the lower ends thereof, respectively. Feet45bbecome contact under pressure with base sheet11, when rods45aare driven by a cylinder45cto extend downward as shown by imaginary lines inFIG. 7, to maintain the stretched condition of base sheet11.

A nozzle46with small apertures (not shown) is connected to a heater46cwherein an atmospheric air is heated to a predetermined temperature to create hot air, which is injected through the apertures of nozzle46against the intermediate portion of artificial hair30caught by hook ends41d,41dof needles41a,41abetween frames44A,44B of hair catcher44. Heater46cis connected to a cylinder46bso that nozzle46can extends horizontally from its stand-by position shown inFIG. 6(B)andFIG. 7to its operable position shown inFIG. 10(A). A reference numeral47inFIG. 7indicates a repairing liquid supplying unit with a cylinder47aand a nozzle47b. Nozzle47bmay be driven by cylinder47ato extend to a vicinity of lower apex44cof catcher frames44A,44B, as shown inFIG. 7, for supplying repairing liquid to base sheet11to repair each hole11a.

FIG. 11shows a hair-orienting unit5including a chain conveyor51arranged below base sheet11to which artificial hairs30have been transplanted. Conveyor51has a plurality of engaging bars52at predetermined intervals and a plurality of retainer bars53at predetermined intervals greater than the interval of engaging bars52. Conveyor51is intermittently driven to rotate in a direction shown by an arrow inFIGS. 11A and 11B. As conveyor51rotates, the transplanted artificial hairs30are engaged by engaging bars52to orient in a predetermined direction (i.e., to the right in this embodiment), as shown inFIG. 11(A), and then retained by retainer bars53into a bundle of artificial hairs30, as shown inFIG. 11(B). This eliminates obstacles to the vertical movement of needles41a,41aand becomes ready for the next artificial hair transplanting operation.

Shown inFIG. 12is an electromagnetic valve (three-position closed center double solenoid)39awhich operates in synchronization with an air compressor39to activate the vacuum generators32,33.

Operation of the apparatus will now be described in detail with reference toFIGS. 13–17. Slack T1is first given to base sheet11at a point between feeder rollers27and tension nip rollers24,25(FIG.13(A)), and discharge rollers28are rotated to feed base sheet11(FIG. 13(B)). Up to this time, tension nip rollers24and25are separate from each other. Then, nip rollers24,25are closed so that base sheet11is interposed therebetween, thereby again providing slack T1between feeder rollers27and tension nip rollers24,25(FIG. 13(C)). Discharge rollers28are then driven to rotate in a reverse direction to provide another slack T2between tension nip rollers24,25and discharge rollers28(FIG. 13(D)). The total amounts of slack T1and slack T2should be enough to move conveyor table21over a predetermined amount. InFIGS. 13(A)–13(D), the hatched area of sensor29indicates an area capable of detection. Base sheet11is transferred from the left to the right in these drawings.

Base sheet11is nipped between tension nip rollers24,25into a stretched, unwrinkled condition on conveyor table21, as shown inFIGS. 5(A)–5(C). Hair transplanting operation is controlled in accordance with a predetermined program stored in a control unit, that is a computer, not shown, for determining the transplant pitch “P” and the coloring of artificial hair30to be supplied to base sheet11, etc. The color scheme of artificial hair30is determined by a given combination of hairs to be unreeled from the respective bobbins31A–31D. By way of example, a combination of 50% of the hair from the bobbin31A, 30% from the bobbin31B, 15% from the bobbin31C and 5% from the bobbin31D will give a specific color to artificial hair30to be transplanted by unit4.

Before starting hair-transplanting operation by unit4, artificial hair30has already been supplied to above base sheet11. This is carried out by vacuum generators32,33which are driven in response to a command from the control unit to absorb artificial hair30toward unit4. More specifically, when artificial hair30of a specific color reeled around bobbin31A is to be selected, ports “1-A” and “2-A” of electromagnetic valve39a(FIGS. 12(A) and 12(B)) in vacuum generator32are turned on, and a motor for rotation of bobbin31A is energized. When artificial hair30of another color reeled around bobbin31B is to be selected, ports “1-B” and “2-B” of electromagnetic valve39ain vacuum generator32are turned on, and another motor for rotation of bobbin31B is energized. When artificial hair30of still another color reeled around bobbin31C is to be selected, ports “3-A” and “4-A” of electromagnetic valve39ain vacuum generator32are turned on, and still another motor for rotation of bobbin31C is energized. When artificial hair30of yet another color reeled around bobbin31D is to be selected, ports “3-B” and “4-B” of electromagnetic valve39ain vacuum generator32are turned on, and yet another motor for rotation of bobbin31D is energized. When a sensor, not shown, comprising a photoelectric tube, for example, detects that artificial hair30reaches a predetermined length, it is cut by cutter34. The artificial hair segment30of a predetermined length is supplied above base sheet11, as shown inFIG. 3andFIGS. 5(A)–5(C).

Artificial hair transplanting operations may be carried out in the following manner. First, base sheet11that has been supplied to tensioning/positioning unit2is stretched on table21, as shown inFIGS. 5(A)–5(C), and awaits a supply of artificial hair30. Table21is set to a predetermined position. When the continuous, endless artificial hair30is supplied to catcher44, cylinder45cis actuated so that rods45amove down to a position shown by imaginary lines inFIG. 7to maintain the stretched condition of base sheet11. Base sheet11has been stretched by unit2as described before and remains stretched until a predetermined number of artificial hairs30are transplanted and secured to base sheet11. The continuous, endless artificial hair30supported by catcher44is cut into a segment of a predetermined length by cutter34(FIG. 3), which is then supplied to the stretched base sheet11.

As shown inFIG. 6(B), artificial hair segment30extends through catcher44substantially horizontally or in parallel with plane of base sheet11. Head unit42is driven by motor42bto rotate about a vertical axis of post43. At the same time, motor49bis driven in synchronization with motor42bso that needle shaft41ewith needles41a,41abegins to rotate in the same direction with head unit42. When needles41a,41aare rotated after they catch the intermediate portion30aof artificial hair30in a manner described later, a hair whorl is created.

Then, as shown inFIG. 16, head unit42is driven by motor42ato swing as a pendulum. Head unit42first swings counterclockwise (inFIG. 16) toward a direction indicated by an arrow “−R”. The center “O” of swinging movement of head unit42is positioned offset from holes11aformed by needles41a,41awhen they pierce base sheet11during elevation thereof. While head unit42swings toward the direction “−R” to separate far from the needle position, needles41a,41amove upward to pierce base sheet11, and heater nozzle46enters between catcher44and base sheet11, as can be best seen inFIGS. 10(A)and (B). Immediately after needles41a,41areach the upper peel point or level H, motor42ais switched over to swing head unit42toward a direction indicated by an arrow “+R”. When head unit42overruns the center line “O”, artificial hair segment30extending through catcher44is caught by hook end41dof each needle41a. When head unit42further swings in the direction “+R” to reach a position indicated by a reference “S”, base supporter41ibegins to elevate. When head unit42still further swings in the direction “+R” to reach a position indicated by a reference “T”, needles41a,41anow begin to move down. The amplitude of swinging movement of head unit42may be determined optionally within a range of the mechanical maximum amplitude, one of dead points of which is indicated by a reference “U”.

Base supporter41ibegins to elevate at the time when head unit42reaches the position “S” and continues elevating until head unit42reaches the position “T”. At this time, the upper end41jof base supporter41iurges base sheet11, more specifically an area11bthereof in vicinity to holes11a, to raise to maintain holes11aunclosed, as best seen inFIG. 17. This allows needles41a,41a, already carrying artificial hair segment30, to pass through holes11a, without being entangled in base sheet11, during their downward movement.

Hole11ais formed when needle41apierces base sheet11during its elevation and, accordingly, has an aperture of a very small diameter that corresponds to a diameter of needle41a. After needle41acatches artificial hair segment30during its descending movement, it passes through the same hole11a. However, base sheet11, which is very thin material, tends to intervene downward movement of needle41a. If base sheet11should be engaged or hooked by needle hook end41d, the thin base sheet material between holes11a,11awould easily tear off so that these two holes are connected to each other to form a single slit, making it impossible to transplant artificial hair30onto base sheet11. This will be effectively prevented by base supporter41ithat compulsorily lifts base sheet11to keep hole11aunclosed to a sufficient size for allowing entry and passing of needle41aduring its descending movement.

As specifically shown inFIGS. 10(A)and (B), hook ends41d,41dof needles41a,41aengage artificial hair30between spaced frames44A,44B of catcher44, while they move down from the upper peak level “H”. As needles41a,41afurther move down, artificial hair30slips out of frames44A,44B little by little, as shown inFIG. 10(C), and separates therefrom at last. At the time shown inFIG. 10(C), heater nozzle46comes into contact with an intermediate portion of artificial hair30which has been engaged by the descending needles41a,41a, thereby forming intermediate turn30a. Then, heating nozzle46is moved away toward the stand-by position shown inFIG. 16. Needles41a,41acarrying artificial hair30will pass through holes11a,11awhich have been enlarged by base supporter41ifor smooth and accurate passing of hook ends41d,41dtherethrough, as described above in detail.

Accordingly, as shown inFIG. 10(D), when needles41a,41areturn to the lower dead point or level L, hair extensions30b,30bhave passed through holes11a,11ato beyond the external surface of base sheet11, while turn30aat the intermediate position thereof remains on the underside of base sheet11between holes11a,11a. Thus, artificial hair30is interconnected with base sheet11at a predetermined point thereon. When a sensor (not shown) detects that the lower end of holder41freaches a predetermined lower limit position, head unit42returns to its original position both in swinging movement and in axial rotation. It is to be noted that, as described before, the intermediate portion of artificial hair30is subjected to contact with heater nozzle46, in the course of the descending movement of needles41a,41awhich already engage artificial hair30, to form turn30aat the intermediate portion thereof, which remains its specific shape, such as the shapes a letter “U”.

Then, cylinder47aof repairing liquid supplying unit47is actuated to lower nozzle47b, from which the repairing liquid drops onto holes11a,11a. After holes11a,11ahave been repaired with the repairing liquid, nozzle47bis retracted to the stand-by position shown inFIG. 7, and rods45aare returned to the upper position shown by solid lines inFIG. 7to separate away from base sheet11. Needles41a,41aare oiled to be ready for transplantation of the next artificial hair.

Meanwhile, conveyor51is intermittently driven in synchronization with movement of needles41a,41ato rotate in the arrowed direction inFIGS. 11(A)and (B). As conveyor51moves in that direction, the transplanted artificial hairs30are engaged by bars52,53and, therefore, become oriented to the right. This manner of the artificial hair orientating operation is carried out each time when artificial hair30has been transplanted but not secured to base sheet11, for providing a sufficient space below base sheet11to allow needles41a,41ato move up toward base sheet11in the next artificial hair transplanting operation.

Artificial hair30is secured onto base sheet11by means of adhesive applied to turn30a. Application of adhesive to turn30ais carried out by applying drops of the first adhesive toward turn30from a conduit, not shown, substantially at the same time when turn30ais formed by heater nozzle46or immediately thereafter. At this time, base sheet11remains in the stretched condition. The applied adhesive surrounds each turn30aand also enters a gap g (FIG. 1(C)) between turn30aand the underside of base sheet11, thereby forming the first adhesive layer111, by which turn30ais fixedly secured to the underside of base sheet11. A part of the adhesive enters holes11afrom the above, which serves to fixedly secure artificial hair30to holes11awhen the stretched condition of base sheet11is released (FIG. 2(B)).

First adhesive layer111is formed partially or dotted by applying the first adhesive onto each turn30aof artificial hair30. This will not affect elasticity of the base sheet material and, therefore, allows sufficient contraction of base sheet11when the tension to base sheet11is released after application of the first adhesive. The adhesive applied to the stretched base sheet11will be adhered to or enter holes11awhich remain unclosed, so that, when holes11aare made narrower by releasing the stretched condition, artificial hair30is fixedly secured to holes11a. In addition, the first adhesive that has not yet been completely hardened will also contract together with base sheet11, which increases an amount of adhesive per unit area of base sheet around turn30aand, therefore, improves the bonding strength.

First adhesive layer or swell111preferably comprises adhesive having a main ingredient identical to a material of base sheet11. By way of example, base sheet11is made from polyurethane and the adhesive of first adhesive layer111comprises polyurethane-base adhesive. When irradiation of ultraviolet rays are applied after the polyurethane-base adhesive has been applied, not only the adhesive is melted but also base sheet11of polyurethane is at least partly melted or softened, so that first adhesive layer111will be partly merged into base sheet11, thereby ensuring that artificial hair30is fixedly bonded to base sheet11. This also lowers the height of first adhesive layer111and, therefore, reduces the overall thickness of the finished hairpiece.

In the above-described sequential manner, transplantation of one artificial hair30(two hairs in appearance) has been completed.

Then, after table21is moved by a predetermined pitch “P”, for example of 1 mm, in a direction of X or Y (FIG. 14), the same manner of operation is carried out to transplant another artificial hair30. Movement of table21in directions X and Y will be made in a controlled order, so that artificial hairs30are transplanted onto base sheet11with predetermined pitches “P” in both directions X and Y. The transplanting pitch “P” between adjacent artificial hairs30in X and Y directions will depend on the amount of intermittent movement of table21. The transplanting pitch “P” may be different in the X and Y directions. Also, the transplanting pitch “P” in X and/or Y directions may not be constant, because this could provide favorable appearance just like natural hairs.

The above-described artificial hair transplanting operation is repeated each time table21is moved at the predetermined transplanting pitch P until a predetermined number of artificial hairs30are transplanted to base sheet11and secured by first adhesive layers111thereto. After that, the stretched condition of base sheet11is removed.

Then, the second adhesive is applied on the entire underside of base sheet11to form a second adhesive layer112, as shown inFIGS. 1(B)and (C)), which completely covers the first adhesive layers111and provides a substantially flat surface that is, in turn, covered with separator113.

Second adhesive layer112is made from a so-called “soft” adhesive having a relatively low initial tack. Accordingly, when such adhesive is applied onto the entire underside of base sheet11after forming the first adhesive layers111at the respective intermediate turns30a, it will slip down from swells of first adhesive layers111, so that second adhesive layer112can be formed as a very thin, but uniformly thick layer with a flat surface, as shown inFIGS. 1(B)and (C).

Since second adhesive layer112is formed by transfer, it may entirely overlie the underside of base sheet11with a very small, but uniform thickness. Therefore, when the hairpiece is fitted onto a human skin, there is no markable boundary between the base sheet and the human skin, which looks like the user's own hair.

After second adhesive layer112is formed to overlie the entire underside of base sheet11, discharge roller28begins rotating to discharge base sheet11awith a predetermined number of artificial hairs30transplanted and secured thereto, as shown inFIG. 15(A). Then, another base sheet11bis supplied to tensioning/positioning unit2in the manner described before, as shown inFIG. 15(B).

When the hairpiece of the above-described embodiment is fitted onto the human skin, the entire surface of second adhesive layer112will be in direct contact with the human skin. Accordingly, even when a tension is applied to any specific point or area of base sheet11, it could be dispersed over the whole of base sheet11, which prevents the hairpiece from separating from the human skin.

In the hairpiece manufactured by the apparatus and method of the above-described embodiment, each artificial hair30is heated by contact with heater nozzle46, so that it is transformed and curled such that it has a shape-retainable turn30aat the intermediate portion of artificial hair30. The shape-retainable turn30aremains on the underside of base sheet11after the artificial hair transplanting operation is completed, and is then fixedly secured to the underside of base sheet11with first adhesive layers111. In addition, as described before, the opposite end portions of turn30aare fixedly secured to holes11a,11a. Accordingly, the artificial hairs30thus transplanted and secured to base sheet11will not lie along the external surface of base sheet11, but extend in an upstanding orientation with respect to the external surface, which successfully provides a natural appearance when the hairpiece is worn on human skin.

Second adhesive layer112formed by transfer of adhesive layer will have a very small and even thickness and provide a smooth, flat surface to be fitted onto human skin. When the hairpiece is fitted onto human skin, it assimilates as a part of the human skin. The hairpiece once fitted remains in position. Anybody can scratch, brush, shampoo or swim, without paying any special care to the fact that he or she really wears the hairpiece. The hairpiece is stuck to the human skin and, therefore, provides a favorable affinity to natural hairs. This means that the hairpiece may suitably be used as a toupee for hiding any bald spot, on the head or on any part of the human skin. No one feels a sense of incongruity because the artificial hairs on the hairpiece could be merged into the surrounding natural hairs. The hairpiece fitted onto the human skin with no gap therebetween will not make an unnatural, echo sound, even when knocked with a fist, for example. By these reasons, a hairpiece wearer is free from any mental stress and unpleasantness.

Most of the conventional wig are of a type wherein a net-like base sheet is capped on a head, for example, and artificial hairs transplanted on the base sheet are mixed up with his or her own hairs. On the contrary, the hairpiece in accordance with the present invention is directly adhered onto the skin via second adhesive layer112, which can be applied to any part of human skin. No burden is applied to the own hairs, when it is worn or fitted. It may be adhered to hairless private parts.

Artificial hair30slips out of opposite frames44A,44bof catcher44during descending movement of needles41a,41awith hook end41dengaging artificial hair30. It then passes through holes11a,11atogether with needle hook ends41d, while intermediate turn or hair root30aremains on the underside of base sheet11. Artificial hair30is disengaged from needle hook ends41dwhen the needle further moves downward, as shown inFIG. 10(D). This manner of operation makes smooth hair transplantation, with no risk that base sheet11could tear off between holes11a,11a.

When artificial hair30is engaged by needle hook ends41d, and is to pass through holes11a,11a, it makes contact with heater nozzle46which enters between catcher44and base sheet11, which makes sure that the shape-retainable turn30ais formed at the intermediate portion of artificial hair30. More specifically, along with the descending movement of needles41a,41a, artificial hair30entrained by needles41a,41awill first make contact with nozzle46. Then, intermediate turn30amakes a soft landing on the underside of base sheet11after nozzle46is moved away. Such dual-phase, moderated movement of artificial hair30will reduce the load to be applied to base sheet11when turn30alands on base sheet11, which prevents tearing-off of base sheet11between adjacent holes11a,11a. This is very important when considering that base sheet11is an extremely thin sheet.

The intermediate portion of artificial hair30is heated by heater nozzle46and, therefore, curled or transformed into a predetermined shape with turn30a, which remains on the underside of base sheet11as a hair root. Accordingly, artificial hair30is securely interconnected to base sheet11.

Each frame44A,44B of catcher44has a pair of slanting sides44a,44aconnected with each other at the lower apex44c. This assures that artificial hair30supplied to interior space44dof frame44A,44B is guided along one of slanting sides44a,44ato be finally held at the lower apex44c, resulting in proper positioning of artificial hair30. In accordance with the present invention, artificial hair30is transplanted onto the extremely thin base sheet11by means of the extra-fine needles41a,41a. Proper positioning of artificial hair30is one of the important factors for achieving an accurate hair transplanting operation.

Before artificial hair30is actually transplanted onto base sheet11, base supporter41i moves upward to push up base sheet11at an area close to the row of holes11a,11a, so that holes11a,11aremain unclosed (FIG. 17). Base sheet11is supported by base supporter41ito prevent the descending needle41afrom becoming engaged with base sheet11. If needle hook end41dshould collide against base sheet11during the needle descending movement, base sheet11could tear off between adjacent two holes11a,11a, making the hair transplantation impossible.

In accordance with the present invention, the artificial hair transplanting pitch “P” can be controlled very precisely to an amount equivalent to the pitch of natural human hairs. This enables mechanization and automation of hairpiece manufacturing. Even in automated manufacturing, there is less probability of producing inferior goods.

It is to be understood that the present invention is not limited to the embodiments described and illustrated herein, but allows various changes, modifications and alterations within a scope of the invention defined in the appended claims.

For example, the base sheet may be made from any material as far as it has a sufficient elasticity to allow expansion when stretched, as well as contraction when the stretched condition is cancelled. The base sheet is stretched by any desired means. Making slack T1, and T2is favorable but not always necessary.

In the foregoing embodiment, the first adhesive layers are formed while remaining the stretched condition of the base sheet, and the second adhesive layer is formed after the stretched condition is completely removed. However, the second adhesive layer may be formed after not completely removing the stretched condition of the base sheet but loosening the stretched condition. In this case, similar functions and effects may be enjoyed.

The intermediate turn which functions as a hair root may be formed into a desired shape. The rounded turn is shown in the drawings but may be a square one, for example. The shape of the turn depends on the shape of the upper surface of the heater nozzle, when the heater nozzle is used to make contact with the artificial hair to thereby curl the same. Curling the artificial hair may be achieved in other ways as well. For example, the heater nozzle positioned below the supply path of the artificial hair is moved upward so that the intermediate portion of the artificial hair is interposed under pressure between the heater nozzle and an upper stationary member, thereby curling the intermediate portion of the artificial hair to form the turn. In another modification, there is a stationary bar below the supply path of the artificial hair and the heater nozzle is moved downward so that the intermediate portion of the artificial hair is interposed under pressure between the heater nozzle and the bar, thereby curling the intermediate portion of the artificial hair to form the turn. The heater nozzle may be replaced by a cylindrical heater bar wherein its outer periphery may be heated to a predetermined temperature.

Adhesive material forming the first and second adhesive layers may be selected as desired. The artificial hair transplanting operation is carried out by a pair of needles in the illustrated embodiment, but more needles may be employed. The hair segments to be transplanted onto the base sheet may not always be artificial hair, and natural hair may be used. When the artificial hair is used, its material is optional. The hair segment may be supplied to any side of the base sheet. The base sheet may be supplied with its underside down and the hair segment may be supplied to below the base sheet.